How to Unlock the Potential of 48-Volt Robotic Systems
The shift from 12 V to 48 V systems is driven by the need for improved efficiency and reduced cooling requirements.
48 V systems are increasingly used in industrial automation and robotics, offering higher power and improved safety over lower voltage systems.
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January 2, 2026
The demand for efficiency and cost-effectiveness in electrical systems is driving the adoption of 48 V systems across industries. These higher-voltage systems offer a more optimal alternative to conventional 12- or 24-V architectures, particularly where high power delivery is essential. Industrial automation and telecommunications leverage 48 V to power motors, actuators and other high-power equipment.
The advantages of using 48 V systems include:
Drive larger loads: unlike 12 V systems, which struggle to meet modern power requirements.
Lower currents: higher voltage reduces current requirements fourfold
Reduced power loss: lower currents mean less power loss, less heat to dissipate and higher efficiency; operating at a higher voltage, Allegro's 48 V solutions drastically reduce energy loss compared to conventional 12 V systems
Higher power density: Allegro’s highly integrated 48 V solutions enable higher power density space compared to competitive solutions, translating to further driving range and lower energy loss in clean energy systems
Lighter cabling: thinner cables lower costs and reduce weight and space
Lower current requirements of 48V systems, coupled with Allegro's innovative design approaches, allow for thinner and lighter wiring harnesses and fewer overall components.
History of power distribution systems
The 6 V power distribution system became a practical standard for ignition and lighting in early automobiles, largely influenced by the widespread use of batteries at the time. Its simplicity and ease of use made it a popular choice. Although 24 V systems were initially trialed – for example, in the 1912 Cadillac with its electric starter – the 6 V system quickly gained dominance for most automotive electrical functions.
As automotive technology advanced, the demand for electrical accessories such as radios, heaters, and, later, power windows, grew. This placed greater strain on the electrical system, highlighting the limitations of the 6 V setup. A 12 V system offered a key advantage: for the same power output, it required only half the current, reducing the risk of overheating and allowing the use of lighter, more manageable wiring.
The development of reliable 12 V lead-acid batteries and alternators further supported the transition. With these components becoming easier to produce and more cost-effective, the 12 V system became the new standard. This led to the design and widespread adoption of compatible electrical components, including lighting and motors that operated more efficiently at higher voltages.
Struggles of traditional systems
Modern power demands cannot be met with traditional 12 V systems, currently the mainstay of power delivery. The limitations of 12 V systems become clear when considering factors like power loss and cable thickness.
As power demands increase, so do the currents within a 12 V system in a linear fashion (P = V * I). This results in higher power losses along any wiring from the supply source to the load (Ploss = I2 * R) (Figure 1).
Figure 1: Power loss comparison between a 48 V system and a 12 V system.Allegro
These power losses manifest as unwanted heat and reduced system efficiency. Also, managing higher currents requires thicker, heavier cables, which add weight and cost to system designs.
Industrial automation equipment
48 V systems are increasingly used in industrial automation and robotics, offering higher power and improved safety compared to lower-voltage systems. This includes components such as motors, sensors, and gate drivers designed to handle the higher voltage and power demands of industrial applications.
The lower currents present in these systems reduce heat generation and potential fire hazards. Compared to higher voltage systems, 48 V systems require less insulation, which can be a factor in compact designs. As they fall below the 60 V safety limit, they are often considered SELV (Safety Extra Low Voltage), meaning they are designed to be safe for direct contact with unshielded equipment.
48 V systems offer enhanced efficiency and precision by reducing energy loss, enabling faster control and allowing for smaller, lighter equipment, increased dexterity and improved thermal management.
48 V solutions with high efficiency and maximum performance
Allegro offers a broad array of sensor and power IC products ready for use in the design of 48 V systems across a myriad ofrobotic applications.
The reduced power loss with Allegro's 48 V solutions translates to a tangible increase in fuel economy for mild hybrids, significantly extending the range for all electrified vehicles and improving energy conversion efficiency in solar inverters.
Motor and gate-drive units
Allegro’s motor and gate drivers provide precise and efficient control for 48 V motors and actuators used in automotive and industrial automation, improving productivity and reliability.
Figure 2a: AMT49100 3-Phase BLDC Gate DriverAllegroTheir integrated current sensor IC supports high-voltage applications, while the digital position sensors deliver robustness and reliability to complement the motor drivers.
Figure 3a: ACS37220 Low-Resistance Current Sensor.AllegroCurrent sensors with functional isolators
ACS37220: low resistance, high power density 200A current sensor in QFN Package
ACS37041: +/- 2.8% sensitivity error, 7.6 bits resolution, is a small leaded magnetic current sensor for cost-optimized applications
ACS724 and ACS725: high-accuracy, isolated current sensor ICs with stray field rejection
Isolated gate drive units
AHV85000: primary side of GaN FET isolated gate driver chipset with power-thru integrated isolated bias supply
AHV85111: self-powered single-channel isolated GaN FET gate driver with regulated bipolar output drive
Figure 3b: ACS37041 Small Leaded Magnetic Current SensorAllegroAutonomous Mobile Robots (AMRs)
AMRs navigate dynamic environments for logistics and inspection, demanding precise motion, robust battery management and reliable obstacle detection.
Allegro’s integrated motor drivers, magnetic sensors for positioning and load sensing, and efficient power management ICs enhance AMR performance, optimize energy usage and ensure operational safety in diverse settings.
AAS33001: Motor Position Sensor for precise wheel/lift motor control with easy integration and on-chip misalignment calibration
ACS71240: Current Sensor that enables efficient battery life with low-cost, low-loss current sensing for motors
Collaborative Robots (Cobots)
Cobots work safely with humans, requiring precise motion, advanced safety features (SIL-2/3) and efficient power for articulated joints.
Allegro’s true 48 V gate drivers, high-resolution position sensors and accurate current sensors enable robust joint performance, dependable braking and optimized power management for reliable human-robot collaboration.
AMT49100: 3-Phase BLDC Gate Driver with true 48V capability, integrated CSAs and SIL-3 for safe servo motor control
CT310: TMR Bridge Angle Sensor with high-resolution (13-14 bit) analog output for precise motor commutation and joint feedback
Humanoids
Humanoid robots aim for human-like motion and interaction, demanding sophisticated actuation, dynamic balance and complex perception.
Allegro’s advanced servo motor control, versatile multi-axis position sensing, and efficient power management technologies are fundamental to the intricate mechanics and demanding performance requirements of the numerous joints in Humanoid robots.
AMT49100: 3-Phase BLDC Gate Driver with SIL-3 compliant 48V motor driving for precise control of multiple high-performance joints
A31301: Multi-Axis Position Sensor with user-selectable axes for flexible, precise angle sensing in complex, space-constrained joints
Figure 4: ACSEVB-EZ7-37220-100B3 Eval.Board for the ACS37220 Current Sensor.AllegroEvaluation boards
Figure 5: APEK85111KNH-02-T-MH Eval.Board for AHV85111 Isolated Gate DriverAllegro
Why stop at 48 V?
The primary factor behind this limit was the safety standards that had to be met. Organizations such as UL and NFPA classify voltages below 60 V as Safety Extra Low Voltage (SELV), considering them safe for human contact with unshielded equipment. Systems operating above 48 V required more robust components and engineering to ensure adequate insulation and isolation, which increased overall cost and complexity.
Although 48 V systems can be cost-effective, higher-voltage systems often entail higher initial costs due to the need for specialized components and wiring. Their design tended to be more complex, and implementation could be more costly, as specialized parts were either more expensive or demanded more intricate manufacturing processes.
Powering the artificial intelligence revolution
Delivering low-latency AI responses requires substantial computing power, thereby significantly increasing data center energy demand. To improve efficiency and reduce cooling requirements, data centers are transitioning from 12 V to 48 V power systems.
Innovations in power supply design support this shift, with future developments aimed at improving performance and density. Consequently, data centers need to be equipped with high-performance servers, advanced cooling systems, and robust power infrastructure to manage workloads effectively.
Data center operators are increasingly adopting energy-efficient technologies such as liquid cooling, renewable energy sources and server virtualization to reduce their carbon footprint and lower operating costs.
The shift from 12 V to 48 V systems is driven by the need for improved efficiency and reduced cooling requirements. In industrial automation, these systems offer higher power and enhanced safety compared to lower voltage options.
Rich Miron is a senior technical content developer for DigiKey.
Figure 1: Power loss comparison between a 48 V system and a 12 V system.Allegro
Figure 2a: AMT49100 3-Phase BLDC Gate DriverAllegro
Figure 3a: ACS37220 Low-Resistance Current Sensor.Allegro
Figure 3b: ACS37041 Small Leaded Magnetic Current SensorAllegro
Figure 3b: ACS37041 Small Leaded Magnetic Current SensorAllegro
Figure 4: ACSEVB-EZ7-37220-100B3 Eval.Board for the ACS37220 Current Sensor.Allegro
Figure 5: APEK85111KNH-02-T-MH Eval.Board for AHV85111 Isolated Gate DriverAllegro