DC Motors in Vehicles

A Practical Guide to 12V, 24V, 48V, 60V, and 72V Applications

Direct current (DC) motors are the workhorses of modern vehicle electrification, powering everything from auxiliary systems to full propulsion. Their voltage ratings—12V, 24V, 48V, 60V, and 72V—map directly to vehicle size, duty cycle, and performance requirements. Here is how each tier serves the market.

12V: The Universal Standard for Passenger Cars
12V DC motors are the backbone of automotive auxiliary systems, compatible with every gasoline and diesel passenger car on the road. They are compact, low-cost, and easy to integrate into existing 12V electrical architectures. Common applications include windshield wiper motors, power window lifts, seat adjusters, cooling fan motors, and fuel pump motors. For example, a typical 12V wiper motor delivers 5-15 N·m of torque, sufficient to clear a sedan’s windshield in heavy rain, while a 12V seat adjuster motor uses a worm gear reduction to provide smooth, quiet movement. Nearly all entry-level electric vehicles also retain a 12V system to power these accessories, even if their main propulsion runs at hundreds of volts.

24V: The Workhorse for Commercial Vehicles
24V DC motors are the standard for medium and heavy-duty commercial vehicles, where higher voltage reduces current draw and minimizes wiring losses over long cable runs. They are ubiquitous in trucks, buses, construction machinery, and agricultural equipment. Key uses include starter motors for large diesel engines, air conditioning compressor motors, power steering assist motors, and hydraulic pump motors for dump truck beds. A 24V starter motor for a heavy truck, for instance, can output over 5 kW of cranking power to turn a 15-liter diesel engine, while a 24V hydraulic pump motor drives the lift mechanism on a garbage truck reliably through thousands of cycles per year.

48V: The Mild-Hybrid Sweet Spot
48V DC motors are the core of mild-hybrid electric vehicle (MHEV) systems, balancing performance gains with minimal cost and complexity. They are too powerful for pure accessories but not large enough for full propulsion, making them ideal for start-stop systems, regenerative braking, and torque assist. A 48V belt-driven starter generator (BSG) can restart a gasoline engine in 0.3 seconds, eliminating idle fuel waste, while also recovering kinetic energy during deceleration to recharge the battery. Many European sedans and SUVs now use 48V systems to meet emissions standards without the expense of a full hybrid drivetrain. Beyond passenger cars, 48V motors also power electric power steering and active suspension systems in premium vehicles.

60V: The Entry Point for Light Electric Mobility
60V DC motors are the go-to choice for light electric vehicles that need more range and power than 48V can provide, but do not require the full capability of 72V systems. They are most common in electric scooters, small electric motorcycles, and low-speed electric vehicles (LSEVs) used for campus or resort transport. A 60V 1500W hub motor on an electric scooter, for example, can reach a top speed of 45 km/h and climb a 15-degree incline, making it suitable for urban commuting. Many 60V systems use brushless DC (BLDC) motors for higher efficiency and longer service life compared to older brushed designs.

72V: The Standard for Performance Electric Two-Wheelers
72V DC motors are the mainstream choice for full-size electric motorcycles and high-performance electric scooters, offering the power needed for highway-capable speeds and long range. A typical 72V 3000W BLDC motor can propel an electric motorcycle to 80 km/h, with peak torque outputs of over 100 N·m for quick acceleration from a stop. These motors are also used in electric three-wheel cargo vehicles and small electric utility vehicles, where their high torque output can handle heavy loads over rough terrain. Many 72V systems are paired with lithium-ion battery packs and regenerative braking controllers to maximize range, often achieving 80-120 km on a single charge.

Choosing the Right Voltage
The right DC motor voltage depends on three factors: vehicle size, required power output, and existing electrical infrastructure. 12V and 24V dominate auxiliary and commercial applications, 48V is the mild-hybrid standard, and 60V/72V power the growing electric two-wheeler market. As vehicle electrification expands, DC motors will remain essential across all these segments, offering reliable, cost-effective motion control for decades to come.

Wuxi Pinghao focuses on the research, development, and manufacturing of DC motors to drive hydraulic and pneumatic mechanisms. Our products are widely used in hydraulic lifting systems for equipment such as trucks and forklifts, as well as industrial conveyor belt systems.