Electric Truck Project in Portugal with Brogen Electric Truck Motor
This project marks an important milestone as we partnered with a new energy company in Portugal to deliver their first next-generation electric heavy truck. The vehicle is powered by our e-powertrain system, integrating the electric motor and the gearbox, supporting the client’s transition toward cleaner and more sustainable transport solutions.
Project Overview
- Project timeline: 2021
- Offered solutions: e-powertrain, power steering system, braking system, integrated auxiliary converter
- Application model: 40-ton pure electric heavy duty truck
- Provided services: pre-sales consultation, solution planning, technical coordination, product testing, post-sales technical support, remote debugging
Challenges in the Client's First Battery Electric Truck Project
Because this was the client’s first battery electric truck development, both sides faced several challenges:
1. Limited EV Technical Background: Although the parent company had experience in construction and energy storage, the EV division lacked the engineering expertise needed to develop a fully electric powertrain, high-voltage system, and vehicle integration plan.
2. High Development Costs & Long Timelines: Building an in-house solution would require significant R&D investment, potentially prolonging development and delaying vehicle launch.
3. Need for Clear Technical Alignment: Our first priority was to establish efficient communication and fully understand the client’s performance targets, vehicle architecture, and expectations – so we could provide a tailored EV solution that met all operational requirements.
Our Approach
To support the project from concept to delivery, we followed a structured and collaborative process:
- Requirement Analysis: We worked closely with the client to review propulsion needs, electrical architecture, voltage standards, thermal management, and packaging constraints.
- Customized Engineering: Our engineering team designed a complete e-powertrain solution, assisted the client with system integration, and provided engineering guidance during development and testing.
- Long-Term Support: We continued to provide remote technical support, software updates, and troubleshooting after delivery, ensuring stable long-term operation of the vehicle.
Solutions We Provided
A. 350 kW Integrated E-Powertrain System
System Features
- Integrated motor: a streamlined design for convenient vehicle layout, eliminating phase harness EMC radiation while minimizing energy loss.
- Real-time weight measurement: ensures precision within 10%, while dynamic slope measurement boasts an accuracy of ±0.2° and static accuracy of ±0.1°.
- Adaptive shift timing: responds to factors like vehicle weight, slope, and driver input, including throttle system, pedal depth, and acceleration, adjusting shift points dynamically. Shift time clocks in at under 0.7s.
- Digital intelligent shifting: employs an electronically controlled shifting system for precise gear changes, enhancing overall performance.
Technical Parameters
- Rated / peak power: 220 / 350 kW
- Rated voltage: 618 V
- Rated / peak speed: 1400 / 3000 rpm
- Rated / peak torque: 1500 / 2500 N.m
- Rated / peak current: 340 / 610 A
- Protection level: IP67/H
- Cooling method: liquid cooling
- Applicable models: heavy truck
Explore our other electric truck motor solutions here: https://brogenevsolution.com/electric-motors-for-truck/
B. 4 kW Electro-Hydraulic Power Steering (EHPS)
We have supplied the 4 kW electro-hydraulic power steering system (EHPS) on the truck. The integrated design combines a motor, steering pump, ECU, DC power processing, and oil tank into a single unit, which maximizes space utilization, simplifies system integration, and offers compact size and light weight.
System Parameters
- Rated power: 4 kW
- Rated voltage: AC 380 V
- Rated current: 7.4 A
- Rated torque: 34.2 N.m
- Rated speed: 1200 rpm
- Peak power: 10.75 kW
- Back EMF (rated speed): 140 V/krpm
- Peak current: 19.2 A
- Peak torque: 85.6 N.m
- Peak speed: 1281 rpm
- Controlled flow: 18±2 L/min
- Insulation class: H
- Rated efficiency: 92%
- Line resistance (20°C): 1.88Ω
- Phase resistance (20°C): 0.9Ω
- Working frequency: 80 Hz
- Protection class: IP67
- Pole pairs: 4
- Q-axis inductance: 9.3 mH
- D-axis inductance: 12.5 mH
Explore our other EHPS solutions here: https://brogenevsolution.com/electro-hydraulic-power-steering-system-ehps/
C. 4 kW Air Brake Compressor
We have supplied the 4 kWÂ oil-free air brake compressor for the electric heavy truck. With the latest technology, our air compressor delivers air that’s entirely oil and water-free, eliminating concerns of oil emulsification, leaks, and fire hazards. Its innovative structural design minimizes energy waste during compression, optimizing efficiency.
System Parameters
- Rated exhaust: 380 L/min
- Rated exhaust pressure: 1 Mpa
- Exhaust pressure: 1.2 Mpa
- Dimensions: 560*335*370 mm
- Motor power: 4 kW
- Weight: 65 kg
- Operating temperature: -40°C ~ + 60°C
- Protection class: IP67
Explore our other electric air brake compressor solutions here: https://brogenevsolution.com/air-compressors-for-commercial-vehicles/
D. Integrated Auxiliary Inverter
We have used the 3-in-1 auxiliary inverter for the project, which consists of a DC/DC converter, a DC/AC oil pump, and a DC/AC air compressor. This integrated and lightweight design significantly reduces system weight and size. It not only offers a lightweight solution but also delivers substantial space, wiring, and cost savings for electric commercial vehicles.
Explore our other integrated auxiliary inverter solutions here: https://brogenevsolution.com/auxiliary-inverters-for-hev/
Project Results
Our systems performed exceptionally well on the client’s 40-ton electric heavy trucks, earning high satisfaction from the client.Â
Due to the strong results, the client promptly initiated another project involving a 26-ton logistics truck (AGV) for port operations, utilizing our systems to efficiently transport goods between sites.
Our Customizable Solution for Heavy-Duty Trucks
At Brogen, we provide a wide portfolio of EV systems for electric trucks, including:
- Electric truck motors or integrated e-powertrain
- Traction battery systems
- Steering and braking systems
- Auxiliary power electronics
- High-voltage distribution and wiring harnesses
Our modular and customizable solutions help OEMs accelerate the development of reliable electric commercial vehicles while reducing engineering complexity and cost.
- Looking for an EV solution for your project? Reach out to us at contact@BrogenEVSolution.com
Contact Us
Get in touch with us by sending us an email, using the Whatsapp number below, or filling in the form below. We usually reply within 2 business days.
Email: contact@brogenevsolution.com
Respond within 1 business day
Whatsapp: +8619352173376
Business hours: 9 am to 6 pm, GMT+8, Mon. to Fri.
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