40-ton Electric Heavy Truck Project in Portugal
Introduction
This project marks a significant milestone as we partnered with a new energy company in Portugal to successfully deliver their first all-electric heavy-duty truck, signaling a decisive step towards zero carbon emissions. It embodies our mission and underscores our commitment to accelerating the transition to green renewable energy, advancing humanity’s journey to carbon neutrality, and driving societal progress.
Project Overview
- Project timeline: 2021
- Offered solutions: e-powertrain system, power steering system, braking system, 3-in-1 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
Challenge
Collaborating with this company on their first electric heavy-duty truck project presents both exciting prospects and challenges for both parties involved.
For them, embarking on their first electric heavy truck endeavor poses a learning curve. Given their parent company’s background in construction and energy storage, their newly established new energy department may lack the technical expertise needed for designing and developing comprehensive EV solutions. Additionally, the R&D costs could be substantial, potentially leading to longer project timelines and delayed vehicle launches.
For us, our foremost task is to establish clear lines of communication and grasp a thorough understanding of their requirements, preferences, and expectations for the heavy truck project. From there, we must devise tailored EV solutions to precisely meet their needs. Effective collaboration with their team is paramount to address any technical hurdles, tackle challenges head-on, and ensure seamless project execution.
Our Approach
In assisting this company in its EV truck project, our approach has been anchored in robust communication from inception to completion, ensuring a thorough understanding of our client’s needs. We’ve tailored the EV solution precisely to their specifications, guiding them through any technical challenges encountered along the way. Furthermore, we extend ongoing remote technical support and engage in cooperative discussions with their team to address any lingering technical concerns.
Solutions We Have Provided
1. E-Powertrain (Electric Motor + Gearbox)
We’ve equipped the truck with our 350 kW 2-in-1 integrated e-powertrain system, seamlessly combining the EV motor and gearbox alongside an independent MCU.
System 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
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.
2. Power Steering System (Electric Hydraulic Power Steering)
We have supplied the 4 kW electric 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
3. Braking System (Air Brake Compressor)
We have supplied the 4 kW 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
4. 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.
Result
Our systems performed exceptionally well on the client’s 40-ton electric heavy trucks, earning high satisfaction from the client. As a result, they 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
For heavy commercial vehicles, we offer an extensive range of EV systems, including e-powertrains, batteries, chassis, braking systems, steering systems, and more. Our comprehensive solutions are designed to enhance fleet operational efficiency and elevate safety standards in heavy-duty transportation.
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.
