Electric Axle for Truck: Top Use Cases and Benefits
The electrification of heavy-duty trucks is accelerating, and with it, the question of which drive system to choose becomes increasingly important. Among the available solutions, the electric axle for truck – also known as an e-axle or electric drive axle – is gaining attention for its performance and efficiency advantages. In this article, we explore the main application scenarios for electric heavy-duty trucks, comparing the benefits and limitations of different drive systems, and offering practical guidance for selecting the right e-axle configuration.
Electric Heavy-Duty Truck Drive Methods: Central Drive vs. Electric Axle
Currently, there are two main drive methods used in electric heavy-duty trucks: the traditional central drive system and the electric axle (e-axle).
1. Central Drive system: Advantages and Limitations
A central drive system positions the motor and transmission as a powertrain unit in the middle of the chassis, connected to the drive axle via a driveshaft – similar to the layout of traditional diesel trucks.
This design offers high reliability and lower initial cost, as it uses many shared components such as driveshafts, axles, and suspension systems. These parts benefit from mature mass production, reducing overall cost. Additionally, the motor and transmission are mounted using a four-point suspension, minimizing vibration and impact damage.
However, the system also has notable drawbacks. The central location of the powertrain limits underfloor battery installation, which is essential for achieving high-capacity battery configurations. The low level of component integration adds weight, reducing vehicle efficiency and complicating lightweight design. Furthermore, energy losses occur through the driveshaft and universal joints, resulting in lower transmission efficiency and higher energy consumption.
2. Electric Drive Axle (E-Axle): The Compact and Efficient Solution
An electric axle for trucks integrates the motor and transmission into the axle itself, creating a compact, highly efficient system. This layout allows for:
- Optimized chassis space: Enables large battery packs to be installed under the chassis, lowering the center of gravity and improving vehicle stability.
- Lightweight design: Reduced component count minimizes overall weight, which is critical for heavy-duty trucks.
- Higher energy efficiency: Direct power transfer significantly lowers energy losses, reducing electricity consumption.
Despite these advantages, e-axles require a complete redesign and specialized tooling, leading to higher initial costs. Adoption rates remain relatively low – currently under 10% of electric heavy truck applications – but as demand grows, economies of scale are expected to bring prices down.
Electric Axle for Truck: Application Scenarios
1. Construction Transport: When E-Axle May Not Be Ideal
- Examples: 8×4 electric dump trucks, 8×4 electric concrete mixers, and electric mining trucks.
- Construction environments often involve harsh road conditions – unpaved roads, gravel, and heavily rutted surfaces. Overloaded trucks can deepen ruts, increasing the risk of undercarriage contact.
In these conditions, e-axles are less suitable. Motors and gearboxes integrated into the axle are vulnerable to damage from hard impacts, and since the axle assembly forms part of the unsprung mass, rough terrain can lead to higher vibration and shock loads on the chassis and cabin. For severe off-road environments, a central drive system is typically the better choice.
2. Resource Transport: Electric Axle for Truck as a Strong Option
- Examples: Transport of sand, gravel, coal, and ore.
- Operating conditions include loading yards with shallow potholes, along with highways and national routes. The risk of grounding is minimal compared to construction sites, making electric drive axles a viable choice.
For 6×4 electric heavy trucks, the choice between a centralized drive and an electric axle largely depends on operational needs. If the primary application is resource transportation with routes under 220 km per charge, and cost sensitivity is high while annual mileage is relatively low, with less concern for energy consumption, a centralized drive may be more suitable. However, for fleets with higher annual mileage and stricter energy efficiency requirements, an electric axle is the recommended option due to its superior efficiency and overall performance.
Key specifications for e-axles in resource transport:
- Ground clearance: ≥260 mm
- Steel housings for motors and gearboxes to improve impact resistance
- Multi-speed transmission (3-4 gears) to handle steep grades, heavy loads, and varied driving conditions
- PTO interface for installing hydraulic pumps, essential for tipper applications
3. Express Delivery & Line-Haul Freight: The Ideal Fit for Electric Axles
Many logistics companies are transitioning from diesel to electric heavy-duty trucks for routes under 400 km to reduce operating costs. In this segment, vehicles often cover more than 250,000 km annually, making energy efficiency a critical factor. Some fleets have successfully reduced energy consumption from 1.6 kWh/km to as low as 1.3 kWh/km.
Highway operations make this the perfect scenario for electric drive axles. Recommended configurations include:
- Multi-motor strategy: Two driven axles with 3-4 motors. At start-up and during acceleration, additional motors provide extra torque. At cruising speed, only one or two motors operate for maximum efficiency. During downhill driving, regenerative braking through multiple motors can recover energy and provide up to 48% of maximum braking power, enhancing safety.
- Two-speed transmission: Sufficient for highway driving, where steep gradients are not an issue.
- Lightweight design: Aluminum alloy motor and gearbox housings for improved weight efficiency.
- Air suspension and wide medium-pressure tires: To reduce vibration and enhance ride comfort.
Conclusion: Why the Electric Axle for Truck Is the Future
The electric axle is a cornerstone of heavy-duty truck electrification, offering major advantages in efficiency, weight reduction, and flexible vehicle layout. Although initial costs are currently higher than traditional systems, prices are expected to drop as adoption increases.
From a Total Cost of Ownership (TCO) perspective, fleets operating 150,000 km or more per year can typically recover the cost difference within 1-2 years, thanks to significant energy savings.
As the industry continues to evolve, selecting the right drivetrain configuration based on actual operating conditions is essential for achieving maximum performance and cost-effectiveness.
About Brogen
At Brogen, we provide advanced EV solutions for global commercial vehicle manufacturers, enabling them to streamline research and development while capitalizing on cutting-edge technology. Our offerings ensure superior efficiency, extended range, and seamless system integration with proven reliability—empowering our partners to lead in the rapidly evolving green mobility landscape.
Currently, our EV solutions for battery electric vehicles have been adopted by vehicle manufacturers in countries and regions such as Canada, Türkiye, Brazil, the Philippines, Indonesia, the Middle East, and more.
- Discover our electric truck axle solution here: https://brogenevsolution.com/electric-axle-for-truck/
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