Electric Axle for Buses

We provide electric axle solutions for a wide range of public transport vehicles, including hybrid and battery-electric buses, coaches, double-decker buses, and trolleybuses.

The electric axle solutions are available in various technical configurations, including centralized e-axles (parallel-axis and co-axial) and distributed drive e-axles. They also offer flexibility in drivetrain layouts, with front-steering options to accommodate diverse operational needs. Designed for buses from 5 to 18 meters and beyond, our solutions ensure robust and efficient performance across different vehicle sizes.

Email: contact@brogenevsolution.com

Why Choose Brogen

Strong R&D Capability

The development of our electric axle for buses follows a comprehensive and detailed process, including road profile data collection for specific vehicle segments, requirement analysis, and solution confirmation, theoretical validation, bench simulation testing, real vehicle testing, small-batch vehicle validation, bench simulation testing, real vehicle testing, small-batch vehicle validation, and final performance verification.

Why Choose Brogen

Solution Features

Van

Bus

Metro Rail

Our Offerings

Solutions of Electric Axle for Buses

Centralized Electric Axle for Buses

The centralized electric axle solution for buses eliminates the traditional driveshaft by integrating the motor and gearbox directly onto the axle housing or mounting it on the vehicle frame for power transmission. This design reduces system weight and size, allowing for greater flexibility in vehicle layout while enhancing overall efficiency. For public transit buses, it also facilitates a low-floor design and wider aisles, improving accessibility and passenger flow.

Parallel-Axis Electric Axle for Buses - Solution Introduction

For the parallel-axis eAxle system, the electric drive motor and reducer are mounted on the drive axle, with the motor positioned parallel to the axle housing. Utilizing cylindrical gear transmission for a high gear ratio, the integrated design removes unnecessary transmission components, resulting in a more compact structure and increased transmission efficiency.

Advanced Technologies

Integrated One-Piece Formed Axle Housing (Expansion-Formed)
High load-bearing capacity, lightweight design, and reduced risk of oil leakage.
Optimized Housing Design
A single-piece housing minimizes oil leakage risks, while a smooth, curved inner cavity reduces oil churning losses.
High-Precision Two-Stage Helical Gear Transmission
Features dual-surface precision grinding for improved efficiency, lower noise, and extended lifespan.
Compact Motor and Axle Integration
Minimizes offset distance between the motor and axle housing, further reducing the risk of oil leakage at the reducer interface.

Value for Clients

Compact e-axle layout for better chassis integration
Lightweight design for improved efficiency
Precision-ground gears for low noise and comfort
High transmission efficiency, reducing energy consumption
100,000 km interval oil change, maintenance-free wheel ends
Real-time monitoring of key components for enhanced safety

Our Offerings

The specific parameters vary depending on the configuration. For more parameter information, please contact us at contact@BrogenEVSolution.com

Model	5PE	A5PE (steering)	OEEA30	OEEA50	OEEA60	OEEA85	OEEA95
Rated load capacity	3500 kg	2700 kg	3000-3500 kg	4000-5500 kg	6000 kg	8500 kg	9500 kg
Maximum output torque	5400 N.m	5400 N.m	4433 N.m	5730 N.m	7412 N.m	9214 N.m	14415 N.m
Gear ratio	15.58/16.60	15.58	12.665	16.141	16.473	20.475	19.22
Rated/peak motor power	60/115 kW	60/115 kW	60/120 kW	65/120 kW	80/160 kW	80/160 kW	200/320 kW
Rated/peak motor torque	135/325 N.m	135/325 N.m	160/350 N.m	170/355 N.m	235/450 N.m	200/450 N.m	350/750 N.m
Rated/peak motor speed	4244/12000 rpm	4244/12000 rpm	3580/12000 rpm	3600/12000 rpm	4100/12000 rpm	3600/12000 rpm	4093/12000 rpm

Co-Axial Electric Axle for Buses - Solution Introduction

The coaxial electric axle for buses integrates the motor and axle into a single unit. The electric motor is arranged coaxially with the axle housing, resulting in a more compact structure and a highly concentrated power system. This design optimizes the chassis layout, reduces weight, increases transmission efficiency, lowers energy consumption, extends range, and enhances the reliability of the motor and core transmission components.

Advanced Technologies

Coaxial Motor and Axle Integration
Industry-leading integration technology with the most compact chassis footprint and the lightest weight in its class.
Symmetrical Motor Layout
Ensures balanced unsprung mass distribution, minimizing impact on suspension load conditions compared to parallel-axis e-axles.
High-Precision Helical Gear Transmission
Highly integrated reducer for reduced weight, high efficiency, low noise, and extended lifespan.
High-Strength Cast Axle Housing
Designed for heavy loads, with a smooth curved inner cavity to reduce oil churning losses.

Value for Clients

Compact co-axial e-axle layout for better chassis integration
Lightweight design for improved efficiency
Precision-ground gears for low noise and comfort
High transmission efficiency, reducing energy consumption
100,000 km interval oil change, maintenance-free wheel ends
Real-time monitoring of key components for enhanced safety

Our Offerings

The specific parameters vary depending on the configuration. For more parameter information, please contact us at contact@BrogenEVSolution.com

Model	6PE	8PE	8PE-B	31PE
Rated load capacity	3500 kg	5500 kg	5500 kg	8500 kg
Maximum output torque	5700 N.m	7285 N.m	5240 N.m	13000 N.m
Gear ratio	16.5	14.57	14.57	19.89
Rated/peak motor power	60/130 kW	90/160 kW	60/140 kW	80/150 kW
Rated/peak motor torque	145/350 N.m	200/500 N.m	160/360 N.m	230/650 N.m
Rated/peak motor speed	4000/12000 rpm	4300/9000 rpm	3580/12000 rpm	3400/10000 rpm

Controller for Electric Axles for Buses

According to clients’ different requirements, we can provide standalone MCUs or high-voltage integrated controller systems, integrating MCU, PDU, DC-DC, and steering and braking DC/AC.

Note: Controllers are usually supplied as part of the electric powertrain system and are not sold separately.

Advanced Technologies

The specific features vary depending on the configuration. For more parameter information, please contact us at contact@BrogenEVSolution.com

ISO 26262 Compliance
Functional safety requirements and software/hardware development meet ASIL C standards.
Dual-Integration Design
Combines functional and physical integration to significantly reduce size, weight, and manufacturing costs.
Dual-Inverter Control Technology
Minimizes losses and achieves a maximum efficiency of 98.5%.
Advanced EMC Design
Multi-stage filtering, optimized wiring layout, enhanced shielding, and structural improvements ensure Class 5 compliance under no-load conditions.
Modular & Scalable Architecture
Designed for flexibility and easy expansion.
Digital Simulation & Optimization
Uses digital modeling for simulation analysis, enabling more efficient and cost-effective component selection.

Distributed Drive Electric Axle for Buses

For the distributed drive electric axle solutions, we have integrated two electric motors with the axle, significantly reducing system weight and enhancing vehicle power efficiency. The distributed drive approach allows for independent and precise control of each motor’s torque and speed. It also provides additional safety redundancy: in the event of a single motor failure, the remaining motor can compensate, ensuring continuous power delivery and improving overall vehicle safety.

Rigid Wheel-Side Electric Axle for Buses - Solution Introduction

The rigid wheel-side distributed drive electric axle for buses is characterized by the highly compact design, incorporating dual motors that deliver substantial power. Specifically engineered to support fully flat low-floor configurations and one-step entry, this electric axle solution has undergone comprehensive testing.

Advanced Technologies

Electronic Differential System (EDS)
The advanced Electronic Differential System (EDS) has been proven over millions of kilometers
Electronic Acceleration Slip Regulation (EASR)
Leading torque control algorithm with millisecond response time enhances safety and reduces tire wear
Intelligent Regenerative Braking System (IRBS)
Ensure braking performance while recovering energy in various driving conditions to reduce energy consumption and extend driving range
Intelligent Electronic Stability System (IESS)
Adjust the torque of various components in real-time based on the vehicle status to ensure safety and stability under extreme conditions

Value for Clients

Compact e-axle layout for better chassis integration
Enables a wide passage and low-floor design, enhancing overall vehicle safety and comfort
Dual-tire configuration ensures driving stability
Reliable electronic differential system with a tire replacement interval of over 100,000 km
The gearbox's symmetrical forward and reverse torque improves energy regeneration efficiency by 100%, extending driving range
The distributed drive approach enhances safety redundancy, ensuring that if one motor fails, the other continues to operate

Our Offerings

The specific parameters vary depending on the configuration. For more parameter information, please contact us at contact@BrogenEVSolution.com

Model	F058AE	100041C	N0012AE	P0012AE
Rated axle load capacity	5000 kg	9000 kg	13000 kg	14000 kg
Motor rated voltage	540 VDC	540 VDC	540 VDC	540 VDC
Motor rated/peak power	2×37/2×74 kW	2×60/2×120 kW	2×80/2×160 kW	2×80/2×160 kW
Motor rated/peak torque	2×126/2×382 N.m	2×145/2×400 N.m	2×220/2×580 N.m	2×220/2×580 N.m
Motor peak speed	10000 rpm	9500 rpm	8000 rpm	8000 rpm
Gear ratio	10.63	17.55	18.58	18.58
Brake type	Hydraulic disc brake	Air disc brake	Disc brake	Disc brake
Total system weight	550 kg	850 kg	1080 kg	1127 kg

Steering Wheel-Side Electric Axle for Buses - Solution Introduction

The steering electric portal axle solution is suitable for public transport vehicles from 8 meters to 10 meters or trolleybuses. It adopts the 4-airbag independent suspension system. This solution enables highly customizable configurations for buses and provides passengers with greater convenience.

Advanced Technologies

Electronic Differential System (EDS)
The advanced Electronic Differential System (EDS) has been proven over millions of kilometers
Electronic Acceleration Slip Regulation (EASR)
Leading torque control algorithm with millisecond response time enhances safety and reduces tire wear
Intelligent Regenerative Braking System (IRBS)
Ensure braking performance while recovering energy in various driving conditions to reduce energy consumption and extend driving range
Intelligent Electronic Stability System (IESS)
Adjust the torque of various components in real-time based on the vehicle status to ensure safety and stability under extreme conditions

Value for Clients

Compact e-axle layout for better chassis integration
Enables a wide passage and 100% low-floor design, enhancing overall vehicle safety and comfort
Reliable electronic differential system with a tire replacement interval of over 100,000 km
Integrated steering functionality allows rear wheels to track the front, significantly reducing inner wheel difference accidents during right turns
The gearbox's symmetrical forward and reverse torque improves energy regeneration efficiency by 100%, extending driving range
The distributed drive approach enhances safety redundancy, ensuring that if one motor fails, the other continues to operate

Our Offerings

The specific parameters vary depending on the configuration. For more parameter information, please contact us at contact@BrogenEVSolution.com

Model	K0011AE
Rated voltage	600 VDC
Motor rated/peak power	2×55/2×90 kW
Motor rated/peak torque	2×140/2×350 N.m
Motor peak speed	9500 rpm
Axle weight	850 kg
Rated axle load capacity	9000 kg
Gear ratio	17.55
Rim size	22.5″
Brake type	Air disc brake
Maximum steering angle	±18°

Distributed Drive Electric Powertrain Controllers

For distributed drive electric axles for buses, our solution includes the necessary controllers, such as the integrated motor control unit (MCU), and the distributed drive control unit (DCU), which also incorporates the transmission control unit (TCU).

Advanced Technologies

Drive / Brake Decoupling
- Distributed Drive → Enhanced control on complex surfaces
- Distributed Brake → Reduced braking distance on complex surfaces
Distributed Steering
- Four-wheel Independent Steering → Reduces turning radius; enables lateral movement and zero-radius turns; significantly enhancing maneuverability
- Eliminates Mechanical Transmission → Increases user space; reduces energy transmission losses

Comprehensive Torque Control System
Ensures precise and efficient power distribution
Advanced Software Decoupling
Enhances system responsiveness and integration
Electronic Differential Module
Enables intelligent torque distribution between wheels
Electronic ASR (Anti-Slip Regulation)
Improves vehicel stability on low-traction surfaces, ensuring smooth starts and acceleration
Electronic ESP (Electronic Stability Program)
Enhances safety and maneuverability on icy or snowy roads by adjusting wheel torque and speed to optimize yaw control

How We Work

Navigating Our Process

Demand Analysis & Project Evaluation

Once we receive your inquiry, our experts will connect with you within two business days to understand your specific requirements for the EV solution and conduct an initial feasibility evaluation of your project.

Project & Technical Coordination

If the project is deemed feasible, our engineering team will collaborate closely with your team on both hardware and software aspects to develop a viable solution. We will also provide a detailed quotation based on the technical requirements.

Development, Manufacturing & Testing

For customized or modified systems, we proceed with product development, including hardware and software adaptations. Our EV systems undergo rigorous testing to ensure quality, reliability, and full functionality before deployment.

In-Time Global Shipping & Delivery

We have established strong partnerships with international shipping providers, ensuring safe and timely delivery of products to your specified location. This guarantees a smooth and efficient deployment of your EV project.

Full-Stage Remote/Onsite Technical Support

We provide technical support throughout the entire project lifecycle, including consultancy, hardware and software development, calibration, and both onsite and remote debugging, ensuring optimal performance and long-term success.