Battery-Electric Concrete Mixer Truck With Axial Flux Motor E-Axles
- Client: A concrete mixer truck manufacturer
- Demand: An electric axle solution for their 31-ton heavy-duty battery-electric concrete mixer trucks
The electrification trend in commercial vehicles extends to concrete transportation, driven by a dual desire for environmental sustainability and cost savings. Facing the challenge of high fuel costs, concrete mixer truck manufacturers seek innovation solutions to optimize efficiency and reduce operational costs.
Description
In 2023, a leading concrete mixer truck manufacturer approached us for an EV solution for their 31-ton heavy-duty battery-electric concrete mixer requirements. Understanding the industry’s need for cost-effective electrification, our experienced experts recommended the e-axle solution with axial flux motors for heavy-duty trucks to meet their demands.
The 460 kW E-Axle Solution for the Battery-Electric Concrete Mixer
Our integrated e-axle system features two axial flux motors, each with 230 kW of power. With the maximum power of 460 kW, the drivetrain system achieves a wheel-end transmission efficiency exceeding 96%, and the maximum gradeability reaches 50%. This also helps effectively increase the cruising range.
Benefits of the E-Axle Solution With Axial Flux Motors
- Enhanced transmission efficiency and range: since the weight and size of the axial flux motor is 50% that of the traditional radial flux motor, this e-axle system uses the three-speed automatic transmission. The first, second, and third gears each have a two-stage transmission. While significantly improving transmission efficiency, the system operates in the high-efficiency range at almost any vehicle speed.
- Dual-mode shifting: The dual-mode shifting mode can achieve differential shifting between the front and rear axles as well as power compensation. There’s no interruption of power to the vehicle during the shifting process, with a shift response time of less than 0.6 seconds.
- Optimized vehicle layout: thanks to the use of the axial flux motors, this solution offers a more spacious vehicle layout, allowing the entire vehicle’s traction battery pack to be positioned under the vehicle’s main beams. As a result, the electric concrete mixer truck’s center of gravity is lowered by more than 100 mm compared to conventional gasoline-powered vehicles. And it’s 130 mm lower compared to similar all-electric concrete mixer trucks from other brands. Thus, this fully electric concrete mixer truck has better roll stability, ensuring safer driving.
Results
The application of the lightweight and more efficient axial flux motor system has enabled this 31-ton new energy concrete mixer truck to achieve a range of 260 km (according to the steady-speed method), with an actual operational range of up to 180 km, significantly outperforming similar products on the market.
A driver of this battery-electric concrete mixer truck remarked, “This electric truck has strong power and is comfortable to drive, just like driving a car. Plus, charging it once at night is basically enough for a day’s use, and charging speed is also very fast, almost done in an hour.”
Brogen Electric Powertrain Solutions
At Brogen, we provide electric powertrain solutions for commercial vehicles, ranging from mature and reliable direct-drive motors to integrated e-powertrains (motor, transmission, and controller) as well as compact, high-efficiency e-axle solutions. Our offerings help EV manufacturers accelerate development and reduce R&D costs for their projects.
- If you’re looking for a tailored EV solution, don’t hesitate to contact us at contact@BrogenEVSolution.com
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