brogenevsolution.com, Author at Brogen EV Solution | Shanghai OE Industrial Co., Ltd.

30 kW / 70 kW Electric Axles for Pickup Trucks, Mini Trucks, Vans

30 kW / 70 kW Electric Axles for Pickup Trucks, Mini Trucks, Vans Our 30 kW / 70 kW electric axles for pickup trucks, mini trucks, and vans are engineered with a lightweight and compact architecture, reducing both weight and space for light commercial vehicles. With a highly compact design, the motor and gearbox are integrated directly into the rear axle, enabling easier installation, simplified layout, and improved energy efficiency. This integration also contributes to a more sustainable and environmentally friendly vehicle platform. Currently, this solution has entered the SOP phase and is now in mass production, with large-scale deployment across electric mini truck platforms. Email: contact@brogenevsolution.com Get Custom Quote Solution Details High integration: compact structure, efficient transmission Fully release the X-direction space for battery layout Lighter system weight than traditional central drive system Low development difficulty, low manufacturing cost Better overall performance indicators such as the driving performance, economu, and EKG value Model OEHY-192 Rated power 30 kW Peak power 70 kW Rated torque 80 N.m Peak torque 230 N.m Rated speed 3600 rpm Peak speed 9000 rpm Cooling method Liquid cooling Final drive ratio 10.5:1 *The specifications may vary based on configuration, and customization options are available. For detailed parameter information, please contact us at: contact@BrogenEVSolution.com Case Studies Electric Mini Truck Project in Thailand A Thailand-based OEM sought to develop an electric mini truck prototype and engaged us to provide an electric powertrain solution. After assessing their vehicle requirements, we supplied our integrated e-axle system with an MCU, along with a 3-in-1 CDU combining the OBC, DC/DC converter, and PDU. Throughout the development phase, our engineering team customized and optimized the software to match the client’s vehicle architecture. Our experts remained on standby to provide prompt technical support and resolve any issues encountered during integration and testing. Within less than a year, the customer placed a second purchase order for further vehicle validation. Following a successful full-vehicle testing, the electric mini truck entered mass production. Refrigerated Pickup Truck Conversion Project in the United States A U.S.-based fleet operator specializing in refrigerated pickup trucks aimed to electrify its fleet to achieve more sustainable operations and reduce long-term operating costs. After receiving the complete vehicle specifications and refrigeration system requirements, we proposed our 70 kW electric axle purpose-built for pickup applications, along with other auxiliary systems. 30kW / 70kW electric axle for pickup trucks DC/DC converter Electric air-conditioning compressor Electric water pump Air brake compressor 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. LinkedIn channel Follow us for regular updates > YouTube channel Ev systems introduction & industry insights > ContactFill in the form and we will get in touch with you within 2 business days.Please enable JavaScript in your browser to complete this form.Please enable JavaScript in your browser to complete this form. Name * FirstLast Work Email *Company Name *Your Project Type *– Please select –Car, SUV, MPVBus, coach, trainLCV (pickup truck, light-duty truck, etc.)HCV (heavy-duty truck, tractor, trailer, concrete mixer, etc.)Construction machinery (excavator, forklift, crane, bulldozer, loader, etc.)Vessel, boat, ship, yacht, etc.Others (please write it in the note)Your Interested Solutions *– Please select –Motore-AxleBatteryChassisAuxiliary inverterOBC / DCDC / PDUAir brake compressorEPS / EHPS / SbW / eRCBBTMSOthers (please write it in the note)Do you have other contact info? (Whatsapp, Wechat, Skype, etc.)Please introduce your project and your request here. * Checkbox * I consent to receive updates on products and events from Brogen, and give consent based on Brogen’s Privacy Policy. Submit

Light Commercial Vehicles

240 kW E-Axle for Light Truck, Van, Minibus

120 kW / 240 kW E-Axle for Light Truck, Van, Minibus The 120 kW / 240 kW e-axle adopts a dual-motor design with a rated axle load capacity of 5,000 kg. It is engineered for light commercial vehicles, including light trucks, vans, and 7-8 meter minibuses or coaches, that demand high performance, efficiency, and compact integration. Featuring a distributed drive architecture, the e-axle enables precise torque control for improved traction and stability under various driving conditions. Its built-in safety redundancy further enhances operational reliability, meeting the stringent requirements of premium electric commercial vehicles. The system has successfully entered the SOP phase and is now in mass production. Email: contact@brogenevsolution.com Get Custom Quote Solution Details This 240 kW e-axle features a highly compact and integrated design, incorporating two motors, two reduction gear assemblies, two brake assemblies, two brake chambers, upper and lower cross beams, dual hydraulic reservoirs, a 2-in-1 motor controller, and an electronic differential system. With the adoption of electronic differential technology, the left and right drive systems are independently controlled, enhancing overall performance and maneuverability. Basic Structure With high torque and power density, the two PMSM drive motors provide a strong and reliable output. The wheel-side reducers on each side reduce the motor output speed while amplifying the torque delivered to the wheels. The 2-in-1 motor controller controls the left and right motors to operate at the desired speed, angle, direction, and response time. Working Principle The VCU calculates the total torque demand based on the driver’s acceleration or deceleration intent. The electric drive control unit (DCU) allocates the total torque between the left and right drive motors based on the steering angle, vehicle posture sensors, and road surface traction coefficients. Technical Specifications Model OEEA850F Axle load 5000 kg Maximum output torque 2×4272 N.m Maximum output power 2×120 kW Maximum wheel speed 880 rpm Tire specifications (standard) 215/75R17.5 Axle assembly weight 421 kg Protection level IP68 Speed ratio 10.68 Motor type PMSM Working voltage range 450-720 VDC Coolant 50% ethylene glycol + 50% water The parameters may vary depending on the configuration. For more parameter information, please contact us at contact@BrogenEVSolution.com Key Features of Brogen 240 kW Electric Axle for Light Truck, Van, Minibus Distributed Drive It employs distributed drive technology, enabling precise independent control of torque and speed for each wheel. This enhances safety redundancy, ensuring the vehicle remains operational even if one motor fails. Compact & Lightweight The compact design integrates two motors, the reduction assembly, braking systems, and the drive axle, effectively minimizing the need for complex components and the space required by traditional drivetrains. Advanced Core Technologies Our electric axles for light trucks can be integrated with advanced safety configurations and strategies, such as EDS, EASR, and IESS, to enhance vehicle safety and stability, especially during critical maneuvers like steering or acceleration. Gallery 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. LinkedIn channel Follow us for regular updates > YouTube channel Ev systems introduction & industry insights > ContactFill in the form and we will get in touch with you within 2 business days.Please enable JavaScript in your browser to complete this form.Please enable JavaScript in your browser to complete this form. Name * FirstLast Work Email *Company Name *Your Project Type *– Please select –Car, SUV, MPVBus, coach, trainLCV (pickup truck, light-duty truck, etc.)HCV (heavy-duty truck, tractor, trailer, concrete mixer, etc.)Construction machinery (excavator, forklift, crane, bulldozer, loader, etc.)Vessel, boat, ship, yacht, etc.Others (please write it in the note)Your Interested Solutions *– Please select –Motore-AxleBatteryChassisAuxiliary inverterOBC / DCDC / PDUAir brake compressorEPS / EHPS / SbW / eRCBBTMSOthers (please write it in the note)Do you have other contact info? (Whatsapp, Wechat, Skype, etc.)Please introduce your project and your request here. * Checkbox * I consent to receive updates on products and events from Brogen, and give consent based on Brogen’s Privacy Policy. Submit

electric air brake compressor for truck, bus

EV Industry, Technologies

Oil-Free Air Brake Compressors For Commercial EVs

Oil-Free Air Brake Compressor for Commercial EVs: The Next Step in Clean Mobility With the rapid growth of electric vehicles worldwide, the electrification of commercial vehicles has entered a stage of fast expansion. Among their key subsystems, the electric air brake compressor plays a critical role in the pneumatic braking system, air suspension, and other auxiliary air systems. It’s a core component that directly impacts vehicle safety, reliability, and efficiency – and is now entering a rapid phase of technological evolution. This article explores the current market landscape and development trends of EV air brake compressors, particularly for commercial vehicles. 1. What is An Electric Air Brake Compressor in Commercial Vehicles In traditional commercial vehicles, the air compressor is typically driven by the engine. However, in electric vehicles, which no longer rely on internal combustion, an electric air compressor replaces this function. It provides compressed air for the vehicle’s brake system, air suspension, and auxiliary actuators, making it an essential element of EV safety and performance. With strong government policies promoting EVs globally, the market demand for electric air brake compressors has grown significantly. Traditional air compressor Electric air brake compressor 2. Current Status of Electric Air Brake Compressor Technology The shift toward electrification in commercial vehicles has given rise to multiple types of electric air brake compressors, such as screw, vane, and scroll compressors. However, over nearly a decade of market validation, these designs have shown limitations such as oil-gas emulsification, low discharge pressure, and poor reliability – leading to their gradual replacement. Today, piston-type air compressors have become the mainstream solution for electric commercial vehicles, offering better efficiency, reliability, and adaptability to high-pressure systems. Screw compressor Vane compressor Scroll compressor Piston compressor Item Oil-lubricated piston type Screw type Vane type Scroll type Lubricating oil type Traditional diesel engine oil Special screw compressor oil Special vane compressor oil – Driving safety Safe If maintenance is not timely, it will contaminate the air system, causing rubber parts to expand and age, easily leading to brake system failure – Lubricant consumption Small Large Large – Lubricant emulsification and deterioration None Easy Easy – Environmental adaptability (air contact) Less contact with external air Easily affected by external air contamination – Oil-gas separator Not required Required Required – Oil separator filter element lifespan – Short Short – Lubricant temperature control Not required Required Required – Impact of ambient humidity Small Large Large – Discharge pressure Can withstand short-term overload General General Low Special maintenance experience requirements None High High Very high Environmental adaptability Good Poor Poor Poor Service life Good Poor Poor Poor 3. The Rise of Oil-Free Piston Electric Air Brake Compressor Most piston-type electric air compressors in use today are still oil-lubricated, which requires regular oil changes and maintenance. Problems such as oil leakage or contamination can lead to secondary pollution and increased maintenance costs. In constrast, oil-free air brake compressors eliminate the need for lubrication oil, reduce system complexity, and ensure clean, oil-free compressed air – protecting pneumatic components and improving environmental sustainability. Based on years of market application and customer feedback, the trend is clear: oil-free piston compressors are becoming the future direction of EV air brake compressor technology. Oil electric air brake compressor Oil-free electric air brake compressor 4. Oil-Free Air Brake Compressor Technology Overview Among current oil-free air compressor designs, scroll compressors have seen early adoption in electric vehicles. They offer compact structure, smooth operation, and high efficiency. However, due to their tight sealing gaps, scroll compressors require extremely clean intake air, making them vulnerable to dust and humidity, especially since compressors in commercial EVs are often mounted on the chassis. Additionally, scroll compressors tend to have high discharge temperatures and struggle to meet the >1 MPa high-pressure requirements of commercial brake systems. Maintenance is also costly, as damaged scroll plates must be replaced entirely. As a result, oil-free piston compressors have emerged as the mainstream solution due to their superior pressure performance, environmental adaptability, and long service life. Comparison of Oil-Free Air Compressor Types Item Oil-free piston air compressor Oil-free scroll air compressor Discharge pressure Strong high-pressure capability; easily meets the standard requirement of ≥ 1 Mpa. Limited by the scroll sealing structure, poor high-pressure sealing performance leads to low discharge pressure. High-pressure performance decays significantly over time, making it difficult to maintain 1 MPa for long periods. Structural sealing Use a direct-drive motor design with a simple and reliable transmission structure; minimal high-pressure attenuation. Requires a precise clearance between moving components to achieve sealing, resulting in high requirements for sealing materials. The complex sealing structure is prone to thermal deformation and leakage. Environmental adaptability Excellent adaptability; IP67 or higher protection level allows operation in harsh environments (high temperature, low temperature, high altitude). Both the orbiting and fixed scroll plates feature curved surfaces requiring high machining accuracy. The strict sealing demands on upper and lower end faces make it sensitive to environmental conditions. Cooling performance The compressor head uses air or water cooling with an additional cooler, providing excellent heat dissipation. The internal working chamber cannot be externally cooled, making heat removal difficult. Localized overheating occurs easily, resulting in high discharge temperatures. Maintenance Requires no special maintenance – only periodic air filter cleaning. High sealing precision requirements lead to faster seal wear. Maintenance involves disassembling the entire unit to replace seals, making servicing difficult and costly. If scroll plates are damaged, the entire assembly must be replaced. Service life High reliability and long service life. Due to its unique sealing structure, service life is highly dependent on working conditions. Components operate under high temperature, humidity, and pressure, significantly shortening lifespan and overall reliability. 5. Advantages of the Two-Stage Oil-Free Piston Air Brake Compressor In response to the GB 7258 national standard requiring brake air pressure above 1 MPa, and OEMs demanding even higher efficiency and emission reduction, two-stage oil-free piston compressors have become the latest evolution trend. They are designed for high discharge pressure, low exhaust temperature, high efficiency, and long service life. Single-stage oil-free

Heavy Transport, Technologies

Mining Electrification Solutions: Electric Dump Truck System Design

Mining Electrification Solutions: Electric Dump Truck System Design 1. Introduction The electric dump truck is a specialized off-highway vehicle designed for short-haul material transport in industries such as mining, metallurgy, cement, water conservancy, and construction. Its working conditions are characterized by steep slopes, short routes, large load variations, fixed transport lines, and complex operating environments. Traditional diesel-powered dump trucks face several challenges in these conditions: high fuel consumption, elevated maintenance costs, and shorter service life. By contrast, electric dump trucks replace diesel engines and manual transmissions with battery packs and electric drive motors. When traveling on flat roads or downhill, the motor operates in regenerative braking mode, converting braking energy into electricity to recharge the battery. This not only reduces wear on the mechanical brake system – improving safety and extending component life – but also increases vehicle range. With fewer maintenance needs, high protection levels, and superior adaptability to harsh mining environments, electric dump trucks are becoming the preferred choice for heavy-duty operations. 2. High-Voltage System Architecture of Electric Dump Truck High-voltage system architecture for the electric dump truck (for reference) Electric dump trucks replace the conventional powertrain with a high-voltage system. The main high-voltage components include: traction battery, PDU, DC fast charging port, integrated controller, thermal management system, and other auxiliary high-voltage systems. ● Traction Battery It’s the energy supply unit in an electric dump truck, providing electric power to all vehicle systems. When the battery is depleted, it also requires recharging. Therefore, the energy flow of the battery is bidirectional. ● High-Voltage Power Distribution Unit (PDU) The PDU is a distribution hub for high-voltage power, supplying electricity to all components within the high-voltage system. For example, battery heating, charging circuits, and power distribution to the integrated controller. Inside the PDU are fuses, relays, and a pre-charge circuit for each controllable high-voltage loop. Between the traction battery and the PDU, a Manual Service Disconnect (MSD) is installed. The MSD is a mandatory safety device that allows physical disconnection of the high-voltage circuit during battery servicing or vehicle maintenance. It ensures safe isolation of the high-voltage system and often incorporates fuse protection to enhance electrical safety and reliability. ● Thermal Management System The thermal management system integrates both heating and cooling functions, maintaining the traction battery within its optimal operating temperature range to ensure safety, efficiency, and extended service life. Brogen traction batteries for electric trucks Brogen PDU for electric trucks Brogen BTMS for electric trucks ● Motor Controller and Drive Motor The motor controller converts high-voltage DC from the integrated controller into three-phase AC to power the drive motor. It regulates motor torque and rotational direction, enabling smooth vehicle start, stop, forward, and reverse operations. Additionally, during braking or deceleration, the drive motor recovers kinetic energy, converts it into electrical energy, and feeds it back to the traction battery for extended range and efficiency. Brogen e-powertrain (motor+AMT) for heavy-duty trucks System schematic for Brogen’s electric motor + AMT e-powertrain ● DC Fast-Charging Port The DC fast-charging port delivers high-voltage direct current, which can be routed through the PDU directly to the power battery for rapid charging without additional processing. ● Integrated Controller The integrated controller receives commands from the VCU and coordinates both the main drive system and auxiliary subsystems. Key auxiliary loads include the cab air-conditioning compressor, PTC heater, electro-hydraulic power steering pump, air compressor, and DC/DC converter. The DC/DC converter steps down high-voltage DC from the traction battery to low-voltage DC to charge the auxiliary lead-acid battery. Compared with traditional distributed controllers, the integrated controller offers reduced size and footprint, optimizing vehicle layout. Minimizing high-voltage external wiring between discrete controllers reduces potential failure points, lowers costs, and enhances overall system reliability and safety. Brogen 4-in-1 integrated auxiliary inverter System schematic for Brogen’s integrated auxiliary inverter ● Auxiliary High-Voltage Systems The electric A/C compressor and PTC heater serve as the core components of the HVAC system, delivering cooling and heating functions. The electric air compressor supplies high-pressure compressed air for the braking system. The electro-hydraulic power steering pump provides hydraulic assistance to the steering system. 3. Traction Battery Selection and Design At present, mainstream electric vehicles generally adopt ternary lithium batteries or lithium iron phosphate (LFP) batteries. LFP batteries use lithium iron phosphate as the cathode material and graphite as the anode material. Compared with ternary batteries, LFP batteries offer the following advantages: High safety performance: The decomposition temperature of LFP is about 600°C. Even under high temperature or overcharge conditions, it does not undergo structural collapse, generate excessive heat, or form highly oxidative substances as ternary batteries do. In the event of a collision or short circuit, LFP batteries are also highly resistant to explosion. Long cycle life: The cell cycle life can reach up to 4,000 cycles, and around 3,000 cycles at the PACK level. Excellent high-temperature performance: Wide operating temperature range with strong thermal stability. Environmental friendliness: LFP batteries contain no heavy metals or rare metals, making them non-toxic and pollution-free. These features make LFP batteries particularly well-suited for mining applications, where operating conditions are harsh, ambient temperatures vary widely, and safety requirements are stringent. Battery packs for electric dump trucks Brogen traction battery factory Brogen traction battery pack details 4. High-Voltage Power Distribution Unit (PDU) Design The High-Voltage Power Distribution Unit (PDU) is responsible for distributing electrical power throughout the vehicle’s high-voltage system. Its function is similar to a fuse box in a low-voltage electrical system, primarily managing power distribution and providing overload and short-circuit protection for high-voltage circuits. High-voltage distribution schematic Brogen PDU system, typically integrated with the battery system The PDU distributes the energy supplied by the power battery to the integrated controller, as well as to the battery heating and cooling systems. During DC fast charging, the charging current also flows through the PDU to charge the power battery. Additionally, the Battery Management System (BMS) is integrated into the PDU. The BMS performs the following key functions: Monitoring the total battery voltage and charge/discharge current. Monitoring battery status, including individual cell

semi trailer ev solution electrified trailers

Heavy Transport, Technologies

Electrified Trailers: Driving the Next Evolution of Semi-Trailer Trucks

Electrified Trailers: Driving the Next Evolution of Semi-Trailer Trucks 1. The Strategic Role of Semi Trailers in Commercial Vehicles In the commercial vehicle sector, semi-trucks and semi-trailers are typically manufactured by two separate companies. While semi-truck sales often attract more attention, semi-trailers represent an equally important and sizeable market segment. The performance of a tractor-trailer combination largely depends on how well the two units are coordinated and matched. Electrifying semi-trailers brings new opportunities. By integrating batteries into trailers, the overall driving range can be extended. In more advanced scenarios, an electrified trailer could even supply supplementary power to the semi-truck, reducing operating costs. This multi-mode adaptability – whether paired with internal combustion engine (ICE) semi-trucks, hybrid semi-trucks, or fully electric semi-trucks – creates flexibility in today’s mixed market where ICE trucks still dominate. For fleet operators, return on investment must be visible in the short term. This is why leasing models for intelligent or electrified trailers are emerging: the upfront cost of advanced perception and drive systems is high, but a leasing approach allows broader adoption. Traditional semi-trailers are already widely leased in the logistics sector, making this model a natural fit. 2. Technical Trends: Architecture of Electrified Trailers Despite trailers’ relatively simple structures, electrification presents unique engineering challenges. Semi-trailers require integration of electric drive components, with the most efficient solution being the use of an electric drive axle (e-axle) (Discover our e-axle solution for electrified trailers here). With the mature e-axle technology, trailers can become independent driving units, capable of moving under their own power while still requiring support from the semi-truck. This allows for better performance when combined with semi-trucks, as integrated control systems can optimize the overall semi-trailer truck dynamics beyond what conventional, loosely coupled combinations can achieve. Advantages of Semi-Trailer Truck Integrated Control With Electrified Trailers Energy Efficiency: Up to 20%-30% reduction in fuel consumption and CO₂ emissions through optimized power coordination; More than 50% of braking energy can be recovered; Supply power to refrigeration units or other auxiliary equipment. Performance: Improved traction on slippery surfaces (up to +80%); Enhanced acceleration (time reduced by 50%); Stronger climbing ability; Safer lane-change and overtaking capability. Cost Benefits: Lower lifecycle operating costs; Better synergy with smart vehicle technologies; Moderate weight increase offset by efficiency gains. Safety: Improved stability; Reduced risk of jackknifing or trailer swing; Integration with braking systems enables advanced dual electric braking control. Electrified trailer with Brogen e-axle solutions Electrified trailer with Brogen e-axle solutions 3. Engineering Challenges in Electrified Trailers Adapting semi-truck e-drive technology to trailers is technically feasible. The primary challenges lie in: Integrated Control: Developing precise tractor-trailer coordination strategies. Electronic Architecture: Reconfiguring trailer E/E systems to support additional electric drive and control functions. Lightweight Design: Since gross vehicle weight limits are fixed, adding e-axles and batteries reduces payload. This necessitates advanced materials and optimized structural design to preserve carrying capacity. 4. Industry Outlook and the Future of Electrified Trailer The commercial vehicle industry faces a paradox of limited market size but high R&D demands, as system complexity in trucks far exceeds that of passenger cars. This tension requires innovative approaches to balance performance, cost, and adoption. Under the dual trends of electrification and intelligent vehicle systems, technologies such as smart chassis, electrified trailers, and tractor-trailer integrated control are becoming core areas of research and competition. Electrified trailers, with their potential to boost efficiency, safety, and versatility, are set to become a vital part of the commercial transport market. 5. Toward Our Electrified Trailer Solution While challenges remain, the trajectory is clear: electrified trailers will reshape the performance of semi-trailer trucks. Our electrified trailer solution builds upon these insights – delivering integrated power, control, and efficiency to unlock new value for logistics operators. We deliver an integrated electrified trailer solution, covering electric axle, controller, and battery system. Hardware + software co-developed for seamless performance, simplified integration, and faster time-to-market. Discover our electrified trailer solution here: https://brogenevsolution.com/electrified-trailer-solution/ Business inquiry: 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. LinkedIn channel Follow us for regular updates > YouTube channel Ev systems introduction & industry insights > ContactFill in the form and we will get in touch with you within 2 business days.Please enable JavaScript in your browser to complete this form.Please enable JavaScript in your browser to complete this form. Name * FirstLast Work Email *Company Name *Your Project Type *– Please select –Car, SUV, MPVBus, coach, trainLCV (pickup truck, light-duty truck, etc.)HCV (heavy-duty truck, tractor, trailer, concrete mixer, etc.)Construction machinery (excavator, forklift, crane, bulldozer, loader, etc.)Vessel, boat, ship, yacht, etc.Others (please write it in the note)Your Interested Solutions *– Please select –Motore-AxleBatteryChassisAuxiliary inverterOBC / DCDC / PDUAir brake compressorEPS / EHPS / SbW / eRCBBTMSOthers (please write it in the note)Do you have other contact info? (Whatsapp, Wechat, Skype, etc.)Please introduce your project and your request here. * Checkbox * I consent to receive updates on products and events from Brogen, and give consent based on Brogen’s Privacy Policy. Submit

DC_DC for hybrid excavator dc-dc converter

EV Industry

DC-DC Converter in EVs: Role, Architecture, and Operating Principles

DC-DC Converter in EVs: Role, Architecture, and Opearting Principles 1. The Role of a DC-DC Converter In simple terms, a DC-DC converter in an electric vehicle (EV) is a step-down voltage converter. Its primary function is to convert the high-voltage DC power from the traction battery into the low-voltage DC power required by the vehicle’s auxiliary electrical system. Conventional internal combustion engine (ICE) vehicles: Powered by an alternator and a 12V lead-acid battery, which supply electricity to components such as headlights, infotainment systems, the ECU, power windows, door locks, and wipers. Electric vehicles: Since there is no engine, there is no alternator. Instead, EVs rely on a high-voltage traction battery (typically 200V-800V) for propulsion. However, most onboard systems – such as the instrument cluster, lighting, infotainment, controllers, and window motors – still operate on a traditional 12V low-voltage system. Without a conversion path, energy cannot flow between the high-voltage and low-voltage domains. The DC-DC converter bridges this gap. It replaces the alternator in ICE vehicles and acts as the core low-voltage power supply in EVs. 2. Circuit Composition of a DC-DC Converter Most EVs use isolated LLC resonant DC-DC converters, either unidirectional or bidirectional. While sophisticated in design, their operating principle is similar to that of a common switch-mode power supply. A typical DC-DC converter consists of the following components: 2.1 Main Power Circuit Input EMI filer: Smooths the high-voltage DC from the traction battery, reducing voltage ripple and electromagnetic interference. Power switching stage: Typically a half-bridge or full-bridge structure. Controlled by high-frequency switches (MOSFETs/IGBTs), the DC input is inverted into a high-frequency AC square-wave signal. This is the core of energy conversion. High-frequency transformer: Electrical isolation: Provides galvanic isolation between high-voltage and low-voltage sides for safety and noise immunity. Voltage transformation: Achieves step-down conversion according to the winding ratio. Output rectifier: Converts the transformer’s secondary high-frequency AC into DC. Typically implemented with diodes or synchronous rectification MOSFETs. Output filter: A combination of inductors L and capacitors C smooths the rectified DC to provide a stable 12V output. 2.2 Control and Drive Circuit Main control unit: The “brain” of the DC-DC converter. It continuously monitors voltage and current, compares them with reference values, and generates PWM signals to adjust the duty cycle of the switching devices for precise voltage regulation. Driver circuit: Amplifies the PWM signals from the control unit to ensure the power switches operate rapidly and efficiently. Sampling and protection circuit: Continuously monitors input voltage, output voltage, output current, and temperature. In case of over-voltage, under-voltage, over-current, over-temperature, or short-circuit conditions, the controller immediately shuts down PWM input to protect both the converter and the low-voltage system. 3. Operating Principle of a DC-DC Converter The working process can be summarized in four stages: DC → High-Frequency AC → Transformation → DC. Inversion (DC-AC): The control unit generates four PWM signals to alternately drive the switches in the full-bridge circuit (Q1-Q4). This converts the high-voltage DC (e.g., 400V) into a high-frequency AC square wave, typically in the kHz range. Transformation & Isolation: The AC signal passes through the LLC resonant tank, enabling zero-voltage switching (ZVS) of MOSFETs, which minimizes switching losses and improves efficiency. The high-frequency transformer then steps down the voltage and provides galvanic isolation. Rectification (AC-DC): The transformer’s secondary AC output is rectified by the output stage, often using synchronous rectification with MOSFETs to reduce conduction losses compared to diodes. Filtering & Output: The rectified pulsating DC passes through an LC filter to produce a stable 12V DC supply for onboard low-voltage devices. Closed-Loop Feedback Control: The control chip continuously monitors the output voltage via sampling resistors. If the load increases (e.g., headlights and AC operating simultaneously) and the voltage drops, the controller increases the PWM duty cycle to deliver more energy to the low-voltage side, restoring the output to 12V. If the load decreases, the duty cycle is reduced. This negative feedback loop ensures that the DC-DC converter maintains an extremely stable 12V supply regardless of load variations. Our DC-DC Converter Solutions At Brogen, we provide a full range of DC-DC converter solutions for electric vehicles, covering power outputs from 0.6 kW to 6 kW, with options for natural, air, or water cooling. Our portfolio also includes OBC & DC-DC combo units, as well as 3-in-1 CDU combo units that integrate the OBC, DC-DC, and PDU into a single compact system. Learn more here: https://brogenevsolution.com/obc-dcdc-pdu/ 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. LinkedIn channel Follow us for regular updates > YouTube channel Ev systems introduction & industry insights > ContactFill in the form and we will get in touch with you within 2 business days.Please enable JavaScript in your browser to complete this form.Please enable JavaScript in your browser to complete this form. Name * FirstLast Work Email *Company Name *Your Project Type *– Please select –Car, SUV, MPVBus, coach, trainLCV (pickup truck, light-duty truck, etc.)HCV (heavy-duty truck, tractor, trailer, concrete mixer, etc.)Construction machinery (excavator, forklift, crane, bulldozer, loader, etc.)Vessel, boat, ship, yacht, etc.Others (please write it in the note)Your Interested Solutions *– Please select –Motore-AxleBatteryChassisAuxiliary inverterOBC / DCDC / PDUAir brake compressorEPS / EHPS / SbW / eRCBBTMSOthers (please write it in the note)Do you have other contact info? (Whatsapp, Wechat, Skype, etc.)Please introduce your project and your request here. * Checkbox * I consent to receive updates on products and events from Brogen, and give consent based on Brogen’s Privacy Policy. Submit

Heavy Transport

120 kW / 185 kW Electric Motor + 2-Speed AMT E-Powertrain | Bus, Coach, Truck

120 kW / 185 kW Electric Motor + 2-Speed AMT E-Powertrain for Bus, Coach, Truck This 120 kW / 185 kW electric motor with a 2-speed AMT offers a cost-effective and versatile e-powertrain solution for city buses from 12 meters to 13 meters, highway coaches from 10 meters to 12 meters, and electric trucks from 12 tons to 18 tons. The system features a lightweight design, weighing about 30-40% less than comparable direct-drive products. This weight reduction not only enhances vehicle efficiency but also supports higher payload capacity. The motor and transmission are designed as an integrated unit, which helps reduce both motor and controller costs. The system also eliminates the need for costly transmission matching, further lowering the overall drivetrain cost. Email: contact@brogenevsolution.com Get Custom Quote 120 kW / 185 kW E-Powertrain: Solution Details 1. System Architecture Diagram 2. Technical Parameters *Parameters may differ depending on the configuration and vehicle model. Certain specifications can be customized. For more information, please contact us at contact@BrogenEVSolution.com Model OETED3380 System Maximum Output Torque 3380 N.m Total Weight 210 kg Dimension 636x516x549 mm Motor Parameters Rated/Peak Power 120 kW / 185 kW Rated/Peak Torque 650 N.m / 1300 N.m Peak Speed 3500 rpm Transmission Parameters Gear 2 Speed Ratio 2.741, 1 PTO Parameters Speed Ratio 1.175 Maximum Output Torque 300 N.m 3. Solution Features The e-powertrain assembly features the AMT rated for over 2 million gear shifts and a design lifespan exceeding 8 years or 1 million kilometers. The AMT is precisely calibrated with the motor in an integrated configuration and features a PTO. This design ensures short shift intervals and smoother, more consistent power delivery. Lightweight aluminum-alloy design: Approximately 30-40% lighter than comparable direct-drive systems, enhancing vehicle efficiency and performance. 2-speed pure electric system: Optimizes the motor’s operating point through gear shifting, improving overall efficiency and reducing energy consumption by 3-5% compared to similar products under combined operating conditions. High torque & strong gradeability: Delivers up to 3380 N.m of peak output torque, enabling powerful performance for heavy-duty applications. Achieves a maximum gradeability of over 25% under full load, ensuring strong climbing capability and reliable operation on steep terrains. 4. How Do We Ensure the Reliability of the AMT? To maximize transmission reliability, our 2-speed AMT, specifically designed for pure electric vehicles, undergoes a comprehensive series of environmental and durability tests. Through these interative tests and optimizations, our pure electric AMT achieves a service life exceeding 1 million kilometers, delivering reliability comparable to direct-drive systems. Environmental testing: waterproof, dustproof, high/low temperature, salt spray, and vibration tests. Torque endurance: static torque tests exceeding 3x the rated torque. Durability testing: rigorous comprehensive endurance tests, including over 1 million shift cycles per gear. Bench simulation: over 200,000 km of chassis dynamometer testing simulating real vehicle operation. Real-world road testing: more than 50,000 km of on-road trials. Consistency verification: full-vehicle consistency tests across 50 assembled units. 5. Real-World Applications Discover our other electric truck motors here: https://brogenevsolution.com/electric-motors-for-truck/ Discover our HCV electrification solution here: https://brogenevsolution.com/heavy-duty-vehicle-electrification-solutions/ Business inquiry: contact@BrogenEVSolution.com Relevant Solutions All Posts Autonomous Vehicles Charger & Converter EV Industry EV Motor Heavy Transport Industry Insight Light Commercial Vehicles Marine Electrification Public Transportation Specialty Equipment Technologies Back EV Motor Heavy-Duty Truck Electrification Solutions Electric Truck Motor Public Transport Electrification Solutions Electric Bus Motor / Integrated Electric Bus Powertrain 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. LinkedIn channel Follow us for regular updates > YouTube channel Ev systems introduction & industry insights > ContactFill in the form and we will get in touch with you within 2 business days.Please enable JavaScript in your browser to complete this form.Please enable JavaScript in your browser to complete this form. Name * FirstLast Work Email *Company Name *Your Project Type *– Please select –Car, SUV, MPVBus, coach, trainLCV (pickup truck, light-duty truck, etc.)HCV (heavy-duty truck, tractor, trailer, concrete mixer, etc.)Construction machinery (excavator, forklift, crane, bulldozer, loader, etc.)Vessel, boat, ship, yacht, etc.Others (please write it in the note)Your Interested Solutions *– Please select –Motore-AxleBatteryChassisAuxiliary inverterOBC / DCDC / PDUAir brake compressorEPS / EHPS / SbW / eRCBBTMSOthers (please write it in the note)Do you have other contact info? (Whatsapp, Wechat, Skype, etc.)Please introduce your project and your request here. * Checkbox * I consent to receive updates on products and events from Brogen, and give consent based on Brogen’s Privacy Policy. Submit

Heavy Transport, Technologies

Electric Truck Powertrain Solutions: Single-Motor + AMT Configuration

Electric Truck Powertrain Solutions: Single-Motor + AMT Configuration As the global demand for electric heavy trucks continues to grow, manufacturers are exploring efficient and cost-effective solutions for electrification. One of the most widely adopted configurations in the electric truck powertrain is the single motor + AMT (Automated Manual Transmission) solution, which combines a high-power PMSM with a multi-speed AMT while retaining the traditional driveshaft layout. This article will explore how this solution works, its advantages and challenges, and why it is becoming a mainstream technology for electric truck powertrain in various heavy-duty applications. 1. What is the Single Motor + AMT Solution for Electric Trucks? The single motor + AMT architecture is designed to provide strong power output and optimized efficiency across a wide speed range. By pairing a high-torque electric motor for trucks with a multi-speed AMT transmission, the system delivers excellent climbing capability, high-speed cruising, and smooth shifting performance. 1.1 Advantages of Single Motor + AMT Electric Truck Powertrain Simple Structure and Lower Cost: The single-motor + AMT architecture adopts a straightforward design, minimizing the number of components compared to multi-motor systems. This simplicity not only reduces manufacturing complexity but also lowers the overall system cost, making it an economical choice for OEMs and fleet operators. Easy Integration with Existing Chassis Platforms: One of the key benefits of this electric truck powertrain configuration is its compatibility with traditional heavy-duty truck chassis. OEMs can easily adopt this e-powertrain to their current platforms without major structural modifications, significantly reducing development time and cost. High Reliability for Demanding Applications: The system is designed for rigorous operating conditions such as long-haul transportation, construction vehicles, and high-load scenarios. With fewer components subject to wear, it provides excellent durability and reliability, ensuring stable performance over extended service life. Brogen Single Motor + AMT System for 6×4 Electric Semi Trucks 1.2 Challenges to Consider Mechanical Losses in the Transmission: Although the AMT provides efficient torque transmission across different speed ranges, mechanical losses can slightly reduce overall system efficiency compared to direct-drive configurations. Heat Management Under Continuous Climbing: In extended uphill operations, the motor operates under high load for prolonged periods, which can trigger overheating protection. This highlights the need for optimized thermal management and cooling strategies. Despite these challenges, the single motor + AMT e-powertrain offers strong performance, high durability, and low energy consumption, making it the mainstream solution for electric heavy-duty trucks. 2. Key Application Scenarios for the Single Motor + AMT Electric Truck Powertrain This electric truck powertrain configuration is widely applied in heavy-duty EV segments such as electric concrete mixer trucks, electric dump trucks, electric semi-trucks, and other specialized vehicles. Here are the major use cases: 2.1 Closed-Loop Transport Operations Ports & Terminals: Ideal for container handling and short-haul transfers with fixed routes and frequent stop-and-go conditions. The electric truck motor delivers high low-speed torque combined with regenerative braking for improved loading efficiency. Mining Operations: Handles rough terrain and heavy loads with optimized multi-gear power output, preventing power interruptions. Steel & Power Plants: Short-haul transfers with strict emission regulations benefit from zero-emission electric truck powertrain solutions. 2.2 Short-Haul Urban Logistics Electric Concrete Trucks & Municipal Vehicles: Frequent acceleration and hill climbing require efficient torque distribution, reducing energy consumption. Intermodal Coal Transport: Fixed routes, but long endurance requirements, making electric truck motors paired with AMT a practical choice. 2.3 Line-Haul Logistics While battery-swap heavy-duty trucks currently dominate, the single motor + AMT solution is advancing with higher-density batteries and fast-charging technologies to penetrate this segment. 2.4 Special Operating Conditions Mounting Roads & Complex Terrain: Requires continuous high torque and power stability. Low-Temperature & High-Altitude Regions: Multi-gear adjustment optimizes motor operating range, ensuring reliable performance in harsh conditions. 2.5 Hybrid Transition Scenarios For fuel-cost-sensitive markets, the single motor + AMT solution can work in hybrid configurations with internal combustion engines, bridging the gap toward full electrification. Brogen Single Motor + AMT Solution for Electric Heavy Trucks At Brogen, we deliver proven electric truck powertrain solutions tailored for heavy-duty commercial vehicles. Our single-motor + 4-speed AMT system has been successfully deployed in more than 20,000 vehicles worldwide, providing strong market validation and trusted performance. For EV builders, this solution provides: Faster Time-to-Market with a validated platform Lower Risk through proven mass-production reliability Optimized Cost & Energy Efficiency with a scalable powertrain Compliance & Sustainability for zero-emission transportation Discover this solution here: https://brogenevsolution.com/250-kw-400-kw-electric-motor-for-heavy-duty-truck/ Discover our other electric truck motors here: https://brogenevsolution.com/electric-motors-for-truck/ 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 HCV electrification solution here: https://brogenevsolution.com/heavy-duty-vehicle-electrification-solutions/ 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. LinkedIn channel Follow us for regular updates > YouTube channel Ev systems introduction & industry insights > ContactFill in the form and we will get in touch with you within 2 business days.Please enable JavaScript in your browser to complete this form.Please enable JavaScript in your browser to complete this form. Name * FirstLast Work Email *Company Name *Your Project Type *– Please select –Car, SUV, MPVBus, coach, trainLCV (pickup truck, light-duty truck, etc.)HCV (heavy-duty truck, tractor, trailer, concrete mixer, etc.)Construction machinery (excavator, forklift, crane, bulldozer, loader, etc.)Vessel, boat, ship, yacht, etc.Others (please write it in the note)Your Interested Solutions *– Please select –Motore-AxleBatteryChassisAuxiliary inverterOBC / DCDC / PDUAir brake compressorEPS

Heavy Transport

250 kW / 400 kW Electric Motor for Heavy-Duty Truck

250 kW / 400 kW Electric Motor for Heavy-Duty Trucks This 250 kW / 400 kW electric motor paired with a 4-speed AMT is a highly mature and proven e-powertrain solution for heavy-duty commercial vehicles such as electric dump trucks, electric semi-trucks, and other construction machinery weighing between 31 and 55 tons. The system employs a single high-power motor integrated with a 4-speed AMT, leveraging the gear ratio variation and torque multiplication capabilities of the transmission. This approach enables the use of a smaller, high-efficiency motor while still achieving the high-torque output required for heavy-duty operations. Key technical advantages include optimized torque delivery, smooth gear shifts, high reliability, and a wide operational range. Email: contact@brogenevsolution.com Get Custom Quote 250 kW / 400 kW Electric Motor for Heavy-Duty Trucks: Solution Details 1. System Architecture Diagram 2. Technical Parameters *Parameters may differ depending on the configuration and vehicle model. Certain specifications can be customized. For more information, please contact us at contact@BrogenEVSolution.com System Parameters Model OEHTED16000 OEHTED20000L2 OEHTED22000 Applications Electric concrete mixer truck, heavy truck, semi truck System Maximum Output Torque 16360 N.m 20136 N.m 21814 N.m Total Weight 400 kg 425 kg 445 kg Dimension 1145x612x615 mm Motor Parameters Rated/Peak Power 200 kW / 300 kW 250 kW / 400 kW 280 kW / 420 kW Rated/Peak Torque 850 N.m / 1950 N.m 1200 N.m / 2400 N.m 1500 N.m / 2600 N.m Peak Speed 3500 rpm 3500 rpm 3500 rpm Transmission Parameters Gear Numbers 4 Maximum Input Torque 2600 N.m Speed Ratio 8.39, 3.54, 1.74, 1 PTO Parameters Total Speed Ratio 1.643 Peak Output Torque 700 N.m 3. Solution Features Proven AMT Architecture: Utilizes a 4-speed Automated Manual Transmission (AMT), the industry-standard solution for heavy-duty commercial EVs. This transmission delivers excellent low-gear gradeability, high-speed capability, and optimized efficiency across the entire operating range, ensuring performance in diverse operating conditions. Single Motor + AMT ePowertrain Design: The system adopts a PMSM integrated with an AMT in a clutchless coaxial layout, enabling smooth and synchronized shifting through motor speed control. This design eliminates the need for a mechanical clutch, improving reliability and reducing complexity. High Power Density & Torque Multiplication: Rated at 250 kW (continuous) / 400 kW (peak) and delivering 1200 N.m (continuous) / 2400 N.m (peak) torque, the solution leverages AMT’s gear ratio flexibility to provide high torque for heavy-load starts and steep gradients while maintaining high efficiency at cruising speeds. Operational Efficiency & Energy Savings: Compared with direct-drive systems, this solution offers lighter weight for the same torque capability and superior efficiency at high speeds, reducing energy consumption and enhancing vehicle range. Enhanced Driving Comfort & Reliability: Features smooth gear shifts, robust system reliability, and a quiet powertrain operation, improving driving comfort and reducing NVH levels during operations. Full-Scope Application Adaptability: Designed for heavy-duty applications such as construction material transport, resource hauling, and urban infrastructure projects, delivering high transport efficiency, strong performance, and optimized total cost of ownership (TCO). Proven in the Market: With over 20,000 units in operation, this solution platform has demonstrated stable performance and long-term durability in real-world conditions. It is widely deployed in dump trucks, concrete mixers, semi-trucks, and even electric cranes. 4. Benefits for EV Builders Accelerated Time-to-Market: The mature solution minimizes development cycles, helping OEMs achieve faster commercialization. Proven Reliability: With large-scale deployment and robust performance, we reduce technical and operational risks for new projects. Customization Support: We provide platform adaptability and engineering support to meet specific operational needs and vehicle designs. Sustainability Advantage: Our system supports green mobility, helping OEMs meet regulatory and ESG goals. 5. Real-World Applications The 250 kW / 400 kW electric motor + 4-speed AMT solution has already entered mass production and represents a mature and proven solution. The platform’s products have been deployed in over 20,000 vehicles, demonstrating strong market validation. It’s ideally suited for sectors such as construction waste removal, concrete transport, building materials delivery, and resource logistics. Vehicles equipped with this e-powertrain deliver high transport efficiency, excellent cost-effectiveness, and reduced noise, creating a much quieter and cleaner working environment at depots and job sites. Business inquiry: contact@BrogenEVSolution.com Relevant Solutions All Posts Autonomous Vehicles Charger & Converter EV Industry EV Motor Heavy Transport Industry Insight Light Commercial Vehicles Marine Electrification Public Transportation Specialty Equipment Technologies Back EV Motor Heavy-Duty Truck Electrification Solutions Electric Truck Motor 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. LinkedIn channel Follow us for regular updates > YouTube channel Ev systems introduction & industry insights > ContactFill in the form and we will get in touch with you within 2 business days.Please enable JavaScript in your browser to complete this form.Please enable JavaScript in your browser to complete this form. Name * FirstLast Work Email *Company Name *Your Project Type *– Please select –Car, SUV, MPVBus, coach, trainLCV (pickup truck, light-duty truck, etc.)HCV (heavy-duty truck, tractor, trailer, concrete mixer, etc.)Construction machinery (excavator, forklift, crane, bulldozer, loader, etc.)Vessel, boat, ship, yacht, etc.Others (please write it in the note)Your Interested Solutions *– Please select –Motore-AxleBatteryChassisAuxiliary inverterOBC / DCDC / PDUAir brake compressorEPS / EHPS / SbW / eRCBBTMSOthers (please write it in the note)Do you have other contact info? (Whatsapp, Wechat, Skype, etc.)Please introduce your project and your request here. * Checkbox * I consent to receive updates on products and events from Brogen, and give consent based on Brogen’s Privacy Policy. Submit

EV Industry

High Voltage Wire Harnesses in EVs: Key Design Principles

High Voltage Wire Harnesses in Electric Vehicles: Key Design Principles High voltage wire harnesses play a critical role in electric vehicles, transmitting high voltage and large currents between essential components like the battery pack, high-voltage PDU, inverter, and traction motor. These harnesses ensure efficient energy transfer, enabling EV systems to operate in perfect synchronization. Proper installation and secure mounting of high voltage wire harnesses is essential for safety, reliability, and performance.. 1. Routing Principles for High Voltage Wire Harnesses Before discussing installation and fixation, it’s crucial to understand routing principles. 1.1 Proximity Principle The routing should follow the shortest feasible path to minimize voltage drop and weight, which supports efficiency and cost reduction. 1.2 Ease of Assembly The overall design and fixation method of the EV wiring harness should prioritize ease of assembly to ensure simple and efficient installation. Connector Mounting and Fixation: Allow adequate length and installation space for connectors to facilitate smooth operations. Harness and Component Fixation: Ensure sufficient clearance for fastening tools, maintaining at least a 50 mm gap from the center of the nut for safe operation. Harness Clip Fixation: Position harness clips strategically to minimize quantity while ensuring secure attachment. 1.3 Maintainability The principle of good maintainability in automotive wiring harness design means ensuring ease of maintenance and repair throughout the vehicle’s lifecycle. The layout should allow faults to be diagnosed and repaired in the shortest possible time while minimizing the impact on other components. Connector Placement and Fixation: Connectors should be positioned within easy reach. For connectors that require single-hand operation, the opposite end should be securely fixed. Avoiding Misconnection and Providing Extra Length: Connectors on the same component should be arranged to prevent incorrect mating. The end of the wiring harness should have a reserved length. For example, high-voltage wires near the connector tail must not be bent or stressed, must not be twisted, and should be secured within 120 mm. Fuse Box Harness Allowance: The wiring harness for the fuse box should have sufficient slack to provide adequate operating space during maintenance. 1.4 Safety and Reliability Ensuring the safe and stable operation of the electrical system – and by extension, the proper functioning of all vehicle electrical equipment – is the ultimate goal of wiring harness design. Harness Fixation Location: Whenever possible, secure wiring along edges, channels, or areas that are less likely to be touched to prevent external forces from damaging the harness. Avoid Sharp Bends: When bends are unavoidable, allow adequate space and apply special fixation at the bend points. Ensure no kinks or excessive stress occur. Prevent Cable Damage: Harnesses passing through holes must be protected with sleeves, grommets, or protective tape to avoid abrasion. In the event of a collision, the harness should not be crushed, as this could lead to rupture and short circuits. High-Voltage Wire Harnesses Wrapping Materials Maintain Design Allowance: For main branches, ensure a sufficient bending radius to avoid tight routing that complicates assembly. Do not pull harnesses too tightly during installation, as vibrations during driving could shift fixation points. Avoid High-Vibration Zones: High-voltage harnesses should be routed away from major vibration sources such as air compressors or water pumps. If unavoidable, allow adequate slack based on vibration amplitude and the maximum motion envelope of moving parts to prevent tension on the harness. Avoid High-Temperature Zones: Keep harnesses away from high-temperature components such as compressors, brake lines, steering pumps, or oil pipes to prevent insulation melting or accelerated aging, which could lead to exposed conductors and short circuits. Maintain Bend Radius for High-Voltage Cables: Over-bending high voltage wire harnesses increases resistance, causing higher voltage drop and accelerating insulation aging or cracking. The minimum bend radius should be at least 4x the cable’s outer diameter. High-voltage cables exiting connectors must remain straight, without bending, twisting, or stress. Correct Connector Layout Example (Left) | Incorrect Connector Layout Example (Right) Sealing and Waterproofing: To enhance mechanical protection and ensure dust and water resistance, use seals or gaskets at connector interfaces and cable entry points. This prevents moisture and debris ingress, ensuring insulation integrity and avoiding short circuits, arcing, or leakage. 1.5 Aesthetic and Organized Routing Hidden or Aligned: Harness routing should prioritize a neat and aesthetic layout, either by concealing the harness or arranging it in a horizontal and vertical orientation. The routing should follow the direction of the adjacent components and, in the projected view, maintain a straight, grid-like arrangement wherever possible. Diagonal paths and crossing layouts should be avoided. The harness should align with surrounding harnesses, water pipes, air pipes, and oil pipes to maintain visual uniformity and an overall clean appearance. 2. Installation and Fixation Design for High Voltage Wire Harnesses 2.1 Planning of Harness Fixation Points The distribution of fixation points is the foundation for securing high-voltage harnesses and directly impacts their stability. Generally, the placement of these points should be determined based on factors such as harness length, routing, and bending positions. For longer harnesses, additional fixation points are necessary to prevent displacement caused by vibrations during vehicle operation. At bends, fixation points should be placed at both the start and end of the curve to avoid excessive stress on the harness in these areas. Securing High-Voltage Wiring Harness at Bend Points The spacing requirements for fixation points vary according to the cross-sectional area of the harness. Typically: For smaller harnesses (≤16 mm²), the spacing can be slightly larger but should not exceed 300 mm. For larger harnesses (>16 mm²), due to greater weight and mechanical stress, the spacing should be kept within 200 mm. Additionally: The distance from the high-voltage connector outlet to the first fixation point should be ≤100 mm. The clearance between the high-voltage harness and heat sources should be >200 mm. Through proper planning of fixation points, issues such as shaking or displacement during vehicle operation can be effectively avoided, ensuring stable and reliable power transmission. 2.2 Selection of Fixation Methods In the installation of high-voltage harnesses for electric vehicles, common fixation methods include cable ties, clips,

Author name: brogenevsolution.com