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

Development Trends in Battery Electric Heavy Duty Trucks (e-HDTs)

Development Trends in Battery Electric Heavy-Duty Trucks (e-HDTs) 1. Transition Toward Purpose-Built Development of Electric Heavy Duty Trucks In the current stage of the development of electric heavy-duty trucks (e-HDTs), most models still follow a “diesel-to-electric conversion” approach due to immature technologies and limited production scale. However, in the long run, purpose-built development of dedicated e-HDT platforms will be essential for performance enhancement and is the strategic direction adopted by leading OEMs. Today’s diesel-converted e-HDTs retain the basic layout of their diesel counterparts. The internal combustion engine is replaced with an electric motor, and battery packs are typically mounted behind the cab or on both sides of the chassis. While this transitional approach allows for faster product rollout at controlled costs, it comes with performance compromises, such as inefficient chassis space usage, lower drivetrain efficiency, and limited battery space, reducing cargo capacity and driving range, thus affecting operational effectiveness and cost-efficiency. To achieve large-scale commercialization, industry leaders are moving toward ground-up development of e-HDT platforms, optimizing the e-powertrain, chassis architecture, and vehicle aerodynamics to fully unlock the advantages of electrification. 2. Electric Drive Systems Limitations of Central Drive Architecture Most converted e-HDTs continue to use the central drive architecture typical of diesel trucks – simply replacing the engine with an electric motor. This results in systems that are bulky, heavy, and less efficient. Integrated E-Axles & Distributed Drive Purpose-built e-HDTs allow for deep optimization of the electric drivetrain. As commercial EV powertrains become more integrated, both integrated e-axles and distributed drive solutions are emerging. Although distributed drive systems using hub motors are still in early development, integrated e-axles are currently the mainstream choice. Compared to the central drive, integrated e-axles combine the motor, gearbox, and drive shaft into a compact, highly integrated system. Advantages include: Smaller spatial footprint Higher integration and system efficiency Fewer transmission components Lower vehicle weight and increased usable space These benefits translate into improved performance, energy efficiency, and packaging flexibility. High-Voltage Platforms: The Next Step The trend is shifting from 400V systems (common in passenger EVs) and 600V systems (used in commercial vehicles) toward 800V-1000V high-voltage platforms. Key advantages include: Ultra-fast Charging: Higher voltage enables significantly faster charging, especially critical for commercial vehicles with large battery capacities and tight operational schedules. Enhanced Driving Efficiency: Lower current at higher voltage reduces power losses, increasing overall system efficiency and extending driving range. Porsche first adopted the 800V platform in 2019 with the Taycan. Now, commercial vehicle manufacturers are starting to follow suit. The realization of ultra-first charging requires not only vehicle-side high-voltage systems but also widespread deployment of high-powered charging stations. 3. Fast Charging Technology Evolution The realization of ultra-fast charging requires not only vehicle-side high-voltage systems but also widespread deployment of high-powered charging stations. To support the rising demand for ultra-fast charging: Charging Module Power is steadily increasing – from 7.5 kW (1st gen) to 15-20 kW (2nd gen), and now 30-40 kW (3rd gen) in mainstream systems. Liquid-Cooled Systems are becoming standard for improved heat dissipation, reduced noise, and easier maintenance. Tesla’s V2 Supercharger (2019) and GAC Aion’s A480 (2021) are early adopters of liquid-cooled fast-charging technologies. These trends are expected to transition from passenger to commercial EVs in the near future. 4. Chassis Layout Optimization for Electric Heavy Duty Trucks Diesel truck chassis are traditionally designed with a ladder frame to accommodate a front-engine, rear-drive layout. Retaining this setup in e-HDTs creates challenges, especially in battery packaging, leading to inefficient space use and reduced cargo volume. With a clean-sheet design, purpose-built eHDTs can eliminate the driveshaft and re-engineer the frame to accommodate skateboard-style battery layouts. Benefits include: Higher Energy Density: More battery space improves range without compromising cargo space. Structural Integration: Box-section frames housing the battery enhance structural integrity and load-bearing performance. Lower Center of Gravity: Improves handling, cornering stability, and safety. Sleeker Exterior: Optimized space usage allows for better design flexibility. 5. Aerodynamic and Lightweight Body Design for Electric Heavy Duty Trucks With purpose-built platforms, e-HDTs are no longer limited to the traditional “cab-over” shape. Redesigning the cab structure enables the use of lightweight materials and aerodynamic profiles to reduce drag and improve efficiency. For example, most cab-over trucks in China have a drag coefficient (Cd) between 0.55 and 0.65. In contrast, Tesla’s Semi, which features a bullet-nose design and a single-seat cab, claims a Cd as low as 0.36. Conclusion The electrification of heavy-duty trucks is transitioning from retrofitted solutions to fully purpose-built platforms. From integrated drivetrains and high-voltage architectures to optimized chassis and aerodynamic designs, leading OEMs are paving the way for the next generation of e-HDTs designed for higher efficiency, better performance, and large-scale commercial viability. 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 heavy trucks 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

EV Industry, Technologies

How the VCU Manages Power-Up and Power-Down in Electric Vehicles

How the VCU Manages Power-Up and Power-Down in Electric Vehicles: Comprehensive Control Logic Overview 1. Understanding Vehicle Power-Up/ Power-Down Logic Before delving into the vehicle’s power-up and power-down sequences and understand the control strategy via VCU, it’s essential to clarify two fundamental concepts: (1) Why must the VCU control the wake-up of high-voltage component controllers (e.g., BMS, MCU, DCDC, OBC, AC)? Unified vehicle wake-up logic: The vehicle can be awakened via several sources – key ignition, slow charging, fast charging, or remote control. The VCU receives these wake-up signals and subsequently controls the wake-up of other controllers, enabling centralized monitoring and management of the vehicle status while simplifying low-voltage wiring design. Enhanced functionality: By controlling the wake-up of high-voltage components, the VCU facilitates key features such as charging while the vehicle is OFF, remote preconditioning, scheduled charging, and safe sequencing of high-voltage system operations. (2) Key considerations for high-voltage circuits before power-on/off Before power-on: Prevent inrush current: Motor controllers contain large internal capacitors, which allow AC to pass but block DC. At the moment the high-voltage circuit is closed, the capacitors cause the circuit to behave like an AC circuit. If no resistance is present in the circuit (I=U/R), a large inrush current will be generated, potentially damaging high-voltage components. Ensure system safety: Prior to high-voltage activation, safety checks must be performed – verifying proper interlock connections, insulation resistance to prevent electric shock risks, and ensuring there are no high-voltage-related faults. Before power-off: Relay protection: If the system carries a high current during shutdown, opening the relay under load may damage it or cause welding, leading to failure in disconnecting the high voltage. Component protection: Motors can generate back-EMF when rotating. Disconnecting power at high speed can cause voltage spikes (several kV), risking damage to power devices like IGBTs and electric compressors. (3) Diagrams VCU Low-Voltage Schematic Example: Shows typical low-voltage pins used in the VCU; though simplified, it aligns with the overall power control sequence. Vehicle High-Voltage Circuit Example: While layouts vary by manufacturer, the core principles are similar and correspond with the logic described above. 2. Full Vehicle Power-Up and Power-Down Sequence The vehicle’s power-up and power-down process is not a simple on/off switch but a precise system-level operation. When the driver turns the key or presses the start button, the Vehicle Control Unit (VCU) – the vehicle’s central brain – coordinates the initialization of key systems like the MCU, PDU, TCU, and TMS. It manages their low-voltage power-up and sends wake-up signals, ensuring safe and synchronized startup of high-voltage components. Power-Up Sequence: Key On (KL15), VCU wakes up and completes initialization. Wake up high-voltage controllers such as MCU, BMS, DCDC, DCAC, TCU, and TMS. VCU checks the vehicle’s low-voltage system status. If all high-voltage controllers are initialized and there are no HV-related faults, and a high-voltage activation request is present, proceed to step 4; otherwise, stay in step 3. VCU sends a command to close the negative relay. If feedback confirms the relay closed within time t0, proceed to step 5; if not, switch to negative relay disconnection. VCU sends a command to close the positive relay, which is preceded by pre-charge relay activation. After pre-charging, the system confirms that the MCU DC voltage reaches ≥95% of the nominal battery voltage within time t1. If confirmed, proceed to step 6; otherwise, disconnect the positive relay. VCU performs a high-voltage status check. Enables DCDC/DCAC and verifies their operational status. If confirmed, proceed to step 7; otherwise, enter zero torque state. Drive-ready state: VCU enables the MCU and turns on the READY indicator. If the driver shifts into gear, VCU sends torque or speed control commands for driving. If a shutdown request is received, proceed to step 8. Shutdown request received: VCU sends the zero torque command to the MCU to decelerate. Once motor speed<N, torque<T, bus current<A, and vehicle speed<V or timeout t2 is reached, proceed to step 9. VCU disables DCDC/AC/PTC/DCAC. DCAC, which powers steering/braking assist, is disabled only when the vehicle is stationary to maintain safety. After confirming the shutdown status and that the A/C compressor speed<Nac, or timeout>t3, proceed to step 10. VCU sends command to disconnect the positive relay. Once MCU DC voltage≤ 60V (safe threshold) or timeout>t4, proceed to step 11. VCU sends command to disconnect the negative relay. After confirmation or timeout>t5, proceed to step 12. High-voltage components are powered down. If key=off, VCU proceeds to data storage and sleep; otherwise, return to VCU wake-up. 3. Charging Process and Notes on Power-Up/Down (1) Differences in Charging Process: Wake-up source shifts from ignition to charging signal; If both ignition and charging signals are present, the charging process takes precedence. If the charging cable is connected during READY state, the system performs a shutdown process first, then begins charging. MCU and DCAC are not enabled during charging; driving is not permitted. (2) Key Reminders: During vehicle power-up, low voltage is activated before high voltage. During power-down, high voltage is disconnected before low voltage. For HV activation, negative relay closes before the positive replay. For HV shutdown, positive relay opens before the negative relay. 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 buses and trucks have been adopted by vehicle manufacturers in countries and regions such as Australia, Türkiye, Brazil, the Philippines, Indonesia, the Middle East, and more. 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

high voltage interlock circuit HVIL circuit

EV Industry

Five Key High-Voltage Safety Design Principles in Electric Vehicles

Five Key High-Voltage Safety Design Principles in Electric Vehicles In battery electric vehicles (BEVs), the propulsion system is powered by high-voltage electric motors. These systems typically operate at very high currents—ranging from tens to even hundreds of amperes—and in the event of a short circuit, the current can spike dramatically. Such high voltages and currents pose significant safety risks to both passengers and vehicle components, including electrical systems and control units. Therefore, the high-voltage electrical system in an EV must not only meet performance and power delivery requirements but also ensure operational safety, personal safety, and safe maintenance. Effective high-voltage safety management involves a combination of technical design, operational protocols, protection mechanisms, and user safety education. Below are five fundamental safety design principles widely adopted in EVs to ensure safe handling and operation of high-voltage systems: 1. Leakage Current Protection Electric vehicles are equipped with leakage current protection devices. If either the positive or negative high-voltage bus comes into contact with the vehicle chassis, the protection device will trigger an alert—or in many cases—automatically shut down the high-voltage supply. This prevents scenarios where the motor casing becomes electrically charged, which could lead to an electric shock if someone touches the opposite pole. Leakage protection also safeguards systems such as the air conditioning unit and DC/DC converters from high-voltage leakage. 2. High-Voltage Interlock (HVIL) All high-voltage connectors are designed to prevent disconnection while the system is energized. However, to guard against human error or unauthorized tampering, high-voltage interlock (HVIL) switches are integrated into connectors. If a connector is unplugged, the interlock circuit is immediately interrupted. The system controller detects this and rapidly disconnects the main relay, cutting off high-voltage power in milliseconds—thereby preventing potential electric shock. HVIL is a critical fail-safe in high-voltage circuit design. 3. Collision Power Cutoff In the event of a collision, onboard crash sensors immediately send a signal to trigger the HVIL system. This automatically disconnects the vehicle’s high-voltage power supply to protect occupants from electric hazards. Some modern systems integrate this function directly into the high-voltage connector modules, combining sensing and cutoff in a compact unit. 4. Insulation Resistance Monitoring Higher system voltages require stricter standards for insulation to prevent dangerous leakages. Insulation resistance is a critical safety parameter, with regulatory standards clearly defining minimum thresholds to mitigate risks of electric shock or component failure. Two common methods are used to monitor insulation resistance: Auxiliary Power Method:A 110V DC auxiliary battery is connected across the high-voltage circuit (positive to negative, and negative to vehicle ground). Under normal conditions, no current flows. If insulation is compromised—due to aging, moisture, etc.—a leakage current forms, triggering an alert and shutting down the system. While effective, this method increases system complexity and cannot easily identify whether the issue lies in the positive or negative lead, limiting its application in EVs. Current Sensor Method:Hall-effect current sensors measure differential current flow by passing both positive and negative cables through the same sensor. When no leakage is present, the outgoing and returning currents cancel out, and the sensor reads zero. If leakage occurs, the imbalance is detected, and the direction of current flow helps identify whether the fault is on the positive or negative side. This method requires the system to be powered during testing but is more commonly used in modern EVs due to its efficiency and precision. 5. Access Panel Monitoring Certain critical high-voltage components in EVs are equipped with cover monitoring mechanisms. If a cover is opened while the high-voltage system is still active, a signal is sent to the main controller. The controller immediately cuts off the main relay and activates a discharge mechanism that rapidly reduces internal voltage to safe levels. This feature ensures safety during servicing or accidental opening of enclosures. Conclusion High-voltage safety is foundational to electric vehicle design. From real-time system monitoring to automatic disconnection features, these protective measures are vital for ensuring the safety of passengers, maintenance personnel, and the vehicle itself. As EV technology continues to evolve, robust safety protocols will remain essential in supporting the growth of safe and reliable electric mobility. 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 buses and trucks have been adopted by vehicle manufacturers in countries and regions such as Australia, Türkiye, Brazil, the Philippines, Indonesia, the Middle East, and more. 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

EV Industry

Vehicle Control Unit (VCU) Explained: A Deep Dive into Software Architecture

Vehicle Control Unit (VCU) Explained: A Deep Dive into Software Architecture The Vehicle Control Unit (VCU) is often referred to as the “brain” of the vehicle. It plays a pivotal role in managing and coordinating various systems to ensure efficient, safe, and intelligent vehicle operation. At the core of its operation is a well-structured software architecture, typically divided into three key parts: Signal Input, Function Control, and Signal Output. 1. Signal Input – The “Senses” of the Vehicle Control Unit (VCU) The signal input section enables the VCU to perceive the vehicle’s real-time status, much like how human senses gather information from the environment. The VCU collects data from three primary channels: hardwired inputs, the CAN bus (Controller Area Network), and low-level diagnostic signals. Hardwired Inputs: These are like the vehicle’s nerve endings, directly connected to key components. Through these inputs, the VCU gathers critical information such as accelerator position, brake pedal status, ignition key state, and more. This data reflects the driver’s direct commands and helps the VCU respond accordingly. CAN Bus Inputs: Acting as the vehicle’s internal communication highway, the CAN bus connects essential systems such as the battery management system (BMS), motor control unit (MCU), and transmission control unit (TCU). The VCU monitors these systems in real time, allowing precise and coordinated vehicle control. Low-Level Diagnostics: This includes internal controller states, E-flash storage signals, and I/O diagnostics. Think of it as the vehicle’s health report, providing deeper insights to support system reliability and performance monitoring. 2. Function Control – The “Brain” of the Vehicle Control Unit (VCU) This is the core processing layer of the VCU. Based on the inputs received, the VCU makes intelligent decisions to manage vehicle behavior. While features may vary between manufacturers, most VCUs include the following key control functions: Input Signal Processing: Acts as a centralized filter and organizer. It processes signals such as speed, acceleration, braking, gear logic, and vehicle weight. By unifying data at this layer, the VCU improves efficiency and reduces redundant signal processing across different functional modules. Power Management (Power On/Off Control): The VCU coordinates the high-voltage system to manage key processes, including pre-charging, enabling power output, and entering sleep modes. It ensures components are powered on or off in a safe and orderly manner. Additional features like smart battery charging and battery preheating can also be integrated here. Torque Control: One of the VCU’s main roles is controlling the vehicle’s torque output based on driver inputs such as acceleration or braking. This function ensures smooth torque delivery across various drive conditions like cruising, crawling, or rapid acceleration. Single Power Source Vehicles: For vehicles with one drive motor or a conventional ICE powertrain, the VCU arbitrates between different torque demands (e.g., acceleration, crawl, cruise), filters out torque interference (e.g., from gear shifts or stability control), and adjusts torque output for smooth driving. Multi Power Source Vehicles: In EVs with dual motors or hybrid configurations, after determining total torque demand, the VCU distributes torque appropriately between power sources and filters each source’s output to maintain stability and performance. Energy Management: The VCU optimizes energy usage based on the vehicle’s configuration. Battery Electric Vehicles (BEVs): The VCU controls high-voltage components (DCDC, air pumps, HVAC systems) and calculates available power to adjust motor torque output, improving energy efficiency. Fuel Cell or Range-Extended Vehicles: Whether powered by hydrogen or fuel, these systems rely on the VCU to balance energy supply and demand, activate generation systems as needed, and ensure optimal energy use. Fine-tuned control is required to handle differences in startup behavior, power response, noise/vibration (NVH), and energy consumption. Auxiliary Functions: Many VCUs are equipped with additional smart features, such as: Dashboard Display Control: Provides real-time information such as range, average energy consumption, power output, and gear status to the driver. Anti-Theft & Lock Control: Implements features like random key generation, security level control, and key verification for enhanced vehicle protection. PTO (Power Take-Off) Control: Supports operational requirements in special-use vehicles by managing PTO status, speed control, and idle conditions. Auxiliary Systems Management: Oversees the operation of water pumps, cooling fans, vacuum pumps, EPS motors, and air compressors. 3. Signal Output – The “Executors” of VCU Commands This layer handles the transmission of control signals generated by the VCU to the vehicle’s actuators. The output methods include hardwired signals, CAN communication, and data storage: Hardwired Output: Used to enable or wake up components like the BMS, MCU, and TCU. It also provides direct control over specific functions such as pump and fan speed. CAN Output: Enables efficient communication with various high-voltage systems, controlling torque commands, motor speeds, generator activation, relay switching, and more. E-Flash Storage: Stores vital data such as mileage, learned values, and average energy consumption to support diagnostics, analytics, and long-term performance optimization. Conclusion By understanding the structure and function of a Vehicle Control Unit, we can better appreciate the role it plays in enabling intelligent, efficient, and safe vehicle operation. Whether it’s managing torque output, coordinating energy use, or communicating with dozens of subsystems, the VCU lies at the heart of modern vehicle control strategies. 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 buses and trucks have been adopted by vehicle manufacturers in countries and regions such as Australia, Türkiye, Brazil, the Philippines, Indonesia, the Middle East, and more. 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

Public Transportation, Technologies

Battery Electric Bus Body: Structural Design and Strength Optimization for Lightweight and Safety

Battery Electric Bus Body: Structural Design and Strength Optimization To advance the adoption of electric vehicles and fully capitalize on the energy-saving and emission-reduction benefits of battery electric buses (BEBs), a lightweight electric bus body design is essential. This article presents an overview of topology optimization theory and explores key material options for electric bus body construction, including high-strength steel, aluminum alloys, and carbon fiber composites. It highlights the advantages of advanced materials in improving structural performance and outlines methodologies for analyzing structural loads, optimizing topology, and ensuring strength and reliability. These insights provide valuable guidance for the development, design, and manufacturing of next-generation electric buses, supporting both performance and sustainability goals. Introduction The electric vehicle (EV) sector is undergoing rapid development, particularly in the public transportation segment, where battery electric buses offer significant advantages such as zero emissions, reduced operating costs, and simpler maintenance. However, one of the primary challenges hindering wider adoption is limited driving range. Reducing curb weight – while maintaining safety and structural integrity – is a proven strategy to extend range and improve overall vehicle efficiency. Since the body structure contributes more than one-third of a bus’s total weight, lightweighting the body is a critical focus. By leveraging topology optimization theory and finite element analysis (FEA), engineers can minimize material use while maintaining required levels of stiffness and strength. This approach not only enhances vehicle range but also contributes to long-term energy efficiency and emission reduction goals. 1. Topology Optimization Principles When applying topology optimization to electric bus body design, shape optimization techniques are used to find the most efficient material layout under one or more loading conditions. This approach targets minimum structural stiffness. It starts with developing a digital base model of the bus body, then uses optimization algorithms to remove unnecessary components while retaining critical structural elements. This improves the structural layout’s rationality and reliability. Basic mathematical model of battery electric bus In practice, topology optimization is performed with the following considerations: Analysis Type: Static analysis Element Types: First-order and second-order tetrahedral elements Material Behavior: Liner elastic, elastoplastic, hyperelastic Loading Conditions: Concentrated force, pressure, torque, gravity Boundary Conditions: Displacement constraints Contact Conditions: Bonded and surface contact Connection Types: Rigid and beam connections Objective Function: Maximize stiffness Design Variables: Topology variables Constraints: Volume fraction If the total number of elements is denoted as a, then each element can be represented as y(i = 1, 2, 3, …, a). During the structural optimization process, if the h-th element is determined to be non-essential, it will be assigned a value of yₕ = 0; if it is essential and should be retained, it will be assigned yₕ = 1. The structural optimization design of a pure electric bus body can be carried out using finite element analysis (FEA) combined with variable design methods. 2. Main Types of Electric Bus Materials The evolution of bus body materials reflects a broader shift toward lightweight and high-performance materials. Initially dominated by steel (over 90% of body structure), the industry has gradually shifted toward aluminum alloys and carbon fiber composites. This shift is driven by the demand for lightweight, energy-efficient, and low-emission vehicles. High-Strength Steel (HSS): Created by adding trace elements to low-carbon steel and undergoing specialized rolling processes. It offers tensile strength up to 420 N/mm² and excellent deep-drawing properties, making it a strong candidate for lightweight structural components. Aluminum Alloys: Compared to steel, aluminum alloys have a lower density (2.7 g/cm³), higher specific strength, good corrosion resistance, thermal stability, and recyclability. These advantages make aluminum alloys widely used for lightweight applications. Carbon Fiber Composites: Composed of carbon fiber bundles and resin, these materials offer exceptional high tensile strength (often over 3500 MPa), high stability, and resistance to deformation during impact. Carbon fiber composites can significantly enhance passive safety and are more than twice as durable as steel. With increasing demand for extended range, pure electric buses have transitioned from using high-strength steel to aluminum alloy bodies, which reduce body weight by 25%-35%. Modern aluminum alloy components are often assembled using rivets and bolts rather than traditional welding, and stamped aluminum parts have replaced conventional steel panels. Aluminum alloys also offer high recyclability, with recovery rates exceeding 85% when vehicles are retired. Skeleton layout of 10.5 m battery electric bus aluminum alloy roof Skeleton layout of 10.5 m pure electric bus aluminum alloy bone around on the left side Skeleton layout of 10.5 m pure electric bus aluminum alloy bone around on the right side 3. Performance and Cost of Advanced Automotive Materials Advanced materials and manufacturing processes are key drivers of automotive innovation. High-Strength Steel: Offers 15%-25% higher strength than standard steel, with better balance and 20% improved corrosion resistance. However, it requires additional anti-corrosion treatments to meet durability requirements. Aluminum Alloys: In a 10-meter bus, switching from steel to aluminum components can reduce body weight by over 450 kg. Aluminum also provides superior thermal insulation and vibration damping compared to steel. Manufacturing methods such as hot forming, die casting, and precision machining enhance part performance and structural integrity. Carbon Fiber Composites: Carbon fiber’s strength and stiffness per unit weight surpass all other commonly used materials. It absorbs 4-5 times more impact energy than steel and can reduce body weight by over 40%, while enhancing safety and aesthetic appeal. However, its high cost restricts its applications to high-end or specialized vehicles. Relative Costs: Steel: Lowest cost Aluminum Alloys: Moderate cost Carbon Fiber Composites: Highest cost 4. Structural Load Analysis and Topology Optimization of Battery Electric Bus Body The structural design of a battery electric bus must comply with the requirements outlined in relevant national standards and the specific design brief. This includes determining the vehicle’s primary exterior dimensions – such as length, width, height, wheelbase, front overhang, and rear overhang – while ensuring a balanced and harmonious overall appearance. Effective spatial arrangement of the driver’s cabin and passenger area is essential for optimal internal layout. The number, position, and minimum dimensions of passenger doors and emergency

electric heavy truck with brogen electric truck axles

Heavy Transport

Brogen Electric Truck Axles Drive Our Partner’s First Batch of Heavy-Duty Electric Trucks

Empowering Innovation: Brogen Electric Truck Axles Drive Our Partner’s Heavy-Duty Electric Trucks As the global push toward decarbonization accelerates, electric truck axles are becoming the heart of next-generation heavy-duty trucks. We are thrilled to share that our partner has officially delivered their first batch of electric heavy trucks, each equipped with our advanced electric axle system, to a renowned logistics company. This milestone highlights how the latest EV technology and vehicle manufacturing come together to enable the electrification of real-world logistics operations, with performance, reliability, and efficiency at the core. Electric heavy trucks equipped with our electric truck axles Brogen Electric Truck Axles – Built for Real-World Logistics This deployment isn’t a concept — it’s a real-world logistics application. The electric trucks are now in service for one of the country’s top logistics providers, handling mid-to-long-distance intercity transportation with high operational frequency. To succeed in such conditions, trucks need powerful, efficient, and reliable drive systems. That’s where our electric truck axles come in: Ultra-low energy consumption of just 1.15 kWh/km, ensuring excellent energy efficiency and reducing per-kilometer transport costs. High torque dual-motor architecture delivers up to 51,480 N·m peak axle output, making it perfect for heavy-duty 4×2 logistics use cases. Intelligent shifting algorithm eliminates power interruption during gear changes — smoother, safer, and better for cargo stability. Symmetrical, compact design maximizes underbody space for additional batteries or storage, extending range and flexibility. Brogen electric truck axle used in this project Designed for Heavy-Duty Transport Our electric axle systems aren’t just about power — they’re about delivering performance under real transport conditions: Passed 1,250 hours of continuous transmission testing Survived 1 million cycles of 2.5× load impact without failure Optimized for NVH performance and oil temperature control, even in high-load, high-speed highway use Whether it’s high-speed expressways or urban delivery corridors, these electric axles are ready for the rigors of commercial transport. Brogen electric drive axle motor testing Why It Matters For logistics companies, transitioning to electric vehicles is no longer just a sustainability goal — it’s a strategic move to reduce TCO, improve fleet uptime, and align with increasingly strict emissions regulations. Our electric axle solutions help vehicle manufacturers and fleets unlock: Simplified electric powertrain architecture Higher payload capacity Lower operational and maintenance costs Cleaner transportation footprint For Truck Manufacturers: Build Better, Faster, Smarter If you’re a truck OEM or EV builder looking to electrify your heavy-duty platforms, our electric truck axle solutions are engineered to give you a competitive edge — from R&D to mass production. Accelerated Development TimelinesOur proven, modular e-axle platforms help reduce your system integration time. Whether you’re building a 4×2 urban logistics truck or a multi-axle long-haul vehicle, we offer tailored technical solutions to help you hit your market timelines faster. Seamless System IntegrationWith deep expertise in high-voltage systems, controllers, gearboxes, and cooling architecture, we support full-stack integration — not just the axle, but the total e-powertrain ecosystem. Flexible Customization & ScalabilityOur systems are field-proven in mass-production EVs with Tier 1 OEMs. From fatigue cycles to thermal and NVH optimization, we engineer for endurance. Discover our electric truck axle solution here: https://brogenevsolution.com/electric-axle-for-truck/ Explore our HCV solutions here: https://brogenevsolution.com/heavy-duty-vehicle-electrification-solutions/ Business inquiry: contact@BrogenEVSolution.com, or you may complete the form below to get in touch with us. 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

Technologies

A Comprehensive Guide to CCS Integrated Busbars for EV Battery Packs

A Comprehensive Guide to CCS Integrated Busbars for EV Battery Packs What is CCS on a Battery? CCS, short for Cells Contact System, refers to an integrated busbar system that combines conductive busbars, control circuits (such as voltage and temperature sensors), and other components into a single modular unit. It plays a critical role in the internal electrical architecture of battery modules. By consolidating multiple functions into one system, CCS enhances the integration, reliability, and safety of battery systems. It also helps reduce assembly complexity, save space, lower production costs, and simplify maintenance. In essence, CCS is an electrical connection structure within the battery module. It integrates data acquisition components, plastic structural parts, copper/aluminum busbars, and more into a single module. This allows it to perform high-voltage series-parallel connections, temperature sensing, voltage sampling, and overcurrent protection, serving as a key component of the Battery Management System (BMS). CCS technology is widely used in electric vehicles (EVs), energy storage systems, and other high-voltage battery applications. Advantages of CCS Busbar for EV Battery Packs High Integration: Multiple functions are integrated into one module, reducing the number of components and wiring complexity. Enhanced Reliability: The integrated design improves system stability and reduces failure rates. Lightweight Design: With compact architecture and lightweight materials, CCS helps lower overall vehicle weight and improve energy efficiency. Improved Production Efficiency: Simplified assembly processes and high automation levels reduce labor costs and improve manufacturing throughput. Ease of Maintenance: Modular design allows for easier maintenance and component replacement, reducing downtime and service costs. CCS Structure and Classifications CCS systems vary based on the type of signal acquisition component used, and include several solutions such as wire harnesses, PCB, FPC, FFC, FDC, and FCC. Various integration techniques are employed, including injection-molded brackets, vacuum-formed plates, hot pressing, and die-cut PET films. The industry currently sees multiple technical paths coexisting and evolving. Common Materials Used in CCS Include: Hot-pressed insulation film Aluminum busbars Vacuum-formed trays Injection-molded structural brackets PCB/FPC/FFC signal acquisition components Type Signal Acquisition Component Common Integration Techniques Wire Harness Traditional Wiring Harness Injection-molded bracket; Thermal riveting process with vacuum-formed tray (blister riveting process) PCB Printed Circuit Board Hot pressing process; Thermal riveting process with vacuum-formed tray (blister riveting process) FPC Flexible Printed Circuit FFC Flexible Flat Cable FDC Flexible Die-cut Circuit FCC FFC connected with FPC or FDC Overview of CCS Variants for EV Batteries Each CCS implementation offers unique benefits depending on the application scenario: 1. Wire Harness Solution Structure: Wire harness + acquisition terminals + NTC sensors + aluminum busbar + injection/vacuum-formed bracket Features: Cost-effective and stable signal transmission, but with lower automation potential. 2. PCB Solution Structure: PCB + nickel strips + aluminum busbar + hot pressing with PET film or vacuum thermal riveting Features: Lightweight, high automation, and excellent signal integrity. 3. FPC Solution Structure: FPC + nickel strips + aluminum busbar + hot pressing with PET film or vacuum-formed plate Features: Ultra-lightweight with high automation and stable signal transmission, though with higher costs. 4. FFC Solution Structure: FFC + nickel strips + aluminum busbar + PET film hot pressing or vacuum thermal riveting Features: Lightweight, low cost, high automation—ideal for long-format battery modules. 5. FDC Solution Structure: Die-cut flexible circuits using rotary die technology Features: Fewer processing steps, low cost, and suitable for mass production. 6. FCC Solution Structure: FFC as the main body with soldered FPC or FDC branches through window openings Features: An emerging cost-effective solution still under evaluation and testing. Key Considerations for CCS Design and Manufacturing 1. Material Selection & Integration Process The choice of conductive (copper, aluminum) and insulating materials, as well as integration techniques like hot pressing and riveting, greatly impacts performance, safety, and durability. 2. Automation & Manufacturing Efficiency High levels of automation are essential for scale and cost control. However, due to differing requirements across battery and vehicle manufacturers, semi-automated processes may offer better return on investment at lower volumes. 3. Signal Transmission Reliability Ensuring stable and accurate transmission of voltage and temperature data is crucial. PCB and FPC solutions perform well in this regard but come at a higher cost. 4. Lightweight Design & Cost Control As electrification continues to grow, CCS must balance performance, weight reduction, and affordability. FFC and FDC solutions offer promising trade-offs, but continuous optimization is necessary. 5. Safety & Protection Features CCS must provide overcurrent protection, corrosion resistance, and thermal stability. Design considerations must include cell-level protection to ensure safe operation under extreme conditions. 6. Thermal Management Proper heat dissipation and thermal balance within the battery pack are vital. CCS design must support efficient thermal management through material selection and structural layout. 7. Quality Control & Testing Rigorous quality assurance is key to reliable CCS performance. This includes testing electrical performance, mechanical durability, and environmental adaptability to ensure consistent results across operating conditions. 8. Market Competition & Innovation With growing competition, CCS manufacturers must innovate in process technologies, improve product quality, and reduce costs to stay competitive. Our CCS Technology for EV Battery Packs Our intelligent integrated CCS technology, featuring a fully integrated design that replaces the traditional complex approach of “wiring harness + BMS + temperature sensors.” By integrating multiple cell state detection components directly into the system, we achieve a streamlined, intelligent solution. Starting from the battery cell level, our CCS system establishes a multidimensional safety architecture—combining active and passive protection mechanisms and system-level thermal runaway risk management. Centered on real user needs, our solution delivers smarter, safer, and more reliable battery management—putting safety at the core. Cost-Effective Standardized integrated systems enhance quality and production efficiency, significantly improving PACK assembly speed while reducing overall costs. The use of standardized components greatly simplifies the assembly process. Ultimate Safety Superior insulation and high-voltage withstand capability reduce the risk of accidents. The design minimizes common issues associated with traditional sampling harnesses, such as insulation failure, aging, breakage, and short circuits. Highly Integrated Combines sampling harnesses, aluminum busbars, temperature sensors, as well as internal PACK components like air pressure sensors, explosion-proof valves, electrolyte

Heavy Transport, Industry Insight, Specialty Equipment

Case Study: Electric Street Sweeper for Urban Cleaning

Electric Street Sweeper: Leading the Way in Urban Sanitation Electrification Introduction: Electrification Is Reshaping Urban Sanitation As cities around the world prioritize sustainability, the transition to electric vehicles (EVs) has become increasingly significant. One key player in this movement is the electric street sweeper, a revolutionary piece of sanitation equipment that combines powerful performance with environmental responsibility. This electric road sweeper represents a game-changing step forward in municipal cleaning technology, offering a cleaner, quieter, and more efficient alternative to traditional diesel-powered models. This case study highlights a production electric street sweeper model, demonstrating how electrification is transforming the industry — and how we can support street sweeper manufacturers with tailored electrification solutions, including high-performance motors, battery systems, and charging technologies. A Benchmark in Electric Street Sweeper Design The electric sweeper featured here represents a new generation of urban cleaning equipment: Dimensions: 9270 × 2490 × 3150 mm Curb weight: 8.05 tons Gross vehicle weight: 18 tons Sweeping width: Standard 4.1 meters; Deep-cleaning mode 2.4 meters Tank capacity: 8.5 m³ freshwater, 7.5 m³ wastewater Functions: Full sweeping and washing, one-sided sweeping, deep cleaning, winter water-blow, high-pressure tank self-cleaning This electric sweeper is engineered for high performance in city streets, municipal squares, industrial sites, and more, delivering superior cleaning efficiency while reducing environmental impact. Core Electrification Technologies 1. High-Efficiency Electric Motor The electric street sweeper is powered by a permanent magnet synchronous motor, which offers 350 kW peak power (about 476 horsepower), ensuring strong and reliable performance under various urban conditions. The motor operates with a high efficiency rate of 98%, converting electrical energy into mechanical power with minimal loss. Key benefits of this electric motor include: Mud and condensation resistance: Ensures the motor stays protected even in challenging working environments. 8-year maintenance-free bearings: Reduces maintenance costs and extends the lifespan of the vehicle. IP68 & IP6K9K protection levels: The motor is protected against water, dust, and debris, allowing it to perform reliably even under extreme weather conditions, including heavy rain and floods. 2. Multi-In-One Controller for Optimized Energy Efficiency This electric street sweeper is equipped with a carbon-silicon (SiC) multi-in-one controller. This state-of-the-art controller is designed for high efficiency and low energy consumption, and it offers a host of advantages: Energy savings: The system boosts overall energy efficiency by 8%, allowing the vehicle to run longer on a single charge. Reduced failure rates: The failure rate is reduced by 25%, ensuring more reliable performance. Weight reduction: The controller weighs 50% less than traditional models, helping to improve the vehicle’s overall energy efficiency and performance. Together, these elements combine to make the electric road sweeper a highly reliable and efficient vehicle for urban sanitation needs. 3. Powerful and Efficient EV Battery Design At the heart of this electric sweeper is a high-capacity EV battery system that ensures both longevity and performance. The electric street sweeper’s battery is housed behind the driver’s cabin and is designed for long-lasting power: Rated voltage: 589.26V Rated capacity: 456Ah Total energy capacity: 268.7 kWh This system provides excellent energy density, achieving 175Wh/kg, which allows for longer operational times between charges. Moreover, the battery has been engineered for durability with an IP68+IP6K9K protection level, allowing it to withstand extreme conditions — including up to 72 hours submerged under 2 meters of water. 4. Fast Charging Capabilities The electric street sweeper incorporates fast-charging technology that dramatically reduces downtime: Single gun fast charge: 300A Dual gun fast charge: 600A This unique charging system increases the charging speed by 20%, ensuring the sweeper is ready to return to work quickly, minimizing the interruptions to city cleaning operations. With the combination of fast charging and long-lasting battery capacity, this sweeper is built to tackle large-scale urban cleaning projects without requiring extensive downtime. Environmental and Economic Impact Sustainability Benefits The electric street sweeper is a key part of the ongoing effort to electrify municipal vehicles and reduce urban pollution. Unlike traditional fuel-powered sweepers, which emit harmful pollutants and contribute to greenhouse gases, this electric sweeper has: 10% of the energy consumption compared to a diesel-powered model. A significant reduction in carbon emissions, supporting cities in their sustainability efforts. Cost-Effectiveness Additionally, the operating costs are significantly lower than those of diesel vehicles: Lower fuel costs due to the use of electricity instead of diesel. Reduced maintenance costs thanks to the maintenance-free bearings and robust motor design. The vehicle’s overall economic performance and long-term cost savings make it a highly attractive option for municipalities looking to upgrade their sanitation fleets without sacrificing performance. Partner with Us: Your Expert in Electric Street Sweeper Solutions With over 14 years of experience in the EV industry, we’ve helped more than 300 EV builders worldwide successfully deploy their projects — from electric trucks and buses to sanitation vehicles like electric sweepers. Our electrification solutions for street sweepers or other municipal vehicles include: Electric Powertrain Solution Electric Drive Motor The motor achieves a maximum efficiency of over 97%, with the system efficiency exceeding 90% in 90% of the operational range. 2m 72h extreme water-proof, sediment-proof structure, anti-condensation structure, long-life bearing and oil seal. Noise at full speed section of motor ≤72dB(A), linearity≤2dB(A). Lightweight design X-in-1 Integrated Controller Maximum efficiency>99% EMC reaches class 5 under no-load Functional safety level ASIL C Motor controller+steering controller+air compressor controller+DC/DC+high voltage power distribution Tailored EV Battery System Full system integration of battery Pack+BMS+BTMS+PDU Premium battery cells from top battery cell suppliers Excellent thermal management strategy for enhanced reliability Lightweight design with alumium alloy composites for battery box DC Fast Charging Solution Tailored solutions from project consulting, product delivery to after-sales support. Professional training for installation, operation, and maintenance. Free technical support throughout the product lifecycle for safe and efficiency operation 60 kW to 420 kW integrated DC fast chargers with CCS2 standard 80 kW to 400 kW integrated DC fast chargers with GB/T standard Power distribution system Charging operation management system, flexible user-friendly payment and charging options Security & monitoring system Fire safety system Other Solutions Onboard Charger Auxiliary Inverter Electric Power Steering Air Brake

Public Transportation, Technologies

Integrated Electric Bus Powertrain Axle Assembly Design

Integrated Electric Bus Powertrain Axle Assembly Design Introduction to Electric Bus Powertrain Development Electric buses have increasingly been recognized worldwide as a leading direction in EV development. As the consumption of non-renewable resources accelerates, the automotive industry’s shift toward electrification is becoming even more pronounced. However, due to current limitations in energy storage technology, electric vehicles continue to lag behind traditional vehicles in areas such as driving range, battery lifespan, and charging convenience. Consequently, pure battery electric buses (BEBs) tailored to specific routes and operating conditions are at the forefront of pilot programs. In recent years, the electrification of public transportation fleets in major cities around the world has gained significant momentum. With substantial investments flowing into the pure electric bus sector, it is critical to harness emerging technologies to strengthen product competitiveness. Among these advancements, the integration of electric motor and drive axle design has notably enhanced the performance of electric buses and has become a key focus in EV safety development. Overview of Integrated Electric Bus Powertrain Axle Assembly Traditional bus powertrains consist of an engine, transmission, driveshaft, and axle assemblies. As the electric bus powertrain industry continues to evolve, many manufacturers initially adopted transitional solutions — replacing the internal combustion engine with an electric motor while largely retaining the traditional mechanical layout, as illustrated in Figure 1. However, this approach introduces several challenges: Low transmission efficiency: Overall system efficiency remains below 80%. Poor system integration: The design conflicts with the industry’s ongoing lightweighting initiatives. Limited regenerative braking performance: Due to the inherent limitations of traditional bevel gear axles, brake energy recovery rates are typically below 30%. The new generation electric bus powertrain layout proposed in this paper effectively overcomes these shortcomings (Figure 2). In this new design, the electric motor is fully integrated into the drive axle assembly, eliminating the need for separately mounted motors, suspension components, and driveshafts within the vehicle frame. This integrated configuration simplifies vehicle layout and installation. The suspension system mounts directly to the axle housing, and the battery packaging is optimized, significantly improving internal space utilization. Nevertheless, engineering challenges remain. Precisely determining the torque axis is complex due to factors such as vehicle and drivetrain layout, packaging constraints, and the mechanical characteristics of rubber isolators, all of which affect the compression-to-shear stiffness ratio and complicate accurate positioning of the fore-aft mounting centers along the torque shaft. System Design of the Integrated Electric Bus Powertrain Axle Assembly Taking an 8.5-meter pure electric bus as a design example: Current mainstream design: Uses a low-speed, permanent magnet synchronous, water-cooled electric motor. Max power: 300 kW Max torque: 2070 Nm Speed: 4000 rpm Axle load: 8 tons Gear ratio: 5.857 Motor weight: 550 kg Driveshaft weight: 40 kg Maximum wheel driving torque: 2070 × 5.857 = 12100 Nm The suspension system’s natural frequency is below 30 Hz. New high-speed design: Introduces a high-speed permanent magnet synchronous, water-cooled motor: Power: 205 kW Torque: 500 Nm Max speed: 12,000 rpm Motor weight: 102 kg Axle weight: 580 kg (with no driveshaft required) Gear ratio: 24.8 Maximum wheel driving torque: 500 × 24.8 = 12400 Nm In traditional axles, the engine layout perpendicular to the driving direction necessitates the use of bevel gears to redirect power. Bevel gear manufacturing limitations mean that convex and concave gear sides have different accuracies. During regenerative braking, if over 30% of braking energy is recovered, the concave gear side’s insufficient precision can cause gear surface damage or even failure. To address this, the new solution arranges the motor parallel to the vehicle’s driving direction, eliminating the need for bevel gears. All gears are cylindrical gears, which are easier to design and manufacture with high precision, improving durability and supporting more efficient brake energy recovery. Weight Comparison Category Weight (kg) Traditional pure electric design 300 + 550 + 40 = 890 kg Integrated axle motor design 102 + 580 = 682 kg Weight saving 890 – 682 = 208 kg Application of Integrated Electric Bus Powertrain Axle Assembly By integrating the motor and axle into a unified powertrain system, there is no longer a need to reserve separate space for the motor. This design reduces the rear suspension space requirements, as shown below, and significantly improves passenger cabin space by increasing the distance between the front and rear doors. Performance Comparison Between Integrated and Traditional Electric Bus Powertrains The integrated electric bus powertrain offers the following advantages over traditional designs: Higher system integration:The axle self-assembles with the powertrain, simplifying vehicle layout and improving transmission efficiency. Enhanced regenerative braking:Brake energy recovery capacity can reach up to 100%. Significant weight reduction:Lightweighting of approximately 208 kg for an 8.5-meter electric bus. Improved vibration isolation and vehicle stability:Experimental tests confirm enhanced ride quality and comfort. Conclusion This study explores an innovative electric bus powertrain layout that significantly improves electric vehicle performance. Through ultra-short rear suspension designs and system lightweighting, the proposed integrated axle motor assembly enhances vehicle energy efficiency (EKG indicators) and extends the continuous driving range. The results demonstrate higher transmission efficiency, superior regenerative braking capabilities, and reveal the future electrification trends for heavy-duty vehicles. Discover our integrated electric bus powertrain (electric bus axle) here: https://brogenevsolution.com/electric-axle-for-bus/ Business inquiry: contact@BrogenEVSolution.com Or you can complete the table below to get in touch with us. 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

Autonomous Vehicles, Industry Insight

Autonomous Street Sweeper: Ushering in the Smart Era of Urban Cleaning

Autonomous Street Sweeper: Ushering in the Smart Era of Urban Cleaning The sanitation industry is undergoing a technological revolution. The autonomous street sweeper, combining green energy and smart capabilities, leverages lidar and multimodal sensors to autonomously complete operations such as 3cm-edge cleaning, watering, dust suppression, obstacle avoidance, and self-driving tasks — achieving truly unmanned street sweeping. This 0.6-ton low-speed autonomous street sweeper has been operating continuously for about six months on semi-open roads in industrial parks, becoming a distinct symbol of innovation and attracting significant attention from local citizens. The Future is Now: Technology Transforming Sanitation Operations A leading automotive company is pioneering a comprehensive product matrix for autonomous sanitation vehicles, covering closed, semi-open, and open-road scenarios. Through trial operations, they have demonstrated robust vehicle perception capabilities: lidar mounted on top, mid-360 radars on the lower body, 12 ultrasonic radars, and surround-view cameras ensuring complete, seamless environmental perception. “This low-speed autonomous street sweeper integrates sweeping, watering, dust suppression, rain protection, and self-driving functionalities,” explained one of the lead engineers. Powered by a single Orin-based domain controller delivering up to 254 TOPS of computing power, and equipped with lidars, ultrasonic sensors, and cameras, the sweeper forms a comprehensive and precise perception system. Thanks to this system, the sweeper can detect pedestrians, vehicles, and various obstacles, autonomously stopping or maneuvering around them, significantly enhancing safety and efficiency. Take obstacle avoidance, for example: if a pedestrian suddenly crosses into the operational path, the autonomous street sweeper swiftly identifies the unexpected event, activates its turn signal, and smoothly sidesteps the obstacle. After confirming safety, it quickly returns to its original route, maintaining 3cm precision edge-cleaning. “Our decision-making system can instantly perceive and generate a bypass path,” the engineer added. In case of autonomous failure, the vehicle can switch to remote driving mode via camera data. A custom-built remote monitoring platform enables unified management of all operating vehicles. For liability protection, the system includes video recording and real-time monitoring to capture the entire cleaning operation process for later review. Autonomous Street Sweepers Address Key Challenges in Sanitation Operations “Today, our autonomous street sweepers can independently complete sweeping, watering, and dust suppression tasks without any manual intervention,” the engineer noted. “Starting the operation is simple: just open the program and press start. The sweeper follows the pre-set route autonomously.” Operators can monitor operations in real time through a mobile app or remote platform, checking detailed information such as battery level, driving mode, fault status, and mileage. Inside the app, selecting the bound vehicle displays comprehensive data, and the control panel provides six function buttons: autonomous driving, sweeping and spraying, garbage dumping, emergency stop, and more. The management interface also records operational anomalies, system faults, chassis issues, and prolonged parking, allowing for rapid problem identification and resolution. In today’s era of rapid technological advancement, intelligent unmanned operation is becoming a key pathway for transforming the sanitation industry. By taking advantage of fixed routes and simpler operational scenarios, autonomous street sweepers reduce labor costs, enhance efficiency, minimize safety risks, and lower pollutant emissions — offering a new sustainable solution for the future of urban cleaning. Real-World Deployment: A Proven Solution for Labor and Cost Challenges The featured autonomous street sweeper has been officially in operation for over six months. Operating daily from 8:30–11:30 AM and 1:30–4:30 PM, it covers around 10 kilometers each day. In areas like parking lots and bike lanes, the sweeper reliably performs obstacle avoidance, emergency stops, and hazard warnings. Facing challenges such as rising labor costs (up 12% annually) and an aging workforce (average age 52), the sweeper provides an innovative answer. Equipped with a 5.04 kWh battery, supporting a 30 km range, each sweeper can cover nearly 30,000 square meters per charge — equivalent to the workload of three sanitation workers. This dramatically addresses labor shortages, enhances per-person efficiency (compared to traditional four-shift operations), and cuts energy consumption by 35% versus conventional vehicles. The company’s management emphasized: “Our goal was always to achieve fully autonomous, intelligent cleaning, and today we are gradually realizing that vision. The deployment of these unmanned vehicles greatly eases labor burdens and has received strong support from local governments. As an innovative pilot project, the autonomous street sweeper offers valuable insights and benchmarks for the sanitation industry.” Autonomous Vehicle Chassis: Enabling the Future of Street Sweeping Want to lead the future of street sweeping?To support the development of autonomous street sweepers, we offer a comprehensive autonomous vehicle chassis solution, designed to accelerate product validation and innovation for vehicle manufacturers. Our chassis platform features: Open-source skateboard chassis design for faster R&D Layered SCA (Software, Computing, Actuation) architecture Hardware-software decoupling for greater flexibility Decoupled upper and lower body structure for modularity Automotive-grade high reliability components Expandable for multiple scenarios including sanitation, logistics, and security High system safety and reliability Highly integrated and modular design for quick customization Open architecture enabling secondary development Strong scalability to adapt to diverse operational needs By leveraging our autonomous vehicle chassis solutions, manufacturers can significantly reduce development time, lower costs, and deliver reliable, efficient, and intelligent street sweepers that meet the evolving needs of modern cities. Discover ourAutonomous Vehicle Chassis Solutions here: https://brogenevsolution.com/autonomous-vehicle-chassis/ Business inquiry: contact@BrogenEVSolution.com Or you can complete the table below to get in touch with us. 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,

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