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

2-ton Electric Pickup Trucks in South Korea With Our E-Axles

2-Ton Electric Pickup Trucks in South Korea With Our Electric Axles Project Overview In 2021, a leading vehicle manufacturer in South Korea sought our expertise to develop an electric powertrain system for their new 2-ton electric pickup trucks. The client’s primary requirement was an electric axle capable of delivering a maximum power output of 60 kW. Our team swiftly proposed a comprehensive solution tailored to meet their specific needs. Systems We Provided for the Electric Pickup Trucks Electric Axle Rated axle load: 2000 kg Maximum output torque: 2266 N.m Maximum output power: 60 kW Wheel speed: 870 rpm Speed ratio: 10.5 Axle weight: 105 kg Protection class: IP 67 Rated voltage: 336 VDC Explore more e-axle solutions Motor Controller Applicable motor type: three-phase AC synchronous motor Applicable voltage range: 250 – 420 VDC Rated voltage: 336 VDC Conversion & Distribution Unit (OBC+DC/DC+PDU) For the On-Board Charger Input voltage: 85 – 264 VAC Maximum input current: 32 A Maximum output power: 6.6 kW Output voltage range: 200 – 420 VDC Maximum output current: 20 A Module efficiency: 95% For the DC/DC Converter Input voltage: 200 – 450 VDC Maximum input current: 11 A Maximum output power: 1.5 kW peak Output voltage range: 13.8±0.3 V Maximum output current: 145 A Module efficiency: 94% Explore more onboard charger systems Project Execution and Collaboration To facilitate efficient communication and problem-solving, we established a dedicated WeChat group, bringing together engineering teams from both companies. This platform allowed for real-time discussion and on-site debugging, ensuring a smooth development process. Our software engineers customized the control software to align with the client’s specific vehicle requirements, and regular video meetings were held to address any challenges encountered during testing. Results and Achievements Our factory preparing the shipment of the electric axles. Our factory preparing the shipment of the electric axles. In 2022, the client successfully completed vehicle verification for their electric pickup trucks and proceeded to the SOP phase. They introduced eight different models based on the same electric axle system and held a local press conference to showcase their new lineup. The client expressed gratitude for our technical support and responsiveness throughout the project. By the end of 2022, the client commenced mass production and placed an order for 1,000 sets of our electric powertrain systems for their pickup trucks. This collaboration not only highlighted our capability to deliver high-quality, customized solutions but also solidified our partnership with the client for future projects. 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

Charger & Converter

6.6 kW Onboard Charger & 2.5 kW DC/DC Combo

6.6 kW Onboard Charger & 2.5 kW DC/DC Combo This integrated system consists of a 6.6 kW onboard charger and a 2.5 kW DC/DC converter. The OBC converts energy from AC power grid into high-voltage DC power to charge the electric vehicle’s traction battery, with the entire charging process being monitored by the vehicle. The DCDC converter transforms the high-voltage DC power into the required low-voltage DC power, providing 12 V power supply to the vehicle and charging the auxiliary battery. The OBC and DCDC communicate voltage, current, and other information via the CAN bus, allowing for information exchange and status feedback with the Battery Management System (BMS) and Vehicle Control Unit (VCU). Applicable for PHEV and BEV Compact design for enhanced vehicle layout Flexible platform design Efficiency up to 92% Technical Parameters Appearance System weight 5.5 kg Size 279*202*68 mm (connector and mounting feet not included) Charging Mode Input voltage range 85 – 265 VAC Rated input voltage 220 VAC Input frequency range 45 – 65 Hz Input current 32 A max. Power factor ≥0.98@rated input, output, half load Output voltage range 270 – 450 VDC Rated output voltage 350 VDC Max. output current 22 A Output power 6.6 kW max. Efficiency ≥92%@rated input, output DC/DC Mode Input voltage range 270 – 450 VDC Rated input voltage 350 VDC Max. input current 12 A Output voltage range 9 – 16 VDC Rated output voltage 14 VDC Output current 180 A continuous Output power 2.5 kW continuous Output power under charging status 2 kW max. Efficiency 92%@rated input, output 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 EV On Board Charger & DC-DC Converter Combo Light Commercial Vehicle Electrification Solutions 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

20 kW High Voltage On-Board Charger for EV

20 kW High Voltage On-board Charger for EV System Introduction This 20 kW high voltage on-board charger is designed to convert three-phase or single-phase AC input power into high-voltage DC power output. It is used to charge the vehicle’s power battery or supply power directly to other vehicle loads in real time. Applicable for PHEV and BEV Worldwide usage by wide input range, 1 phase and 3 phase Flexible platform design Efficiency up to 95% Wide output voltage range from 200 to 715 VDC Product Parameters Output power: 3-phase 20 kW; 1-phase 6.6 kW Input voltage range: 3-phase 267 – 456 VAC; 1-phase 154 – 265 VAC Maximum input current: 32 A Input frequency range: 45 – 65 Hz Power factor: 0.99 (rated input, rated output, half load) Output voltage range: 200 – 715 VDC Maximum output current: 3-phase 42 A; 1-phase 14 A Peak efficiency: >95% Protection level: IP67 Weight: 40 kg Discover Our On Board Charger Solutions All Posts EV Industry EV Products EV Projects EV On Board Charger & DCDC Converter Combo EV On Board Charger (OBC) Experience peak performance and reliability with our integrated EV on board charger (OBC), DC/DC converter,… Read More 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. Whatsapp: +8619352173376 Email: contact@brogenevsolution.com 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 EV Project Type *– Please select –BusLight-duty truckHeavy-duty truckConstruction machineryVesselOthers (please write it in the note)Your Interested Solutions *– Please select –MotorBatteryChassise-AxleAuxiliary inverterOBC / DCDC / PDUAir compressorEPS / EHPSBTMSOthers (please write it in the note)Do you have other contact info? (Whatsapp, Wechat, Skype, etc.)Please introduce your EV 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

Industry Insight, Technologies

Axial Flux Motors for Electric Motorcycles – Benefits & Applications

Axial Flux Motors for Electric Motorcycles – Benefits & Applications As environmental awareness increases and the shift towards sustainable energy continues, the motorcycle industry is rapidly advancing towards electrification, smart technology, and high performance. The demand for electric motorcycles is on the rise, and their market share is expanding significantly. To meet the growing consumer demand for personalized experiences, future motorcycles will focus on enhanced performance, including faster speeds, more stable handling, and improved safety. Our axial flux technology is at the forefront of these trends, significantly boosting the performance of electric motorcycles. This innovative technology provides manufacturers with a crucial competitive advantage in the rapidly growing electric motorcycle market. Explore how our cutting-edge solutions can drive your success in the evolving landscape of electric motorcycles. Powerful Electric Motorcycle Motors for High-End Models Increase in storage space 0 % Improvement in overall range 0 % 0-50 km/h acceleration 0 s Our e-powertrain for electric motorcycles adopts innovative axial flux motor technology, delivering higher torque and output power while reducing kinetic energy loss and increasing traction efficiency. With the same motor diameter, our axial flux motor‘s power density is 3 times that of a radial flux motor, and its torque density is twice as high. When delivering the same torque and power output, our motor’s volume is reduced by 50%, and its weight is decreased by approximately 50%. Additionally, our motor features a larger cooling surface and superior cooling performance, allowing for prolonged high-output power. Compared to radial flux motors, our motor’s peak power output capability is more than doubled. In continuous operation, our 15 kW electric powertrain matches the power output of a 150 cc fuel motorcycle. It can operate at over 90% efficiency in more than 90% of conditions, resulting in lower energy consumption, better performance, and increased energy recovery. With our axial flux motor, motorcycle range can be improved by over 15%, without changing other components. Moreover, even the 15 kW axial flux electric motor system weighs just 15 kg, significantly lighter than radial flux drive motors. Even with a side-mounted layout, it hardly affects the vehicle’s center of gravity. The side-mounted axial flux motor still allows the electric motorcycle to achieve a lean angle of 40 degrees, comparable to fuel motorcycles. This maintains the vehicle’s performance and range while preserving the joy of riding. 9 Advantages for a Comprehensive Upgrade 30% – increase in battery and storage space 3.2 seconds – acceleration from 0 to 50 km/h 15% – increase in range 9% – increase in drive efficiency Double 90% – motor efficiency MAP 40° – maximum tilt angle 108% – increase in energy recovery IP68 – high waterproof rating Excellent heat dissipation capability Benefits of Axial Flux Motors for Electric Motorcycles Compact Design for More Powerful Performance Compared to the commonly used radial flux motors, axial flux motors offer significant advantages. They can deliver multiple times the power within the same volume and weight or reduce volume and weight by more than 50% at the same power level. This means that electric motorcycles using our axial flux motors not only have significantly more power but are also more conveniently and flexibly arranged. For example, our 15 kW side-mounted electric motorcycle powertrain assembly, with a peak power of 15 kW and an axial dimension of less than 83 mm, is only about 1/3 the size of a radial flux motor of the same power. Better Cornering Ability In practical performance, the application of our axial flux motors allows the electric motorcycle to achieve a maximum lean angle of 40°, comparable to that of traditional fuel-powered motorcycles. The power tuning is highly refined, allowing precise torque output with small throttle adjustments within a turn. This ensures excellent cornering ability, on par with fuel-powered counterparts. Additionally, the acceleration response of the electric drive is faster, providing an enhanced riding experience. Higher Torque for Superior Climbing Ability of Electric Motorcycles Professional testing and analysis reveal that an ordinary household car can handle slopes of around 20°, while 4WD SUVs can manage up to 26°. Only a select few robust 4WD off-road vehicles can conquer slopes as steep as 30°. At a 26° incline, it becomes difficult for a person to maintain balance. However, an electric motorcycle equipped with our axial flux motor can easily perform a “half-hill start” on such slopes, thanks to its powerful 300 N.m wheel-end torque. When climbing hills, off-roading, mountain riding, or commuting, our axial flux motors for electric motorcycles help handle these challenges with ease. Product Portfolio – Motors for Electric Motorcycles Model 6K 9K 15K Bus voltage 72 VDC 72 VDC 72 VDC Ratio 6.095 8.75 7.5 Rated power 3.5 kW 4 kW 6 kW Peak power 6 kW 9 kW 15 kW Assembly rated speed 3200 rpm 4000 rpm 4500 rpm Assembly peak speed 5500 rpm 9500 rpm 11500 rpm Assembly weight 9.2 kg 12 kg 15 kg Maximum efficiency 92% 93% 94% https://youtu.be/UhS63H-T0Z4?si=kjOq7NaKO3JRByeG Frequently-Asked Questions How to purchase these axial flux motors for electric motorcycles? You can purchase these motors from us by filling the form below with your project information and requirements. Our Sales Representative will get in touch with you in 2 business days. Notice: Due to high demand, we are currently only accepting business projects and cannot accommodate personal projects. To assist you better, please include your business information in your inquiry to help us understand your requirements. Do you offer customization services? We offer customization services for your project, but please note that an additional development fee will apply. Do you have other options for axial flux motors? Yes, our axial flux motor systems offer power options from 6 kW to more than 800 kW. Learn more here: https://brogenevsolution.com/axial-flux-motor-technology-for-electric-vehicles/ What’s the price of these motors? The price varies based on your purchase quantities. Therefore, we need more information about your project to provide an accurate quotation. Can I purchase just one motor? Sorry, we don’t accommodate personal projects and have MOQ requirements. What’s the process of purchasing these

standard battery pack for electric bus / hcv

Industry Insight

How to Design a BEV Traction Battery System? – Overview

Designing Better BEV Traction Battery Systems Brief Introduction Designing a suitable traction battery system for Battery Electric Vehicles (BEVs) is crucial for ensuring optimal performance, safety, and longevity of the vehicle. As BEVs become increasingly popular due to their environmental benefits and efficiency, the demand for advanced battery systems continues to grow. A well-designed traction battery system not only meets the power and range requirements of the vehicle but also addresses critical factors such as safety, cost, and environmental impact. In this blog, we will explore the key aspects of designing a traction battery system, including safety and performance requirements, issues to be addressed, design processes, and the information needed about the vehicle to achieve a perfect design, as well as a detailed case study of designing a battery system. Purpose of the EV Traction Battery System Design To provide a traction battery system with optimal performance based on the design requirements of the entire vehicle. Safety performance requirements Electrical performance requirements Battery selection and system configuration Issues to be Addressed Design structure and process within allowable size and weight to meet the vehicle’s power requirements Find simple and feasible processes Reduce costs Improve technical performance where conditions permit Address and resolve environmental pollution issues EV Traction Battery Design Process Understand vehicle requirements Design system power Design system capacity Thermal design System integration Simulation and validation Parameters to Determine and Issues to Address 1. Electrical Characteristics Nominal voltage and operating voltage range; Nominal capacity and available capacity range; Regular discharge current of the traction battery system; Charging requirements of the traction battery system. 2. Power Characteristics Maximum output power and duration of the traction battery system; Maximum regenerative power and duration of the battery system. 3. Environmental Characteristics Operating temperature range of the traction battery system; Charging temperature range; Storage temperature range. 4. Physical Characteristics Structural and dimensions of the traction battery system; Quality of the traction battery system; Other mechanical performance and protection requirements. 5. BMS Requirements Management and protection functions of the BMS; Determination of battery SOC and SOH; Communication methods and transceiver design requirements; Control requirements and communication protocols. 6. Vehicle Interface Requirements Physical interfaces: battery installation, fixing methods, space orientation of cooling medium, and related pipelines; Electrical interfaces: vehicle harness definition and technical specifications, connector model, and pin definitions; Communication interfaces: communication with the vehicle, internal communication of the BMS, communication with the charger. Information Needed About the Vehicle The more detailed the understanding of the vehicle, the more perfect the traction battery system design will be. Not only the motor and vehicle control strategies but also the vehicle’s mass, dimensions, space, and operating conditions must be thoroughly understood: Vehicle parameters Vehicle motor parameters Required driving range of the vehicle Regenerative power Installation space dimensions of the traction battery system and installation and fixing requirements Quality requirements of the traction battery system Charging methods and interfaces Vehicle operating conditions Operating environment temperature range Charging environment temperature range Power requirements of auxiliary systems Characteristic parameters of the auxiliary battery Traction Battery System Design Steps Determine vehicle design requirements Determine motor requirements Determine power requirements of the traction battery system Determine the voltage range of the traction battery system Determine the type of batteries required for the traction battery system Determine the SOC application range of the traction battery system Determine the effective and actual capacity range of the traction battery system Determine the combined structure of the traction battery system Determine the BMS requirements of the traction battery system Determine the interfaces of the traction battery system Determine other methods such as cooling methods, gas sources, and charging methods Simulation and validation Design optimization Case Study With the following parameters for a BEV, explore how to design a suitable traction battery system to ensure optimal performance, safety, and efficiency. Curb weight: 12600 kg Gross weight: 17150 kg Wheelbase: 5980 mm Frontal area: 7.95 m² Transmission system efficiency: 0.92 Aerodynamic drag coefficient: 0.7 Rolling resistance coefficient: 0.0076+0.000056Vv Required acceleration time: 13 s Required driving range: 200 km (average speed at 40 km/h) Power consumption for electronic accessories and air conditioning: 8 kW Step 1: Determine the vehicle’s power requirements The power balance relationship of an automobile should satisfy: The vehicle power requirement (Pv1) corresponding to the maximum vehicle speed is: The vehicle power requirement (Pv2) corresponding to the maximum climbing grade αm is: The vehicle’s power requirement Pv3 for accelerating from a standstill to a specified acceleration time T is given by the following formula. The required power during full-throttle acceleration is Pv3. The power requirements of the vehicle under different conditions – maximum speed, maximum climbing gradient, and full acceleration – are as follows: 98.7 kW, 91.8 kW, and 65 kW, respectively. Step 2: Determine the system voltage range Based on the selected motor for the vehicle, determine the nominal voltage and voltage application range of the traction battery system. Standards require that the motor and controller safely handle the maximum current within 120% to 75% of the rated voltage. Additionally, the DC bus voltage should not fall below 80% of the motor’s rated voltage. For instance, if the vehicle uses a 384 V motor, the battery system should operate within a voltage range of 300 to 460 V. In this case, a lithium iron phosphate (LiFePO4) battery system with 120 cells connected in series is selected. Step 3: Determine the maximum output power / current of the system Power supply system power requirements: the motor power is 110 kW. Assuming the motor efficiency and controller efficiency are 0.9 and 0.95, respectively, and the power for electronic accessories and air conditioning is 8 kW, the minimum power required by the power supply system is calculated as follows: 110/(0.9×0.95)+8=137 kW Maximum output current: the system’s nominal voltage is 384 V. For high-power output, it’s calculated at 10% below the nominal voltage: Idmax=Pmax/V=137000/(384×0.9)=396 A Duration: the duration should meet the requirements of the entire vehicle, taking into account the SOC requirements (the maximum power demand at 30% SOC). Design redundancy: ensuring a 30%

Light Commercial Vehicles, Technologies

Electric Power Steering for Light Trucks

R-EPS for Light Commercial Vehicles Rack-assist Electric Power steering (R-EPS) positions the motor directly on the steering rack, making it ideal for medium to large vehicles that require significant power assistance. Typically, a ball screw and belt mechanism is used to transit motor assistance to the rack. This electric power steering for light trucks is of the rack-assist type. The R-EPS, with its rack-mounted direct assist and minimal internal friction, offers an exceptional steering feel. It delivers high rigidity and outstanding dynamic performance, making it one of the most efficient steering systems available today. Model R008 Technical Parameters Applications RH / Light truck Rated Current 80A@DC12V, 60A@DC24V Operating Voltage DC12V / 24V Rack Stroke & Ratio ±80mm & 50.27mm/rev Maximum Pull-Push Force 16kN@12V; 18kN@24V Applicable Vehicle Specs Front axle load 3000 kg (reference) Sensor Type TAS Protection Level IP67 Features Compact design: optimized for space efficiency in vehicle layout. High rack force: the integration of belt and ball screw structures enables a rack force of up to 18 kN Proven reliability: utilizes a mature hardware and software platform, with established production processes, to ensure stability and reliability. Enhanced steering feel: provides a smooth and refined steering experience. Upgraded functionalities, including end-point control, return-to-center, and drift compensation, position this system at the forefront of steering technology. Superior NVH performance: incorporates advanced motor active noise reduction algorithms and production line calibration algorithms to deliver a quiet and serene vehicle environment. Frequently Asked Questions How’s your R&D strength? We have 52 R&D team members for the EPS systems, with a core specialist who has designed and developed steering and suspension systems for world-class vehicle manufacturers such as Toyota, Mitsubishi, Lexus, Honda, etc. What’s your typical annual production volume for EPS systems? Our annual manufacturing capacity for EPS is about 1,100,000 sets. Do you offer custom EPS solutions in addition to standard products? Sure, as we have a professional R&D team, we provide OEM / ODM service and can customize a system for your project. Do you have other EPS products for cars, or trucks? Yes, you can visit here to learn more about our electric power steering systems: https://brogenevsolution.com/electric-power-steering-solutions/ What are the steps of working with you? You may fill in the form below to get in touch with us first. Remember to describe your project info and product requirements as detailed as possible. Then we will arrange an expert to get back to you shortly and provide a customized solution for you. If necessary, our engineering team will discuss with your engineering team to check if our system can work well on your platform and if we need further modification, etc. Then we will provide the quotation to you. 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

Industry Insight

How Long Do Electric Car Batteries Last?

How Long Do Electric Car Batteries Last? The lifespan of electric car batteries is a multifaceted subject influenced by various factors. Here’s a detailed and informative analysis, incorporating relevant figures and information to help you understand how long these batteries typically last. Overview The lifespan of an electric car battery is usually defined not by complete depletion but by the national standard where the battery capacity drops to a specific percentage (e.g. 70%) of its original capacity. Several factors influence the lifespan of EV car batteries, including charging and discharging frequency, depth of discharge, usage duration, environmental conditions, and thermal management. Specific Lifespan for Electric Car Batteries Usage Duration Cycle Life Shelf Life Influencing Factors Electric Car Batteries Maintenance Recommendations Summary The lifespan of these batteries is influenced by various factors. Generally, lithium batteries last between 8 and 10 years, with an effective lifespan of 5 to 7 years. Proper usage and maintenance can extend battery life. Additionally, with ongoing technological advancements, future electric car batteries are expected to have longer lifespans and improved performance. By understanding these factors and following best practices for maintenance, electric car owners can maximize the lifespan and efficiency of their vehicle’s batteries, ensuring reliable performance and cost-effectiveness over time. At Brogen, we provide customizable EV battery solutions. Inquiry: contact@brogenevsolution.com

Industry Insight

What is an Electric Vehicle Traction Battery?

What is an Electric Vehicle Traction Battery? An electric vehicle (EV) traction battery, commonly referred to as an EV battery, is a critical component essential for electric vehicles, electric trains, electric trucks, and other similar applications. It plays a pivotal role in the advancement of new energy vehicles, making a significant stride towards future energy transitions. Below is a comprehensive overview of electric vehicle traction batteries: Definition and Applications Electric vehicle traction batteries serve as energy storage solutions designed specifically to power electric vehicles, electric trains, electric trucks, and comparable electric applications. They distinguish themselves from traditional auxiliary batteries primarily used to ignite combustion engines in automobiles. Types of Electric Vehicle Traction Batteries These batteries encompass a variety of types, including: Structural Composition of an Electric Vehicle Traction Battery Typically, an EV traction battery comprises: Key Features The EV traction batteries offer the following distinct features: Applications These EV batteries find applications across several industries: Conclusion In conclusion, EV traction batteries stand as pivotal components within new energy vehicles, facilitating the transition to sustainable energy practices and environmental conservation. With ongoing technological innovations and expanding market horizons, the future prospects for EV traction batteries appear increasingly promising. At Brogen, we supply EV traction batteries for almost all types of electric vehicles and provide customizable OEM / ODM services. Learn more here: https://brogenevsolution.com/ev-battery/ Inquiry: contact@brogenevsolution.com

Heavy Transport, Technologies

160 kW / 360 kW Electric Axle for Trucks

160 kW / 360 kW High-Voltage Electric Axle for Trucks System Introduction This electric axle for trucks boasts a rated power of 160 kW and a peak power of 360 kW. Utilizing a distributed drive system, it integrates two PMSM electric motors within the e-axle. The advanced gear-shifting control strategy ensures uninterrupted power delivery during gear changes, enhancing driving safety. Additionally, in the event of a single motor failure, the remaining motor continues to provide power, offering an extra layer of safety redundancy to the eAxle system. Benefits of Our Electric Axle for Trucks – Safe Core Strategy Controlled by the distributed drive electronic differential system; equipped with EASR, IESS safety configurations. Benefits Reduce the vehicle energy consumption, and increase vehicle safety and stability in harsh environments; the electronic differential lock can effectively get out of trouble on the road. Lower Gravity Center The gravity center of the battery system is lowered by 1620 mm. Benefits Provide ample space for the bottom placement of the battery and increase the stability of the whole vehicle. Dual Motor Design Integrating the dual motor structure and advanced gear-shifting control strategy to ensure uninterrupted power delivery during gear changes. Beneifts It’s safer and more comfortable to drive the vehicle. Benefits of Our Electric Axle for Trucks – Economical 0 % The transmission system features a simple structure with a concise transmission chain, enhancing overall system efficiency by up to 4% 0 % Enhanced Energy Regeneration by 100%: The gear’s forward and reverse torques are balanced, significantly improving energy regeneration efficiency and extending the driving range. Benefits of Our Electric Axle for Trucks – Powerful & Lightweight 0 N.m The maximum output torque for a single axle can reach 51480 N.m. The maximum motor generation torque can also reach 51480 N.m, reducing brake heat fade on long downhill stretches and eliminating the need for additional water cooling for the brakes. 0 kg The single e-axle weight is about 920 kg. For 4×2 tractor-trailers, the distributed drive system reduces weight by 462 kg compared to direct drive systems and by 300 kg compared to central drive electric axle systems, increasing payload capacity. Product Parameters Motor type: PMSM Motor power (rated/peak): 2×80 kW / 2×180 kW Motor speed (max.): 9500 rpm Motor torque (rated/peak): 2×260 N.m / 2×520 N.m Rated voltage: 540 VDC IP rating: IP68 E-axle weight: 950 kg Rated axle load: 13000 kg Wheel speed (max.): 620 rpm Gear ratio: 49.4/15.3 Rim size: 22.5 inch Tire size: 12R22.5 Brake: Air disc brake 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. Whatsapp: +8619352173376 Email: contact@brogenevsolution.com 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 EV Project Type *– Please select –BusLight-duty truckHeavy-duty truckConstruction machineryVesselOthers (please write it in the note)Your Interested Solutions *– Please select –MotorBatteryChassise-AxleAuxiliary inverterOBC / DCDC / PDUAir compressorEPS / EHPSBTMSOthers (please write it in the note)Do you have other contact info? (Whatsapp, Wechat, Skype, etc.)Please introduce your EV 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

Public Transportation, Technologies

Electric Power Steering (EPS) for Hybrid & Full Electric Buses

Electric Power Steering System (EPS) for Bus Our rack-assist type electric power steering system (R-EPS) for large commercial vehicles like buses is designed with integration, lightweight construction, and energy efficiency in mind, making installation much more efficient. It’s about 15 kg lighter and more compact than traditional EHPS systems. Plus, it only activates during steering, saving 4 kWh of energy per day. Over five years, this adds up to about $3000 in savings on electricity and battery costs. Whatsapp: +8619352173376 Email: contact@brogenevsolution.com Download Brochure Get Custom Quote Working Principle of the EPS for Bus After the motor outputs torque, it is reduced and amplified through the worm gear system. The worm gear drives the ball screw, which moves the piston rod in a linear motion. The piston rod, connected to the outer tie rod via a ball joint, pushes or pulls the steering arm, turning the wheels. Unlike traditional hydraulic power steering systems, this EPS for hybrid or battery electric buses provides a smoother ride. This innovative system controls the operation and torque output of the electric power steering motor according to the driving speed of the vehicle and the steering torque and steering angle of the driver’s steering wheel after processing and calculation by the steering electronic control unit (ECU). It’s a device that optimizes the effect of power steering. Our EPS for Bus VS EHPS for Bus Item Our EPS for Bus EHPS for Bus Layout & Installation Easy to install with high assembly capacity. Requires additional installation space; hydraulic system installation is complex and labor-intensive. Parts Management & Cost Fewer parts, only EPS and ECU. More components, including electro-hydraulic pumps, hydraulic lines, and assist oil; higher procurement, maintenance, and quality costs. Size & Weight Lightweight, approximately 15 kg lighter than EHPS; compact and space-efficient. The hydraulic steering system housing is made of cast iron, resulting in greater weight and environmental pollution during production, particularly in surface coating. Efficiency >83% Approximately 55% Steering Feel Responsive and precise Rigidity Direct push-pull type with high rigidity. Energy Consumption Only operates during steering; saves about 4 kWh per day, leading to savings of about $3000 in electricity and battery costs over 5 years. Operates continuously after vehicle startup; energy consumption is 2-5 times higher than EPS. Pollution, Recycling, Maintenance Maintenance-free, no oil leakage, no environmental pollutions. Hydraulic oil usage and disposal increase environmental burden; regular oil changes required. ADAS & Autonomous Driving Support Lack of control precision may lead to difficulties in autonomous systems. Features of Our Electric Power Steering System (EPS) for Bus Easy installation: adapts to existing layouts for a smooth transition. Simplified design: fewer parts for efficient assembly. Precise handling: delivers sharp steering and exceptional maneuverability. Quiet operation: engineered for low friction and minimal noise. Compact & integrated: boasts a compact design for seamless integration. Advanced sensors: utilizes non-contact sensors for accurate angle measurement. Safety features: equipped with overheating and under-voltage protection. Reliable performance: maintains some steering assistance even under certain failure modes. Future-proof design: IP67-rated and adapts to the needs of advanced driver assistance systems (ADAS) and autonomous driving, particularly for large steering-by-wire chassis. Technical Parameters Type: Rack-assist type Power supply current: 50 A Operating voltage: DC 24 V Rack stroke & ratio: 274 mm & 50.4 mm/rev Maximum pull-push force: 18 kN – 20 kN Applicable vehicle information: Front axle load 4500 kg (reference) How We Work Requirement Analysis After signing the NDA, the client provides the maximum axle load for the steering axle, as well as the 3D models and drawings for the steering axle, suspension, part of the chassis, and wheels if necessary. Steering Torque Calculation and Motion Verification Based on the data provided by the client, we calculate and verify the relevant parameters for the steering system. Client Confirmation The client confirms the mechanical structure and the integration with the complete vehicle assembly. Electrical and Bus Protocol Integration We provide the electrical parameters and bus protocol; the client confirms if any modifications are needed. Signing the Technical Agreement Both parties sign the technical agreement, and we provide the final quotation. 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

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