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

Electric Axle for Truck: Top Use Cases and Benefits

Electric Axle for Truck: Top Use Cases and Benefits The electrification of heavy-duty trucks is accelerating, and with it, the question of which drive system to choose becomes increasingly important. Among the available solutions, the electric axle for truck – also known as an e-axle or electric drive axle – is gaining attention for its performance and efficiency advantages. In this article, we explore the main application scenarios for electric heavy-duty trucks, comparing the benefits and limitations of different drive systems, and offering practical guidance for selecting the right e-axle configuration. Brogen Electric Axle for Heavy-Duty Trucks Electric Heavy-Duty Truck Drive Methods: Central Drive vs. Electric Axle Currently, there are two main drive methods used in electric heavy-duty trucks: the traditional central drive system and the electric axle (e-axle). 1. Central Drive system: Advantages and Limitations A central drive system positions the motor and transmission as a powertrain unit in the middle of the chassis, connected to the drive axle via a driveshaft – similar to the layout of traditional diesel trucks. This design offers high reliability and lower initial cost, as it uses many shared components such as driveshafts, axles, and suspension systems. These parts benefit from mature mass production, reducing overall cost. Additionally, the motor and transmission are mounted using a four-point suspension, minimizing vibration and impact damage. Heavy-Duty Truck with Central Drive Motor However, the system also has notable drawbacks. The central location of the powertrain limits underfloor battery installation, which is essential for achieving high-capacity battery configurations. The low level of component integration adds weight, reducing vehicle efficiency and complicating lightweight design. Furthermore, energy losses occur through the driveshaft and universal joints, resulting in lower transmission efficiency and higher energy consumption. 2. Electric Drive Axle (E-Axle): The Compact and Efficient Solution An electric axle for trucks integrates the motor and transmission into the axle itself, creating a compact, highly efficient system. This layout allows for: Optimized chassis space: Enables large battery packs to be installed under the chassis, lowering the center of gravity and improving vehicle stability. Lightweight design: Reduced component count minimizes overall weight, which is critical for heavy-duty trucks. Higher energy efficiency: Direct power transfer significantly lowers energy losses, reducing electricity consumption. Heavy-Duty Truck with Brogen Electric Axle Despite these advantages, e-axles require a complete redesign and specialized tooling, leading to higher initial costs. Adoption rates remain relatively low – currently under 10% of electric heavy truck applications – but as demand grows, economies of scale are expected to bring prices down. Electric Axle for Truck: Application Scenarios 1. Construction Transport: When E-Axle May Not Be Ideal Examples: 8×4 electric dump trucks, 8×4 electric concrete mixers, and electric mining trucks. Construction environments often involve harsh road conditions – unpaved roads, gravel, and heavily rutted surfaces. Overloaded trucks can deepen ruts, increasing the risk of undercarriage contact. In these conditions, e-axles are less suitable. Motors and gearboxes integrated into the axle are vulnerable to damage from hard impacts, and since the axle assembly forms part of the unsprung mass, rough terrain can lead to higher vibration and shock loads on the chassis and cabin. For severe off-road environments, a central drive system is typically the better choice. An 8×4 electric dump truck designed for engineering and construction applications, operating under harsh and demanding conditions. 2. Resource Transport: Electric Axle for Truck as a Strong Option Examples: Transport of sand, gravel, coal, and ore. Operating conditions include loading yards with shallow potholes, along with highways and national routes. The risk of grounding is minimal compared to construction sites, making electric drive axles a viable choice. For 6×4 electric heavy trucks, the choice between a centralized drive and an electric axle largely depends on operational needs. If the primary application is resource transportation with routes under 220 km per charge, and cost sensitivity is high while annual mileage is relatively low, with less concern for energy consumption, a centralized drive may be more suitable. However, for fleets with higher annual mileage and stricter energy efficiency requirements, an electric axle is the recommended option due to its superior efficiency and overall performance. Key specifications for e-axles in resource transport: Ground clearance: ≥260 mm Steel housings for motors and gearboxes to improve impact resistance Multi-speed transmission (3-4 gears) to handle steep grades, heavy loads, and varied driving conditions PTO interface for installing hydraulic pumps, essential for tipper applications The electric drive axle features a ground clearance of over 260 mm, a robust cast-steel housing, and is equipped with a power take-off (PTO) interface. 3. Express Delivery & Line-Haul Freight: The Ideal Fit for Electric Axles Many logistics companies are transitioning from diesel to electric heavy-duty trucks for routes under 400 km to reduce operating costs. In this segment, vehicles often cover more than 250,000 km annually, making energy efficiency a critical factor. Some fleets have successfully reduced energy consumption from 1.6 kWh/km to as low as 1.3 kWh/km. The electric heavy-duty truck designed for express and freight transport adopts an underfloor battery layout combined with an electric drive axle. Highway operations make this the perfect scenario for electric drive axles. Recommended configurations include: Multi-motor strategy: Two driven axles with 3-4 motors. At start-up and during acceleration, additional motors provide extra torque. At cruising speed, only one or two motors operate for maximum efficiency. During downhill driving, regenerative braking through multiple motors can recover energy and provide up to 48% of maximum braking power, enhancing safety. Two-speed transmission: Sufficient for highway driving, where steep gradients are not an issue. Lightweight design: Aluminum alloy motor and gearbox housings for improved weight efficiency. Air suspension and wide medium-pressure tires: To reduce vibration and enhance ride comfort. A certain brand of electric heavy-duty truck adopts 2 electric drive axles and 3 motors, with a multi-motor drive strategy. Conclusion: Why the Electric Axle for Truck Is the Future The electric axle is a cornerstone of heavy-duty truck electrification, offering major advantages in efficiency, weight reduction, and flexible vehicle layout. Although initial costs are currently

brogen blade battery solution for heavy truck in australia

Heavy Transport

Blade Battery Solution for Heavy-Duty Trucks in Australia

Blade Battery Solution for Heavy-Duty Trucks in Australia Background Our client is a leading provider of drilling services in Australia, operating across remote and challenging sites where reliability and efficiency are critical. Their fleet of heavy-duty trucks serves multiple functions – from transporting massive drilling rigs to carrying auxiliary equipment that keeps field operations running smoothly. In line with Australia’s national push for decarbonization and their own corporate commitment to sustainability and green drilling practices, the client set a bold target: electrify their heavy-duty trucks. This would not only reduce carbon emissions but also cut operating costs, lower noise levels, and future-proof their business against tightening environmental regulations. However, electrifying heavy trucks in such a demanding industry is no simple task. The client needed a solution that was proven, safe, and immediately deployable without incurring heavy R&D costs or long load times. Challenge: High Energy Demand Meets Space Constraints The first and most significant technical barrier was energy demand versus space availability. Energy requirement: Each truck requires around 500 kWh to operate effectively across long shifts without frequent charging interruptions. Space limitation: The trucks offered limited space for battery installation due to the chassis design and the drilling equipment they carried. When evaluated against conventional LFP battery packs (in standard C-box format): Only 10 boxes could be installed, yielding ~350 kWh at most. To achieve 500 kWh, a new mold would need to be developed – raising development costs, introducing significant delays, and creating risks since the new product would not yet be proven in the market. The client made it clear: they wanted a mature solution that was readily available, cost-effective, and reliable under real-world drilling conditions. Brogen Blade Battery Systems Engineers debugging the battery system Brogen Blade Battery Solution for Heavy-Duty Trucks: Unlocking Efficiency with CTP Technology After a thorough technical evaluation, we proposed a blade battery solution for heavy-duty trucks, leveraging BYD blade cells and CTP (Cell-to-Pack) technology. Key advantages of the blade battery solution: 100 kWh per pack: Each blade battery pack offers higher energy capacity than standard LFP packs. Only five packs required: To achieve the 500 kWh, only five packs were needed – fitting within the truck’s limited installation space. Higher energy density: The CTP design eliminates the need for intermediate modules, improving efficiency and sapce utilization. Proven safety: Blade cells are known for their stability and strong thermal runaway resistance, suitable for demanding applications. By adopting this solution, the client could avoid expensive mold development, minimize project risks, and directly deploy a system that was already market-proven and mature. Our Offering: A Complete System, Not Just Batteries We provided a fully integrated electrification solution, tailored specifically for the client’s drilling fleet. System Components Five 100 kWh Blade Battery Packs (500 kWh total) PDU (Power Distribution Unit) for safe, efficient power control BMS (Battery Management System) with software customized from proven cases BTMS (Battery Thermal Management System) for cooling and heating E-Powertrain (Motor+Controller) for both trucks and retrofit equipment Brogen battery system with PDU Brogen battery system with TMS Beyond Hardware – Our Services Pre-shipment debugging: We thoroughly tested and debugged the entire blade battery system before shipment, ensuring readiness on arrival. Remote technical assistance: Our engineers provided ongoing support to help the client integrate, operate, and maintain the system with confidence. This holistic approach ensured that the client received not only components, but a complete balde battery solution for heavy-duty trucks. Outcome: Reliable Blade Battery Solution for Heavy-Duty Trucks in Australia By deploying our blade battery solution, the client can achieve their electrification goals without incurring unnecessary development risks. 500 kWh target capacity achieved within the limited installation space Significant cost savings by avoiding new mold development Higher system efficiency thanks to CTP technology Reliable performance across wide temperature ranges Reduced carbon emissions, supporting sustainability commitments Currently, the project is still in progress, and we remain committed to helping our client drive fleet electrification while contributing to more sustainable drilling practices. About Brogen At Brogen, we provide advanced EV solutions for global commercial vehicle manufacturers, enabling them to streamline research and development while capitalizing on cutting-edge technology. Our offerings ensure superior efficiency, extended range, and seamless system integration with proven reliability—empowering our partners to lead in the rapidly evolving green mobility landscape. Currently, our EV solutions for battery electric vehicles have been adopted by vehicle manufacturers in countries and regions such as Canada, Türkiye, Brazil, the Philippines, Indonesia, the Middle East, and more. Discover our blade battery solution here: https://brogenevsolution.com/blade-battery-technology-for-electric-commercial-vehicles/ Discover our HCV electrification solution here: https://brogenevsolution.com/heavy-duty-vehicle-electrification-solutions/ Looking for an EV solution for your project? Reach out to us at contact@brogenevsolution.com Contact Us Get in touch with us by sending us an email, using the Whatsapp number below, or filling in the form below. We usually reply within 2 business days. Email: contact@brogenevsolution.com Respond within 1 business day Whatsapp: +8619352173376 Business hours: 9 am to 6 pm, GMT+8, Mon. to Fri. LinkedIn channel Follow us for regular updates > YouTube channel Ev systems introduction & industry insights > ContactFill in the form and we will get in touch with you within 2 business days.Please enable JavaScript in your browser to complete this form.Please enable JavaScript in your browser to complete this form. Name * FirstLast Work Email *Company Name *Your Project Type *– Please select –Car, SUV, MPVBus, coach, trainLCV (pickup truck, light-duty truck, etc.)HCV (heavy-duty truck, tractor, trailer, concrete mixer, etc.)Construction machinery (excavator, forklift, crane, bulldozer, loader, etc.)Vessel, boat, ship, yacht, etc.Others (please write it in the note)Your Interested Solutions *– Please select –Motore-AxleBatteryChassisAuxiliary inverterOBC / DCDC / PDUAir brake compressorEPS / 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

High-Voltage Connectors: An Overview

High-Voltage Connectors: An Overview In electric vehicle systems, high-voltage connectors serve as the “bridge” for power transmission and are a critical components in ensuring electrical safety. Although small in size, these connectors integrate multiple precision structures and safety features. Let’s break down their key components and see how they ensure safe and reliable performance in high-voltage, high-current environments. 1. Components of High-Voltage Connectors High-voltage connectors are generally composed of the following structures: housing (male and female ends), terminals (male and female terminals), shielding shell, seals (rear, half-end, wire-end, and contact seals), rear protective cover, high-voltage interlock system, and CPA (Connector Position Assurance device). 1.1 Housing The housing acts as the “armor” of the connector, providing both mechanical protection and structural support. It consists of male and female shells that fit together seamlessly. Material strength: Typically made of PA66+GF (glass fiber-reinforced nylon) or PBT, designed to withstand ≥ 125°C (up to 150°C in some applications) and certified to UL94 V-0 for flame resistance. Anti-static surface treatments prevent arcing in high-voltage environments. Thoughtful design: Male and female housings lock together via snap-fit mechanisms, with mating forces carefully controlled between 80-150 N to ensure both secure connection and ease of operation. 1.2 Therminals If the housing is the armor, the terminals are the heart, responsible for current transmission. Materials: High-purity T2 copper or CuCrZr (copper-chrominum-zirconium alloy) with silver or nickel plating, ensuring contact resistance below 5 mΩ。 Design: Male terminals are typically pin-type, while female terminals use spring or crown structures that apply ≥20 N contact pressure. Even after 500+ mating cycles, resistance variation remains under 10%, ensuring durability. 1.3 Shielding High-voltage transmission can generate EMI (electromagnetic interference) that disrupts vehicle electronics. The shielding enclosure acts as an “invisble barrier”. Performance indicators: Made of copper alloy or aluminum alloy, the shielding efficiency reaches ≥60 dB within the 100 MHz-1 GHz frequency range, equivalent to putting electromagnetic signals into “silent mode”. At the same time, it works with the housing and terminals to form a complete grounding loop, with grounding resistance ≤50 mΩ, effectively eliminating interference risks. Installation details: Fixed to the housing by clips or welding, it achieves a fully enclosed shielding structure, leacing no “escape gap” for electromagnetic signals. 1.4 Sealing System EV batteries are often exposed to harsh environments such as rain and dust. The sealing system acts as a “waterproof shield” for the connectors, building multiple layers of protection: Rear seal: Silicone rubber sealing rings wrap around the cables, achieving IP67 (no water ingress after 30 minutes of immersion at 1m depth) or IP6K9K (resistant to high-pressure water spray). Even when the vehicle drives through water, safety is ensured. Half-end/Wire-end Seal: At the connector interface and cable entry point, O-rings or lip structures fit into housing grooves to form dual protection – like adding a “double safeguard” to every gap. 1.5 Rear Protective Cover The cable interface at the rear of the connector is relatively fragile and prone to damage. The rear protective cover functions like a “safety helmet,” secured to the rear end by threads or clips. It can withstand an axial tensile force of ≥50 N, preventing cable loosening due to pulling, while also enhancing the sealing performance. Some models are further equipped with integrated harness clamps, ensuring a more organized cable layout. 1.6 High-Voltage Interlock System (HVIL) This is an intelligent system that continuously monitors the connection status – serving as the “safety guardian” of the connector. Working principle: A 5V closed-loop circuit is established via micro-switches or Hall sensors. If the connector loosens or disconnects, the circuit is immediately interrupted. The BMS triggers power cut-off protection within 100 ms, cutting the high-voltage supply like an “emergency brake,” fundamentally eliminating the risk of electric shock. 1.7 CPA To prevent issues such as poor contact or overheating caused by incompletely inserted connectors, the CPA (Connector Position Assurance device) was developed. Design details: It typically uses mechanical structures such as plastic clips. When the male and female terminals are fully mated, the CPA provides a clear confirmation – either an audible “click” or a visual color indicator, allowing operators to easily verify the connection status and eliminate the risk of “false mating”. 1.8 Auxiliary Structures In addition to the core components, these auxiliary designs are equally essential: Mis-insertion prevention: The male and female housings feature asymmetric keys, grooves, or other positioning structures – like uniquely shaped keys – preventing connectors of different specifications from being mismated. Thermal management structure: For high-power platforms such as 800 V systems, the connector may include built-in heat sinks or thermally conductive silicone. This controls the temperature rise during high-current transmission to within 50 K, preventing overheating and ensuring stable performance. 2. Key Considerations in High-Voltage Connectors Selection When selecting a high-voltage connector, critical parameters include: Operating temperature: -40°C to 125°C (or higher depending on vehicle requirements). Current capacity: Rated and peak current must meet system requirements. Voltage capacity: Must exceed the maximum battery system voltage. Locking system: Secondary locking (hook+latch) to prevent loosening under vibration. Waterproofing: IP67 / Ip6K9K compliance. Insertion/withdrawal force: Controlled within specified ranges. HVIL support: Determined by system requirements. Conclusion From the housing and terminals to the sealing and interlock systems, every aspect of a high-voltage connector is engineered with safety and reliability in mind. It is this advanced, compact technology that ensures EV batteries can transmit energy efficiently and stably under high-voltage conditions, safeguarding the safe operation of electric vehicles. About Brogen At Brogen, we provide advanced EV solutions for global commercial vehicle manufacturers, enabling them to streamline research and development while capitalizing on cutting-edge technology. Our offerings ensure superior efficiency, extended range, and seamless system integration with proven reliability—empowering our partners to lead in the rapidly evolving green mobility landscape. Currently, our EV solutions for battery electric vehicles have been adopted by vehicle manufacturers in countries and regions such as Canada, Türkiye, Brazil, the Philippines, Indonesia, the Middle East, and more. Discover our HCV electrification solution here: https://brogenevsolution.com/heavy-duty-vehicle-electrification-solutions/ Looking for an EV solution for your project? Reach

Why VCU is necessary for electric vehicles

EV Industry

The Role of the VCU (Vehicle Control Unit) in Electric Vehicles

The Role of the VCU in Electric Vehicles In traditional internal combustion engine (ICE) vehicles, control systems are relatively segmented, with components like the ECU, TCU, ABS, BCM, PEPS, and IPC. In electric vehicles (EVs), the engine and transmission are replaced by the electric motor and battery system. This shift introduces new key systems like the BMS and MCU. Beyond this fundamental shift, EVs also integrate a broad array of high- and low-voltage systems, such as DC/DC converters, onboard chargers (OBC), PTC heaters, and electronic braking systems (EBS), alongside intelligent controllers including the In-Vehicle Infotainment (IVI) system, Thermal Management System (TMS), Telematics Control Unit (T-Box), and Integrated Power Brake (IPB), etc. Why is a VCU Essential for Electric Vehicles? As vehicles evolve, so does the complexity of electronic controls. The number of controllers on board has significantly increased, especially in hybrid electric vehicles, where coordination between the traditional engine system and the electric drivetrain is critical. For example, when the ECU and MCU issue conflicting commands, which system should take priority? This type of decision-making requires a central coordinator – the VCU – to act as the vehicle’s brain. Beyond conflict resolution, EVs also have higher demands for drivability, energy efficiency, and real-time coordination across multiple subsystems. A VCU is necessary to optimize energy use, balance power delivery, improve safety, and ensure consistent performance across various scenarios. VCU Functional Overview The functions of the VCU vary depending on the overall vehicle system architecture. They can be categorized into several functional domains, including vehicle system control, powertrain management, electric power systems, thermal management, diagnostics, communication, and safety monitoring. Key functions include torque control and management, overall energy management, charging and thermal management, fault diagnosis and handling, as well as vehicle status monitoring. 1. Torque Management Torque management governs a vehicle’s acceleration and braking performance – both of which are determined by torque output from the electric motor or engine. The VCU interprets signals from the accelerator and brake pedals (e.g., depth and speed of press), determines the required torque, and coordinates the engine, generator, and coordinates the engine, generator, front and rear drive motors to respond accordingly based on the vehicle’s current operating mode. Case Example: Torque Distribution in AWD EVs All-wheel-drive EVs (as opposed to two-wheel-drive models) feature both front and rear motors. The VCU is responsible for intelligently distributing torque between the two, depending on the efficiency (economy), performance, and stability. The goal of economic torque distribution is to achieve optimal overall efficiency under the current torque demand. This involves intelligently coordinating dual-, triple, or quad-motor systems to ensure the most efficient power distribution, reducing energy consumption and extending battery range. This strategy is typically applied during steady-speed driving scenarios, such as cruising on highways. In the performance-oriented torque distribution, the load distribution function calculates the optimal torque ratio between the front and rear axles by recognizing current road gradients and the vehicle’s acceleration or deceleration status. By building a dynamic load model, the system automatically adjusts torque distribution during load transfers to make full use of the maximum available tire grip. This reduces wheel slip and enhances the vehicle’s acceleration performance. Performance-oriented torque distribution must especially account for scenarios where a wheel becomes stuck and starts to slip, such as in mud or loose terrain. The basic principle is to actively adjust the torque distribution between the front and rear axles, transferring power to the axle that still has traction when one is slipping. This helps reduce power loss. When alternating slip between the front and rear axles is detected, the system dynamically adjusts torque distribution to maximize available grip, enhancing the vehicle’s ability to escape low-speed traction challenges. Stability-oriented torque distribution focuses on maintaining vehicle stability during steering maneuvers. While systems like ESP are designed to ensure body stability, frequent ESP interventions can lead to an uncomfortable driving experience. By monitoring steering behavior and controlling steering torque, the VCU can proactively adjust front and rear axle torque distribution in real time – before ESP activation – to correct vehicle dynamics. This helps suppress understeer (US) and oversteer (OS), reducing the need for ESP intervention during acceleration and cornering. As a result, it minimizes braking jolts and yaw disturbances, enhancing overall driving comfort and control. When calculating the drive torque, it’s also necessary to consider the vehicle’s driving mode. Under different modes, the accelerator pedal position and vehicle speed are used to first determine the base drive torque. This base drive torque typically corresponds to the ECO mode. If the vehicle is in Normal mode, an additional compensation torque is applied. In Sport mode, a larger compensation value is added to enhance performance. 2. Mode & Energy Management 2.1 Operating Modes In addition to driving modes, vehicles – especially hybrid models – also operate under different operation modes. These include pure electric mode, series (range extender) mode, and parallel mode. While both driving modes and operation modes aim to optimize energy efficiency and power distribution, they differ in how they are set: Driving modes (such as ECO, Normal, and Sport) are manually selected by the driver. Operation modes are automatically determined by the vehicle. In pure electric mode, the vehicle is powered solely by the electric motor using energy from the battery. The engine remains off. In series mode (range extender mode), the engine, generator, and battery are connected in series. When the battery’s state of charge is low, the engine activates the generator to produce electricity, which recharges the battery – effectively extending the vehicle’s range. In parallel mode (direct drive mode), both the engine and the battery provide propulsion simultaneously. Typically, the engine drives one axle while the electric motor powers the other. Since the engine directly contributes to wheel drive in this mode, it is also referred to as direct drive mode. So how does the vehicle decide whether to use fuel or electricity? The decision of whether to use fuel or electricity in different driving scenarios is made based on energy efficiency.

504kW_620kW electric truck axle brogen electric truck axle

Heavy Transport

Heavy-Duty Electric Truck Axles (504 kW / 620 kW)

Heavy-Duty Electric Truck Axles (504 kW / 620 kW) These heavy-duty electric truck axles feature a dual-motor integrated design and are engineered for high-performance applications. With a rated axle load of 13 tons and a maximum system power output of 504 kW or 620 kW, they are capable of meeting the demanding requirements of various heavy-duty commercial vehicles, including 4×2, 6×4, and 8×4 configurations such as municipal vehicles, semi-trucks, and dump trucks. By delivering strong performance and efficiency under heavy-load conditions, these e-axles help significantly reduce both carbon emissions and overall energy consumption. Email: contact@brogenevsolution.com Get Custom Quote Heavy-Duty Electric Truck Axles: Solution Details 1. Solution Features of Our Heavy-Duty Electric Truck Axles Dual Motor + 4-speed AMT Configuration: Adaptable to multiple use cases, from high-capacity long-haul electric semi-trucks to high-torque construction trucks operating under frequent load shifts. Modular Design for Easier Maintenance: High integration of motors and gearbox enables a compact layout and simplifies service and maintenance processes. Transverse Layout Without Hypoid Gear Set: Eliminates the hypoid gear set to reduce mechanical losses, enhancing transmission and regenerative braking efficiency. One-piece Axle Housing with Aluminum Alloy Casing: Integrated cast axle housing offers higher structural strength and sealing performance; aluminum casing helps reduce overall system weight. 2. Technical Parameters Model OESTEA45000Z-1 OESTEA45000Z-2 E-Powertrain Rated Axle Load 13 T (16 T Under Development) Wheel-End Output Torque 45000 N.m 45000 N.m Assembly Weight 985 kg 990 kg Reference Leaf Spring Distance 1018-1050 mm (Adjustable) Wheel Mounting Distance 1837 mm Compatible Suspension Leaf Spring / Air Suspension Motor Parameters Motor Rated/Peak Power 150/252 kW*2 190/310 kW*2 Motor Rated/Peak Torque 285/550 N.m 280/590 N.m Motor Maximum Speed 9000 rpm Transmission Parameters Speed Ratio 4-speed 1st: main transmission 71.0+auxiliary transmission 46.8 2nd: main transmission 36.3+auxiliary transmission 46.8 3rd: main transmission 20.0+auxiliary transmission 13.2 4th: main transmission 10.2+auxiliary transmission 13.2 Brake Brake Specifications Drum brake φ410*220; disc brake 22.5″ Brake Torque 2*18000 N.m (drum brake); 2*22000 N.m (disc brake) Air Brake Chamber Specifications 30/24 (recommended) Other Options Differential Lock Optional PTO Optional PTO for retrofit 3. Advanced AMT Technology – Built for Smarter, Smoother Electric Trucks This electric truck axle platform features a 4-speed AMT. It enables active speed synchronization between the motor and the transmission input shaft, allowing for rapid and smooth gear shifts. By combining gear profile modification with in-depth analysis of casing and shaft tooth deformation, the system achieves optimal meshing conditions, minimizing transmission error and reducing efficiency loss. Faster gear shifting: Reduced shift time improves drivability, especially under frequent stop-and-go scenarios. Higher drivetrain efficiency: Enhances energy use and supports longer driving range. Lower NVH: Quiet and smooth gear transitions improve driving comfort. Lower maintenance cost: Long-life gear oil with no initial oil chaange required; supports extended intervals of 50,000-200,000 km. 4. Key Performance Data Weight reduction vs. direct drive (dual axle): 22% per set Range improvement vs. direct drive: Up to 20% Energy use: 10% less per 100 km at 49t full load vs. industry average Axial space saving: 40% Deployed units (to date): ~13,000 Projected annual production capacity (2025): Over 10,000 units How We Ensure the Reliability of Our Electric Truck Axles Our electric truck axles undergo a rigorous multi-level validation process to guarantee long-term performance, safety, and durability under real-world operating conditions. Component-Level Testing Over 50 tests are conducted on individual components to verify structural integrity, strength, and consistency. These include: Vibration Salt spray Tensile Torsion Hardness Full-dimension inspections Subsystem-Level Testing More than 90 tests are performed across all core subsystems – including the shifting mechanism, gearbox, motor, high/low voltage controllers, wiring harnesses, and software. These tests fall into six major categories: Module validation Functional testing Performance testing Durability testing Reliability testing Environmental resistance System-Level Testing Over 50 tests are carried out at the system level using specialized test benches and real-vehicle road trials, including: High and low temperature cycling Thermal shock testing Salt spray and corrosion resistance Waterproof and dustproof validation Vibration and noise testing System integration and special-condition simulation R&D and Manufacturing Excellence Comprehensive and Integrated R&D Capabilities The R&D team is built on a robust, cross-functional framework encompassing structural engineering, electronic hardware, system architecture, software development, testing, and manufacturing processes. We maintain a full-spectrum development capability that spans from concept design to real-world validation. With in-house expertise in mechanical design, control unit development, computer-aided simulation, bench testing, and complete vehicle road testing, we are equipped to support rapid iteration and innovation across the entire product lifecycle. Hybrid and pure electric powertrains Transmission systems and controllers Electric motors and motor controllers Shift and clutch actuators Vehicle control units (VCUs) Quality Management & Full Lifecycle Traceability The factory strictly adheres to IATF 16949, ISO 14001, and other international standards, ensuring precise control over every production process and uncompromising quality in every product. The digital management system enables a full lifecycle traceability and control, ensuring that every component is trackable and accountable from production to delivery. In 2025, the e-axle for trucks production capacity is expected to exceed 10,000 units, further demonstrating our ability to scale with quality and consistency. 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

Heavy Transport

250 kW / 290 kW E-Axle for Trucks, Heavy-Duty Truck E-Powertrain

250 kW / 290 kW E-Axle for Trucks Our 250 kW / 290 kW e-axle for trucks integrates a high-efficiency PMSM, transmission, and axle into a compact unit. By leveraging the gear ratio of the integrated transmission, the system delivers high torque output even with a relatively smaller motor. The wheel-end output torque can reach up to 40,000 N.m, making it ideal for 6×4 and 4×2 truck tractors, semi-trailers, water tankers, garbage trucks, dump trucks, and other heavy-duty transport or municipal vehicles. This e-axle system is already in mass production and has been deployed in batch applications on electric semi-trailers. Email: contact@brogenevsolution.com Get Custom Quote E-Axle for Trucks: Solution Details Item Technical Parameters Model OESTEA40000Z-1.5 OESTEA40000Z-1.6 E-Powertrain Axle Load 13 T Wheel-End Output Torque 40000 N.m Assembly Weight 1030 kg Motor Parameters Motor Rated / Peak Power 121 kW / 250 kW 136 kW / 290 kW Motor Rated / Peak Torque 320 N.m / 850 N.m 326 N.m / 860 N.m Motor Peak Speed 10000 rpm Transmission Gear Ratio 13.2/4.4 Axle Wheel-Side Gear Ratio 3.478 Rim Mounting Distance 1822 mm Brake Type Drum Brake / φ410×220 Maximum Brake Torque (0.8MPa) 2×18000 N.m 2×18000 N.m PTO N.A. Optional Differential Lock Optional Solution Features IP67 water and dust protection, along with rigorous high/low temperature and vibration testing, ensures outstanding system reliability. One-piece axle housing provides high load-bearing capacity while maintaining ease of maintenance. Driveshaft eliminated, allowing more space in the chassis for flexible and efficient battery pack installation. Integrated design results in lighter weight, higher efficiency, and better energy savings. Technology Highlights Our e-axle for trucks features a 2-speed AMT. It enables active speed synchronization between the motor and the transmission input shaft, allowing for rapid and smooth gear shifts. By combining gear profile modification with in-depth analysis of casing and shaft tooth deformation, the system achieves optimal meshing conditions, minimizing transmission error and reducing efficiency loss. Shorter gear shifting time Higher transmission efficiency Lower operating noise How We Ensure the Reliability of Our E-Axle for Trucks Our e-axle system undergoes a rigorous multi-level validation process to guarantee long-term performance, safety, and durability under real-world operating conditions. Component-Level Testing Over 50 tests are conducted on individual components to verify structural integrity, strength, and consistency. These include: Vibration Salt spray Tensile Torsion Hardness Full-dimension inspections Subsystem-Level Testing More than 90 tests are performed across all core subsystems – including the shifting mechanism, gearbox, motor, high/low voltage controllers, wiring harnesses, and software. These tests fall into six major categories: Module validation Functional testing Performance testing Durability testing Reliability testing Environmental resistance System-Level Testing Over 50 tests are carried out at the system level using specialized test benches and real-vehicle road trials, including: High and low temperature cycling Thermal shock testing Salt spray and corrosion resistance Waterproof and dustproof validation Vibration and noise testing System integration and special-condition simulation R&D and Manufacturing Excellence Comprehensive and Integrated R&D Capabilities The R&D team is built on a robust, cross-functional framework encompassing structural engineering, electronic hardware, system architecture, software development, testing, and manufacturing processes. We maintain a full-spectrum development capability that spans from concept design to real-world validation. With in-house expertise in mechanical design, control unit development, computer-aided simulation, bench testing, and complete vehicle road testing, we are equipped to support rapid iteration and innovation across the entire product lifecycle. Hybrid and pure electric powertrains Transmission systems and controllers Electric motors and motor controllers Shift and clutch actuators Vehicle control units (VCUs) Quality Management & Full Lifecycle Traceability The factory strictly adheres to IATF 16949, ISO 14001, and other international standards, ensuring precise control over every production process and uncompromising quality in every product. The digital management system enables a full lifecycle traceability and control, ensuring that every component is trackable and accountable from production to delivery. In 2025, the e-axle for trucks production capacity is expected to exceed 10,000 units, further demonstrating our ability to scale with quality and consistency. Application Example This e-axle for trucks has been successfully deployed in 6×4 battery electric semi-trucks, which are now in mass production. Key vehicle specifications include: curb weight: 11 tons; gross vehicle weight:25 tons; maximum towing capacity: 37 tons; top speed: 89 km/h 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

BTMS project - 1 EV thermal management system for electric mining truck

Heavy Transport, Technologies

EV Thermal Management System for Battery Electric Mining Trucks

EV Thermal Management System for Battery Electric Mining Trucks For battery electric mining trucks, it’s critical to maintain the traction battery within an optimal temperature range to ensure both performance and safety. Given the high charge and discharge currents typical of mining operations, the EV thermal management system adopts a liquid cooling technology with superior heat dissipation efficiency. How Does the EV Thermal Management System for Battery Electric Mining Trucks Work? The EV thermal management system for battery electric mining trucks works by actively heating or cooling the coolant to keep the battery operating between 25°C and 35°C, which is considered the ideal thermal range for lithium battery performance. The system is also capable of maintaining the temperature difference between individual cells within 5°C, ensuring consistent operation and extending overall battery lifespan. Operating Principle The heat exchanger inside the EV thermal management system features two flow channels: one channel circulates coolant, the other circulates refrigerant. These channels are alternately arranged:odd-numbered layers carry coolant, while even-numbered layers carry refrigerant. Heat is exchanged between the two media, reducing the temperature of the coolant before it is circulated into the battery pack to absorb and dissipate heat from the cells. In cold environments, a PTC heater is activated to warm the coolant, which in turn heats the battery, ensuring safe operation and charging efficiency at low ambient temperatures. A simplified schematic of the EV thermal management system Our Integrated EV Thermal Management System for Battery Electric Mining Trucks Our integrated EV thermal management system for battery electric mining trucks is designed to address the following key challenges: Cabin climate control Maintain a comfortable temperature and airflow for the driver. Defrost and defog the windshield for clear visibility. Control cabin humidity and air outlet temperature to ensure a clear driving view. Battery temperature regulation Prevent extreme temperatures from affecting charging/discharging rates and battery lifespan. Motor cooling Maintain optimal coolant temperature for efficient motor operation. Limited space constraints Electric commercial vehicles require additional battery cooling, but lack waste heat from an engine. Complex vehicle layout with multiple components. Solution Introduction The integrated EV thermal management solution is engineered to manage both cabin and e-powertrain temperature needs. By sharing core components such as the condensers module and compressor module, the system supports both air conditioning and equipment cooling/heating, ensuring stable and efficient vehicle operation. Solution Advantages High Efficiency & Energy Saving: Features variable-speed compressor, smart fan control, and motor waste heat recovery to minimize energy consumption. Reliable and Safe: Equipped with multiple layers of protection for pressure, temperature, current, and voltage to ensure system safety. Intelligent Control: Supports CAN bus vehicle communication, human-machine interface (HMI), and real-time display of temperature and airflow conditions. Highly Integrated Design: Combines heating and cooling modules into a single compact unit, with shared use of PTC heaters, fans, and other components to reduce footprint and simplify vehicle layout. Discover our BTMS Solutions here: https://brogenevsolution.com/battery-thermal-management-system-btms/ 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 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

In-Depth Overview of Battery Thermal Management Systems (BTMS) for Electric Semi Trucks

In-Depth Overview of Battery Thermal Management Systems for Electric Semi Trucks As electric semi trucks gain traction in global logistics, maintaining battery performance and safety under varied environmental conditions is critical. This is where the Battery Thermal Management System (BTMS) comes into play. 1. Introduction of BTMS for Electric Semi Trucks The Battery Thermal Management System (BTMS) in electric semi trucks is a closed-loop liquid cooling system composed of coolant circuits and thermal conductive media. By leveraging sensors and a control unit, the system actively regulates coolant temperature to keep the traction battery pack operating within an optimal thermal range. This ensures peak battery performance, extends service life, and enhances overall vehicle safety. 1.1 Key Functions of the BTMS Cooling: When battery cell temperatures rise excessively, the system activates cooling to prevent thermal runaway and potential safety incidents. Preheating: In low-temperature environments, the system preheats the battery cells to ensure safe and efficient charging/discharging operations. Temperature Equalization: It reduces internal temperature differences among cells, minimizing localized overheating and maintaining uniform battery performance. 1.2 Structure and Operating Principle The BTMS consists of the following major components: Liquid Cooling Unit: Provides pressurized, temperature-regulated coolant to the system. Expansion Tank: Manages fluid storage, replenishment, and thermal expansion. Coolant Pipes: Serve as channels for the antifreeze coolant and connect with the battery’s internal cooling plates to form a sealed loop. Antifreeze Coolant: Acts as the heat transfer medium. Two common layout configurations exist for the cooling unit – top-mounted or bottom-mounted on the battery pack. The expansion tank is located on the top of the battery pack. System interfaces include 1 observation window, 2 coolant ports, and 3 electrical connectors. 1.3 System Schematic and Configurations (Examples) 282 kWh Battery System (Charging or Swappable Version): Consists of four H-type modules arranged in a 2-parallel x 2-series configuration. 350 kWh Battery System (Charging or Swappable Version): Includes ten C-type modules arranged in a 5-parallel x 2-series configuration. 2. Liquid Cooling Unit: Three Thermal Circuits The battery thermal management relies on three interlinked circuits: Liquid Cooling Circuit: Electric water pump, plate heat exchanger, battery cooling channels Refrigerant Circuit: Compressor, condenser, expansion valve, plate heat exchanger Air Circuit: Electric fan, condenser There are two heat exchange interfaces: Plate Heat Exchanger: Enables heat transfer between the refrigerant loop and the liquid cooling loop. Condenser: Transfers heat between the refrigerant loop and the air circuit. Key Components and Functions Integrated Controller: This unit combines three control modules – PLC, DC-DC, and DC-AC – in one compact system. It collects data from high-pressure and low-pressure sensors, as well as inlet and outlet temperature sensors. The controller receives operational commands and target coolant temperatures from the BMS, enabling precise control over the operation of the electric water pump, compressor speed, and electric fan speed. Compressor: A core component of the refrigerant circuit, the compressor is responsible for absorbing, compressing, and discharging the refrigerant to maintain circulation. The cooling capacity of the liquid cooling loop depends on the proper functioning of the compressor. Electric Water Pump: It drives the circulation of antifreeze within the liquid cooling loop. It plays a vital role in transferring heat away from the battery cells through the liquid-cooled plates. Without proper pump operation, battery cooling cannot be achieved effectively. Electric Fan: Mounted on the exterior side of the condenser, this suction-type fan delivers continuous airflow across the condenser surface, dissipating the heat absorbed by the refrigerant. If the fan fails to operate correctly, the system may experience pressure faults due to insufficient heat dissipation. Condenser: The condenser transforms high-temperature, high-pressure gaseous refrigerant into a high-pressure liquid state. If the condenser becomes clogged or dirty, airflow is reduced, leading to decreased heat transfer efficiency and diminished cooling capacity. This results in minimal temperature difference across the coolant circuit and continuous temperature rise in battery cells, which may trigger system pressure alarms. Regular cleaning and maintenance of the condenser are essential for safe operation in electric vehicles. Plate Heat Exchanger: This component facilitates thermal exchange between the low-temperature refrigerant and the high-temperature antifreeze. After passing through the exchanger, the antifreeze temperature typically drops by 2°C to 5°C under normal operating conditions. Expansion Valve With Thermal Sensing Bulb: This valve converts the refrigerant from a medium-temperature, high-pressure liquid into a low-temperature, low-pressure liquid. The thermal sensing bulb detects temperature inside the cooling pipe and adjusts the valve’s operating accordingly to regulate refrigerant flow. Due to its high sensitivity to temperature fluctuations, the expansion valve and thermal bulb are insulated with protective layers. Sensors: High-pressure and low-pressure sensors monitor pressure levels within the refrigerant circuit. Inlet and outlet temperature sensors measure coolant temperatures at the water inlet and outlet of the liquid cooling unit. These signals are sent to the PLC controller, which uses the data to dynamically manage the operation and speed of the compressor, water pump, and fan, ensuring stable and efficient thermal regulation. Our Battery Thermal Management Solutions for Electric Semi Trucks At Brogen, we provide tailored EV battery systems along with BTMS solutions. For electric semi-trucks and other heavy-duty vehicles, we offer standard 272 kWh and 350 kWh battery systems, paired with BTMS units ranging from 5 kW to 10 kW. The thermal units feature a lightweight aluminum alloy frame and can be optionally equipped with PTC liquid heaters. They support multiple operation modes, including standby, cooling, heating, and self-circulation. Communication is based on the CAN bus protocol, with built-in self-diagnosis, real-time status monitoring, and fault reporting capabilities. In addition, we offer integrated thermal management solutions tailored to customer requirements. These systems share components, such as the compressor and condenser, between the air-conditioning circuit and the battery cooling system. The architecture includes dual evaporator circuits: one for cabin climate control and the other for battery temperature regulation. The battery cooling loop uses a secondary liquid-cooling heat exchange approach to ensure efficient and stable thermal performance. Technical Parameters Model OETLE205 OETLE207 OETLE208 OEEFDR-01 OEEFDR-02 OEEFDR-03 OEEFDR-04 Cooling capacity 5 kW 7 kW 8 kW 3 kW 5 kW

Heavy Transport

Integrated ePowertrain Solution for Electric Dump Trucks: Motor + 2-Speed AMT

Integrated ePowertrain Solution for Electric Dump Trucks:Motor + 2-Speed AMT This integrated ePowertrain solution is ideal for Class 7 electric heavy-duty trucks around 12 tons, such as electric dump trucks. It combines a high-performance motor with a 2-speed AMT to optimize system efficiency and extend the lifespan of key components, even under heavy-duty operating conditions. Lower energy consumption Higher torque performance Long-term durability Safety and environmental friendliness Enhanced driving comfort Email: contact@brogenevsolution.com Get Custom Quote Optimized ePowertrain for Heavy-Duty, Low-Speed Operations Background In today’s electric heavy-duty truck market, many OEMs adopt a direct-drive architecture – using a single PMSM to drive the shaft – mainly to reduce cost. While simple and cost-effective, this design struggles to deliver efficient motor performance across both low-speed high-torque and high-speed low-torque working conditions. This challenge becomes even more critical for electric dump trucks operating in urban construction and transport scenarios, where vehicles often run under heavy-load and low-speed conditions such as uphill driving or stop-and-go operation. Our Solution: PMSM + 2-Speed AMT ePowertrain To overcome the limitations of traditional direct-drive systems in electric dump trucks, we provide a dedicated ePowertrain solution that pairs a high-performance PMSM with a 2-speed AMT. This configuration is specifically engineered to enhance energy efficiency and extend system durability under heavy-duty, low-speed operating conditions. This combination enables the motor to operate more efficiently in low-speed, high-torque scenarios – such as hill climbing or fully loaded starts, where energy losses are typically high. By optimizing motor load and shifting gears as needed, this system helps reduce overall power consumption and prolong motor life, even during continuous high-load operation. In addition, the inclusion of a 2-speed AMT provides greater flexibility for PTO integration, which is essential for construction and utility vehicles that require hydraulic lifting or other auxiliary power applications. System Parameters Model Drive motor Transmission System PTO Rated/peak power Rated/peak torque Maximum speed Number of gears Speed ratio Maximum output torque System weight Maximum output torque Speed ratio OETED3010 80/160 kW 500/1100 N.m 4500 rpm 2 1st – 2.7412nd – 1 3015 N.m 174 kg 1.175 300 N.m OETED3380 120/185 kW 650/1300 N.m 3500 rpm 2 1st – 2.7412nd – 1 3380 N.m 210 kg 1.175 300 N.m Solution Advantages – High Reliability & Proven Performance Our 2-speed AMT gearbox is rigorously tested to meet the highest reliability standards: Waterproof, dustproof, high/low temperature, salt spray, and vibration resistance Over 3x rated torque in static torsion tests 1 million gear shifts in durability per gear 200,000 km bench durability simulation 50,000+ km road testing Consistency testing across 50 units Targeted service life: 1 million kilometers Over 30,000 units of the motor+AMT ePowertrain have been deployed Application Example This electric dump truck is equipped with a motor and a 2-speed AMT e-powertrain. The motor delivers a peak power of 160 kW, significantly improving efficiency during low-speed, high-torque operating conditions. Discover more of our electric truck motor solutions here: https://brogenevsolution.com/electric-motors-for-truck/ Business inquiry: contact@BrogenEVSolution.com We usually reply within 2 business days. Relevant Solutions All Posts Autonomous Vehicles Charger & Converter EV Industry EV Motor Heavy Transport Industry Insight Light Commercial Vehicles Marine Electrification Public Transportation Specialty Equipment Technologies Back EV Motor Heavy-Duty Truck Electrification Solutions Electric Truck Motor Contact Us Get in touch with us by sending us an email, using the Whatsapp number below, or filling in the form below. We usually reply within 2 business days. Email: contact@brogenevsolution.com Respond within 1 business day Whatsapp: +8619352173376 Business hours: 9 am to 6 pm, GMT+8, Mon. to Fri. LinkedIn channel Follow us for regular updates > YouTube channel Ev systems introduction & industry insights > ContactFill in the form and we will get in touch with you within 2 business days.Please enable JavaScript in your browser to complete this form.Please enable JavaScript in your browser to complete this form. Name * FirstLast Work Email *Company Name *Your Project Type *– Please select –Car, SUV, MPVBus, coach, trainLCV (pickup truck, light-duty truck, etc.)HCV (heavy-duty truck, tractor, trailer, concrete mixer, etc.)Construction machinery (excavator, forklift, crane, bulldozer, loader, etc.)Vessel, boat, ship, yacht, etc.Others (please write it in the note)Your Interested Solutions *– Please select –Motore-AxleBatteryChassisAuxiliary inverterOBC / DCDC / PDUAir brake compressorEPS / EHPS / SbW / eRCBBTMSOthers (please write it in the note)Do you have other contact info? (Whatsapp, Wechat, Skype, etc.)Please introduce your project and your request here. * Checkbox * I consent to receive updates on products and events from Brogen, and give consent based on Brogen’s Privacy Policy. Submit

EV Industry, Heavy Transport

Electric Truck Axle Guide: How to Choose the Right E-Axle for Heavy-Duty Trucks?

Electric Truck Axle Guide: How to Choose the Right E-Axle for Heavy-Duty Trucks? As electric heavy-duty trucks continue to gain market share, a clear understanding of key drivetrain systems—especially the electric truck axle—is becoming increasingly important for OEMs and commercial EV developers. What types of electric truck axles are available today, and what technical factors should be considered when selecting the right solution? In this article, we explore the core dimensions of electric truck axle selection, including structural layout, motor configuration, transmission stages, and PTO integration. This guide is designed to support engineering and product teams in making informed decisions when developing or sourcing electric heavy truck platforms. Brogen Electric Truck Axle on the Heavy-Duty Truck 1. The Structure of Electric Truck Axle Traditionally, a drive axle consists of four main subassemblies. Axle Housing: As the core load-bearing structure, the housing plays a critical role in supporting the entire axle system. Depending on the manufacturing process, axle housings can be categorized into three main types: Stamped and Welded Steel Plates: Known for their cost-effectiveness and relatively low weight, this method is commonly used in light-duty applications. Hydroformed Structures: This process enables superior lightweight performance, making it ideal for applications with strict weight constraints. Precision Cast Housings: These offer high structural strength and load-bearing capacity, which is essential for heavy-duty operations and demanding terrains. Final Drive (Main Reducer): It converts torque from the driveshaft into torque at the drive wheels. One of the key performance indicators of the final drive is the diameter of its ring gear – the larger the diameter, the greater the vehicle’s load capacity and wheel-end output torque. Additionally, the gear ratio of the final drive is a critical factor affecting the vehicle’s power delivery and energy efficiency. Inside the final drive, there is also a differential, which allows the left and right wheels to rotate at different speeds when the vehicle is running. Wheel End: This assembly connects directly to the tires and is responsible for high-speed rotation. In older designs, wheel ends required grease lubrication, which routine maintenance typically needed every 50,000 km. Today, most heavy-duty truck axles have adopted maintenance-free wheel ends, significantly reducing service requirements and improving uptime. Braking System: It typically comes in drum or disc configurations. Among drum brakes, there are two common types: S-cam brakes and wedge brakes. Thanks to their simpler structure, faster response, and better space efficiency (especially in tight chassis layouts), wedge-type drum brakes have become the preferred solution in modern heavy-duty trucks. The axle housing, wheel ends, and braking system of this electric drive axle are largely identical to those of a conventional diesel drive axle. From a structural standpoint, electric truck axles are fundamentally similar to traditional diesel axle systems. There are tow primary structural configurations commonly used in the industry: Configuration 1: Integrated Axle Housing Structure This design retains the conventional layout of the axle housing, wheel hubs, and braking system – essentially mirroring a traditional diesel drive axle. The only major difference is the addition of an electric motor and gearbox assembly, which is mounted at the front flange of the axle. The motor delivers torque, which is then stepped down and amplified by the gearbox before being transmitted to the axle to propel the vehicle forward or in reverse. Electric Truck Axle With Integrated Axle Housing The key advantage of this configuration lies in its simplicity. It leverages proven components from diesel truck platforms – including the axle housing, wheel ends, and braking system – which helps reduce development time and keeps costs relatively low. However, there are notable trade-offs. Due to space limitations, it’s difficult to integrate a multi-speed gearbox – typically restricted to two or three gears at most – and there’s usually no room for a PTO. Another major drawback is that the center of gravity of the entire e-axle assembly is offset from the axle line, which can lead to undesirable dynamic behaviors during rapid acceleration or braking. These include pitching motions such as axle lift (front-up) during acceleration and nosedive during deceleration. Configuration 2: Three-Piece Axle Housing Structure Electric Truck Axle With Three Piece Axle Housing Structure This design features square-section axle housings on both sides, with the electric motor and multi-speed gearbox mounted in the center. The three segments are connected via flanges and bolts. The main advantage of this architecture is its compact layout, which allows the gearbox to be designed with 3, 4, or even 6 speeds. This enables improved vehicle performance and energy efficiency, particularly under varying load and terrain conditions. The primary drawback is the increased overall weight due to the bolted flange connections between the three sections. However, the structural integrity of this design is not compromised – the axle can support up to 13 tons, making it fully suitable for heavy-duty applications. Electric Truck With Three-Piece Axle Housing eAxle From a cost perspective, Configuration 1 is more economical and is currently more common in the market. However, from a technological and performance standpoint, the three-piece structure – with its modular layout and support for multi-speed transmissions – is emerging as the mainstream trend in electric axle development for heavy-duty trucks. 2. Choosing the Number of Motors Due to space constraints, electric truck axles typically integrate a single motor. For example, our latest e-axle features a single motor delivering 300  kW peak power (407  hp) and 200  kW rated power (271  hp). It utilizes an oil-cooled system and achieves a maximum output torque of 38,483 Nm. With its integrated axle housing design, it supports a maximum axle load of up to 16,000 kg. Electric Water Truck With Brogen Single Motor Electric Truck Axle To further increase power output, dual-motor configurations are required. These can be arranged in two main ways: Inline configuration: Two motors positioned front and rear, jointly driving the central final drive. Distributed design: Similar to the layout in the Tesla Semi, where the second axle is used as the drive axle. It employs two motors, each driving one half-shaft independently, using

Author name: brogenevsolution.com