Author name: brogenevsolution.com

coaxial eaxle
Light Commercial Vehicles, Technologies

Coaxial eAxle for Light Trucks: Technology Overview and Performance Analysis

Light Commercial Vehicles, Technologies /

Coaxial eAxle for Light Trucks: Technology Overview and Performance Analysis Traditional fuel-powered trucks reply on a complex drivetrain consisting of an engine, clutch, transmission, driveshaft, and axle. This setup is not only heavy but also has low transmission efficiency. Early electric trucks often adopted a “retrofit” approach, replacing the engine and transmission with a motor and reducer. However, this direct-drive solution was both costly and inefficient. With the growing understanding of electric truck design and the need to lower costs, reduce energy consumption, and lighten vehicle weight, the industry is shifting toward integrated electric drivetrains. Today, many small and light-duty electric trucks are equipped with a coaxial eAxle. A coaxial eAxle integrates the motor, planetary reducer, differential, and axle housing into a single, compact unit, significantly shortening the drivetrain, reducing parts, and simplifying structure. This system offers traction, braking, and efficient energy conversion while ensuring higher transmission efficiency than direct-drive systems. It also features automatic transmission and regenerative braking, which help extend driving range by recovering energy. Advantages of Brogen Coaxial Drive eAxle Over Central Motor Direct-Drive At Brogen, we provide coaxial drive eAxles, suitable for electric light duty trucks. They have the following advantages: Structural Efficiency:The coaxial drive eAxle combines the motor, planetary reducer, differential, and axle housing in one integrated unit, creating a short drivetrain with fewer parts and a simpler structure. In contrast, the direct-drive approach requires separate motor, reducer, driveshaft, and axle assemblies, resulting in a longer, more complex drivetrain. Space Efficiency: The coaxial design is highly integrated, freeing up valuable chassis space and simplifying the assembly process. Direct-drive systems, on the other hand, require space for multiple components, complicating the overall vehicle layout. Energy Efficiency: With a direct-drive and planetary reduction transmission, the coaxial eAxle achieves an overall transmission efficiency of ≥94%, while traditional direct-drive systems fall below 90% due to a longer drivetrain and additional components. Transmission Process: In the coaxial system, power from the battery drives the motor shaft, which in turn powers the differential and planetary reducer to move the wheels. Direct-drive systems use the motor torque to drive a longer sequence of parts, resulting in lower efficiency. Weight Advantage: Coaxial drive axles are 10-25% lighter than direct-drive systems, reducing energy consumption, increasing motor speed capacity, and offering a higher power density, which extends range. Direct-drive systems are bulkier and lower in power density. Technical Superiority: Coaxial eAxles support a high level of regenerative braking and align with future trends in drivetrain integration. Direct-drive systems, by contrast, offer lower levels of integration and energy recovery. Maintenance Benefits: Coaxial drive eAxles have fewer components, which simplifies maintenance and reduces lifecycle costs. Direct-drive systems, with more parts, tend to have more complex maintenance requirements. In sum, the coaxial electric drive axle offers a highly integrated, efficient, and cost-effective solution for electric light trucks, aligning well with the industry’s movement towards compact, high-performance e-powertrains that maximize both range and durability. Discover our e-axle solutions here: https://brogenevsolution.com/electric-axle-system/ 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

60kW / 130kW Coaxial Electric Axle ​
Public Transportation, Technologies

60kW / 130kW Coaxial Electric Axle ​

Public Transportation, Technologies /

60kW / 130kW Coaxial Electric Axle Our 60 kW / 130 kW coaxial electric axle is ideal for light trucks from 4.5-ton to 6-ton or electric vans and buses from 5 meters to 6 meters. With its lightweight design, low noise levels, and high transmission efficiency, it ensures a smooth and comfortable driving experience for drivers and a quiet, enjoyable ride for passengers. Compared to traditional direct-drive systems, this electric bus axle assembly reduces overall weight by more than 100 kg and largely decreases energy consumption. Electric buses with this e-axle have been exported to Japan, Australia, and Europe. Whatsapp: +8619352173376 Email: contact@brogenevsolution.com Get Custom Quote Technical Benefits of the Coaxial Electric Axle Central Direct Drive Motor Minimal modification to existing internal combustion engine (ICE) platforms. The electric motor replaces the engine, with power transmitted to the rear axle through a driveshaft. Low-cost integration and easy comprability with existing vehicle architectures. The need for a driveshaft and traditional rear axle reduces chassis space and limits battery placement, decreasing overall range. Parallel-Axis E-Axle A more compact electric powertrain design for commercial vehicles. The motor is integrated directly into the rear axle, eliminating the driveshaft and creating additional space for battery placement. Simpler structure with fewer parts, improved space for batteries, and better range. The motor’s off-center weight distribution led to vibration issues, and NVH performance become a challenge due to the unique design. Coaxial E-Axle In this electric powertrain system, both the electric drive motor and output shaft are aligned along the same axis, allowing for a more compact, stable, and efficient design, helping improve overall layout. Improved rotational stability, reducing vibrations and enhancing noise control. Weight reduction and space optimization with the motor housing serving as a load-bearing element. Increased system efficiency due to the elimination of high-speed bearings and a more direct power transfer. Superior NVH performance, with reduced center-of-gravity offset and less vibration. Technical Parameters Model 6PE Rated Axle Load Capacity 3500 kg Maximum Torque 5700 N.m Gear Ratio 16.5 Motor Voltage 360 V / 540 V Motor Rated / Peak Power 60 kW / 130 kW Motor Rated / Peak Torque 145 N.m / 350 N.m Motor Rated / Peak Speed 4000 rpm / 12000 rpm 100 kg reduce in weight compared to direct drive systems. 15% reduce in power consumption compared to direct drive systems. 30% increase in passenger capacity. 100% counter torque for increased cruising range. Lower than 70 dB noise for a more pleasant driving experience. Applications Contact Us Get in touch with us by sending us an email, using the Whatsapp number below, or filling in the form below. We usually reply within 2 business days. Email: contact@brogenevsolution.com Respond within 1 business day Whatsapp: +8619352173376 Business hours: 9 am to 6 pm, GMT+8, Mon. to Fri. LinkedIn channel Follow us for regular updates > YouTube channel Ev systems introduction & industry insights > ContactFill in the form and we will get in touch with you within 2 business days.Please enable JavaScript in your browser to complete this form.Please enable JavaScript in your browser to complete this form. Name * FirstLast Work Email *Company Name *Your Project Type *– Please select –Car, SUV, MPVBus, coach, trainLCV (pickup truck, light-duty truck, etc.)HCV (heavy-duty truck, tractor, trailer, concrete mixer, etc.)Construction machinery (excavator, forklift, crane, bulldozer, loader, etc.)Vessel, boat, ship, yacht, etc.Others (please write it in the note)Your Interested Solutions *– Please select –Motore-AxleBatteryChassisAuxiliary inverterOBC / DCDC / PDUAir brake compressorEPS / EHPS / SbW / eRCBBTMSOthers (please write it in the note)Do you have other contact info? (Whatsapp, Wechat, Skype, etc.)Please introduce your project and your request here. * Checkbox * I consent to receive updates on products and events from Brogen, and give consent based on Brogen’s Privacy Policy. Submit

electric power steering systems
Industry Insight

Understanding Electric Power Steering Systems: Types and Key Differences

Leave a Comment / Industry Insight /

Understanding Electric Power Steering Solutions: Types and Key Differences The power steering system is a crucial component of a vehicle, serving as an important connection between the driver and the car. It has evolved alongside the overall development of vehicles and the emergence of new technologies. Initially, there was mechanical steering, followed by hydraulic power steering systems (HPS), electro-hydraulic power steering systems (EHPS), electric power steering systems (EPS), and now the latest steer-by-wire (SBW) technology. Depending on the location of the assist motor, electric power steering systems (EPS) are classified into C-EPS, P-EPS, DP-EPS, and R-EPS. Each type has its own unique functional and performance characteristics. Different Types of Electric Power Steering Systems 1. Column Assist Type Electric Power Steering (C-EPS) Motor placement: the motor and reduction gears are mounted on the steering column. The motor’s torque works together with the driver’s input to rotate the steering column, which then transmits force through the intermediate shaft and pinion to the rack, providing steering assistance. Applicable vehicle types: particularly suitable for compact vehicles that do not require excessive assistance. Structural characteristics: compact design, easy installation, and minimal required installation space. Driving experience: lightweight steering at low speeds, stable handling at high speeds, and excellent self-centering performance. Additional features: equipped with self-diagnosis and safety control functions, highly adaptable, allowing for customization of electric power steering columns and controllers based on different vehicle models. 2. Pinion Assist Type Electric Power Steering (P-EPS) Motor placement: the motor provides assistance directly to the pinion of the rack-and-pinion steering system, combining the precise adjustability of electric power steering with the strong road feedback typical of hydraulic power steering. System performance: equipped with a waterproof, compact, lightweight, high-performance integrated motor-ECU unit, the system delivers high rigidity and excellent dynamic steering performance. Structural characteristics: the compact, integrated housing structure enhances the precision of component manufacturing and improves overall product reliability. Cost: P-EPS is more expensive compared to C-EPS. 3. Dual-Pinion Assist Type Electric Power Steering (DP-EPS) Motor placement: an additional assist motor is placed on another part of the rack, applying steering force to the tie rod via a pinion. Together with the pinion on the intermediate shaft and tie rod, this forms a dual pinion structure. Applicable vehicle types: suitable for mid-size SUVs, large SUVs, MPVs, pickups, and other passenger vehicles, meeting the requirements for ADAS (Advanced Driver Assistance Systems). Performance advantages: the servo motor only operates when steering assistance is needed, reducing fuel consumption by 3-5%. It complies with ISO 26262 functional safety standards at the ASIL D level. The system is designed with high robustness to handle complex driving conditions, with high steering precision to support driving assistance at high speeds. Redundant design: the fully redundant DP-EPS system includes redundancy in power supply, communication, sensors, electronic control, and motor output, significantly enhancing the reliability and safety of the system. 4. Rack Assist Type Electric Power Steering (R-EPS) Motor placement: the motor typically applies force to the rack through a timing belt or ball screw. In some configurations, a coaxial motor directly provides assistance via a roller screw. Structural characteristics: the structure is relatively compact, making it suitable for scenarios where front axle loads are increasing and the steering system is positioned farther from the driver. Driving experience: it offers an enhanced steering feel and higher efficiency, making it more suitable for premium vehicles. Performance advantages: with a finely tuned steering feel and excellent NVH performance, it fully meets the steering needs of vehicles ranging from mid-size sedans to luxury MPVs. It also supports Level 2+ autonomous driving, including features like Lane Keep Assist (LKA), Automated Parking Assist (APA), and Remote Control Steering (RCS). Safety: the entire product platform is developed following ISO 26262 processes, ensuring functional safety at ASIL-D level. Key Differences of Electric Power Steering Systems After gaining a basic understanding of the different EPS structures, let’s take a look at the performance differences and suitable applications for each type: 1. Assist Effect and Applicable Vehicle Types EPS Type Maximum Assist Force Applicable Vehicle Types C-EPS 11 kN Compact cars, small SUVs P-EPS 12 kN Midsize cars, SUVs DP-EPS 13 kN Midsize/large SUVs, MPVs, pickups R-EPS 16 kN Luxury cars, large SUVs, performance vehicles C-EPS, with its compact structure, is typically used for vehicles that require moderate steering assistance. P-EPS, by applying assist force to the pinion, provides stronger assistance and is suitable for heavier vehicles. DP-EPS, with its dual-pinion design, offers even greater assist force to meet the needs of larger vehicles. R-EPS generally delivers the strongest assist, making it ideal for luxury and performance vehicles. 2. Energy Consumption and Efficiency by EPS Type EPS Type Energy Consumption Efficiency C-EPS Low Moderate P-EPS Moderate Relatively High DP-EPS Moderate to High High R-EPS High (operates only when needed) Very High While DP-EPS and R-EPS have relatively higher energy consumption, their servo motors only operate when steering assistance is required, effectively reducing fuel consumption in real-world use. Additionally, these systems generally exhibit higher efficiency, converting electrical energy into steering assistance more effectively. 3. Response Speed and Precision by EPS Type EPS Type Response Speed Precision C-EPS Moderate Moderate P-EPS Relatively Fast High DP-EPS Fast High R-EPS Very Fast Very High R-EPS typically exhibits the fastest response speed and highest precision, thanks to its advanced control algorithms and precise mechanical structure. DP-EPS also performs well, while C-EPS and P-EPS are comparatively slower and less precise. 4. Noise Levels and NVH Performance by EPS Type EPS Type Noise Level NVH Performance C-EPS Moderate Moderate P-EPS Lower High DP-EPS Very Low High R-EPS Very Low Very High Among these types, only C-EPS has the motor located in the passenger cabin, making it the noisiest and has the worst NVH experience. In contrast, P-EPS, DP-EPS, and R-EPS have their motors in the front compartment, resulting in better noise performance. Additionally, R-EPS benefits from its force transmission structure, offering the best NVH performance. 5. Redundancy Design and Safety by EPS Type EPS Type Redundancy Design Safety Level C-EPS Minimal

different e-powertrain layout
Heavy Transport, Industry Insight

Electric Heavy-Duty Truck Design: Which E-Powertrain is Better?

Leave a Comment / Heavy Transport, Industry Insight /

Electric Heavy-Duty Truck Design: Which E-Powertrain is Better? At Brogen, we’ve spent a lot of time developing electric axle systems for commercial vehicles, particularly in heavy-duty applications like semi-trucks, tractors, and trailers. In this article, we’ll explore different electric powertrain systems, compare solutions, and discuss the pros and cons of each. 1. Types of E-Powertrain Systems Electric powertrain systems for heavy-duty vehicles can be categorized into three main configurations based on motor layout: Central Direct Drive: Direct drive motor Electric Drive Axles: Parallel-Axis E-Axle Coaxial E-Axle Vertical-axis E-Axle Distributed Drive Systems  Wheel-End Drive Wheel-Hub Drive Each system offers unique advantages, and we’ll explore them in more detail below. But first, let’s look at some broader trends driving innovation in e-powertrain systems. 2. Key Trends in E-Powertrain Systems 2.1 Increasing Integration of E-Powertrain Systems More and more, motors, gearboxes, controllers, and other key components are being integrated into compact units. This not only reduces weight and space but also improves overall system efficiency and reliability. For example, our 360 kW drive assembly integrates the motor and gearbox into a single unit, which optimizes the layout for heavy-duty trucks and saves valuable space. Similarly, our 360 kW electric axle for heavy commercial vehicles combines the drive system, transmission, braking, and other key components into a compact, efficient assembly. Brogen 360 kW drive assembly for 40-ton to 90-ton HCV Brogen 360 kW E-axle for 4×2/6×2/6×4/8×4 HCV 2.2 Adoption of Dual-Motor E-Powertrain Systems Dual-motor setups are becoming increasingly popular, especially in high-end and specialized trucks. These systems offer better power distribution, improved energy efficiency, and enhanced performance for heavy loads. Our dual-motor drive assembly is a prime example, delivering continuous power during demanding conditions, such as hill climbs, while maximizing operational efficiency. Brogen Dual-Motor Drive Assembly for 55-180T HCV Brogen Dual-Motor 360 kW E-axle for 4×2/6×2/6×4/8×4 HCV 3. Central Direct Drive Systems: A Cost-Effective E-Powertrain Solution Central Direct Drive System Architecture Central Direct Drive System Examples Central direct drive systems are primarily used to convert traditional fuel-powered trucks into electric vehicles. In this configuration, the engine is replaced with an electric motor, along with an electric drive unit (EDU), battery packs, and other key components. The original chassis remains largely unchanged, making this solution adaptable for a wide range of commercial vehicles. Pros: Cost-Effective & Quick to Market: This is the most economical and fastest way to electrify existing vehicle platforms without extensive redesigns. Ease of Conversion: Many manufacturers opt for this approach as it allows them to enter the EV market without the significant financial and time investments required for developing a new platform. Cons: Limited Battery Space: Since the original chassis isn’t significantly altered, space for battery packs is restricted, which limits driving range and affects battery cooling system layout. Compromised Handling & Comfort: Converted models often have poor weight distribution, leading to increased braking distances and reduced driving comfort. Central direct drive systems are commonly used in short-distance transportation scenarios, such as ports, steel mills, power plants, and mines. They are less suited for medium- or long-distance travel. 4. Electric Drive Axles: Optimizing Space & Efficiency In contrast, electric drive axles (e-axles) eliminate the need for a drive shaft, reducing vehicle weight and improving system efficiency. E-axles also allow for better space optimization for battery packs, increasing driving range and better overall efficiency. Among the different types of electric drive axles, three main configurations stand out: parallel-axis, coaxial, and vertical-axis. Each configuration offers distinct advantages and challenges, making them suitable for various vehicle types and operational needs. 4.1 Parallel-Axis E-Axle Parallel-Axis E-Axle System Architecture Brogen Parallel-Axis E-Axle The parallel-axis electric drive axle is currently the most widely adopted configuration for electric axles in the market. In this system, the motor is positioned parallel to the axle, and the motor, drive axle, and AMT are integrated into a single unit. This design eliminates the need for a drive shaft, reducing overall system weight and improving transmission efficiency. Additionally, this configuration uses helical gears, which significantly enhance reverse braking capability—from the typical 30% to an impressive 100%. By removing traditional components such as the universal drive shaft, reducer, and suspension brackets, installation costs are significantly reduced compared to central direct drive systems. This compact design also saves weight and space, allowing for better battery placement and increased driving range. However, there are drawbacks. The large unsprung weight of the system, combined with its offset configuration, can negatively impact the vehicle’s handling, especially in heavy-duty applications. 4.2 Coaxial Electric Drive Axle Coaxial Electric Drive Axle Architecture Brogen Coaxial E-Axle The coaxial electric drive axle features a motor aligned directly with the axle housing. This configuration creates a more compact and concentrated power system, which optimizes the vehicle’s overall chassis layout. Due to its efficient space utilization, coaxial e-axles are ideal for smaller commercial vehicles like light vans and trucks weighing under 4.5 tons. However, their compact nature and lower power density make them unsuitable for heavy-duty vehicles, which require more robust power systems. 4.3 Vertical Axis Electric Drive Axle Vertical Axis Electric Drive Axle Architecture In the vertical axis electric drive axle, the motor is connected to the drive axle at a perpendicular angle. This setup offers some key advantages, such as lower installation costs and the efficient use of longitudinal space, which allows for better battery pack arrangement. Despite these benefits, there are significant trade-offs. The vertical axis design has lower transmission efficiency compared to parallel-axis e-axles, and its system power density is not as high. Additionally, the use of hypoid gears for speed reduction results in a smaller speed ratio and poorer performance in NVH (noise, vibration, and harshness). As a result, this configuration is more commonly used in medium- and heavy-duty commercial vehicles. 5. Distributed Drive Systems As electric vehicles continue to evolve, distributed drive systems are emerging as a powerful alternative to traditional powertrains. Distributed drive systems can be divided into two main types: wheel-end drive and wheel-hub drive. Each of these technologies offers distinct advantages, as well as unique challenges,

electric truck axle
Heavy Transport, Industry Insight, Technologies

4 Motors With 1000 HP? Our Electric Truck Axle May Exceed Your Expectations

Leave a Comment / Heavy Transport, Industry Insight, Technologies /

4 Motors With 1000 HP for Electric Heavy Trucks? Our Electric Truck Axle May Exceed Your Expectations The semi-truck shown here is a battery-swapping electric tractor equipped with our 360 kW electric truck axles. It features two rear electric drive axles, each e-axle housing two motors, delivering 180 kW of peak power per motor. Together, they generate a total of 720 kW, nearly 1000 horsepower. And there’s even more beneath the surface. Our electric axle integrates the motors, along with key components such as the speed reducer and differential gear, directly into the rear axle. The total weight of the electric axle is 950 kg, with each axle capable of delivering up to 50,000 N.m of torque, ensuring abundant power for heavy-duty operations. One of the unique features of this e-axle is its distributed drive system. This means that each motor operates independently, providing added safety redundancy—if one motor fails, the other can continue to function normally. There are additional benefits as well. To improve efficiency, the vehicle’s design allows for both motors to work simultaneously or to alternate between them. When the truck is unloaded, only a minimal amount of power is used, as the motors take turns powering the vehicle. During start-up or climbing, both motors can work together, delivering maximum power. This cooperative strategy is coordinated with the vehicle’s overall control system. For fully electric trucks carrying heavy loads, alternating between the two motors helps prevent overheating, keeping both motors within their optimal operating range. This not only enhances reliability but also enables the motors to work together to deliver ideal power and torque when high demand is required. For example, the maximum torque output of our single electric axle reaches an impressive 50,000 N.m, an extraordinary figure for a heavy-duty tractor. We all know that traditional motor layouts are often limited by space and require numerous components. In contrast, the integrated design of our electric axle, with its compact central structure, reduces the number of parts needed. For example, our e-axle weighs 950 kg, contributing to a vehicle weight reduction of 300 kg. The highly integrated design also frees up valuable chassis space in electric trucks, a critical factor given the current focus on maximizing battery capacity for longer range. This central, compact electric axle allows for more or larger battery packs, improving range. It is also compatible with a variety of suspension systems, including air suspensions and multi-leaf springs, making it adaptable to different truck platforms. By integrating the entire axle assembly into the chassis, and using a highly compact dual-motor design, we’ve reduced the number of parts in the drivetrain, leading to higher transmission efficiency and more effective regenerative braking—both of which contribute to extending the vehicle’s range. This central, integrated electric axle not only offers higher reliability but also benefits from reduced weight, increased chassis space, and higher transmission efficiency. With the rise of hydrogen fuel cell systems, which require even more chassis space than pure electric trucks, this axle design is undoubtedly poised to become the mainstream choice, offering tremendous market potential in the future.

hybrid suv project with brogen onboard charger
Light Commercial Vehicles

Hybrid SUV Project in Europe With Our 800V OBC & DC/DC Combo

Leave a Comment / Light Commercial Vehicles /

Hybrid SUV Project in Europe With Our 800V OBC & DC/DC Converter Combo Project Overview As the automotive industry continues to evolve, the demand for innovative charging solutions is on the rise. In 2022, a European automotive company approached us for an 800V high-voltage onboard charger (OBC) to power their hybrid SUV project. They were in search of a reliable solution that could meet the unique requirements of their vehicle platform. Similar models of hybrid SUVs, as the newly developed vehicle remains confidential The Shift to 800V EV Cars With electric vehicle (EV) adoption expected to grow rapidly in the coming years, the next generation of EVs needs to offer longer range, faster charging, and higher power output to fully replace traditional gasoline-powered cars. To achieve these goals, EV battery systems require higher voltage configurations. This is why the shift from 400V to 800V platforms in the EV market has become inevitable. There are currently two main approaches to implementing an 800V platform for hybrid cars: Partial 800V Platform: This method retains some 400V components, such as air conditioning and DC/DC converters, while upgrading only specific high-voltage parts to 800V. Full 800V High-Voltage System: All high-voltage components, from the battery to the drivetrain (including the inverter, onboard power control unit, air conditioning compressor, and thermal management system), are designed with an 800V architecture. This approach significantly improves charging efficiency, speed, and overall system energy performance. 800V high-voltage platform architectures However, for automotive manufacturers, finding suitable EV systems that support the 800V high-voltage platform with high product quality and reliable performance is challenging. As a result, sourcing the right solutions becomes crucial and can require additional time and costs. How We Worked Despite extensive market research, the client had difficulty finding a reliable solution that matched the 800V high-voltage requirements for their hybrid SUV. When they reached out to us, we were able to offer them the solution from out range of EV onboard chargers and converters, which span from 3.3 kW to 40 kW, with high-voltage and V2X options. After reviewing their specifications, we proposed an OBC and DC/DC converter system designed for 800V EV cars that perfectly matched their needs. They quickly ordered samples for testing, and the results exceeded their expectations. Our system’s compact, lightweight design and high performance amazed the client.  Brogen team preparing the shipment of samples Result The client was so impressed with the results that they placed an additional order for 25 more units and signed a contract with us to begin preparing for mass production of their hybrid SUVs within 2 years. In total, they have ordered 30 units for the initial testing, with plans to order over 500 units for the first phase of production. These hybrid SUVs are set to lead the market with the latest automotive high-voltage system technology. System in This Project 10 kW Onboard Charger & DC/DC Converter Combo Appearance Dimension: 310*219*111 mm (connectors excluded) Weight: 9.2 kg Charging Mode Input voltage range: 90-264 VAC@1φ; 185-456 VAC@3φ Rated input voltage: 230 VAC@1φ; 380 VAC@3φ Input frequency range: 45-65 Hz Input current: 32 A max.@1φ; 16 A max.@3φ High Voltage Output Output voltage range: 350-800 VDC Max. output current: 13.8 A@1φ; 20.3A@3φ Output power: 6.6 kW max. @1φ; 9.6 kW max.@3φ Efficiency: ≥94@rated load; ≥95@half load Inverter Mode Input voltage range: 350-800 VDC Input current: 11 A max. Output voltage: 220 VAC (±5%)@1φ Output voltage frequency: 50 Hz (±1%) Rated output power: 3.3 kVA Output efficiency: 93% DCDC Mode Input voltage range: 350-800 VDC Output voltage range: 11-16 VDC Rated output voltage: 14 VDC Output current: 215 A continuous Output power: 3 kW continuous Explore Onboard Chargers Contact Us Get in touch with us by sending us an email, using the Whatsapp number below, or filling in the form below. We usually reply within 2 business days. Email: contact@brogenevsolution.com Respond within 1 business day Whatsapp: +8619352173376 Business hours: 9 am to 6 pm, GMT+8, Mon. to Fri. LinkedIn channel Follow us for regular updates > YouTube channel Ev systems introduction & industry insights > ContactFill in the form and we will get in touch with you within 2 business days.Please enable JavaScript in your browser to complete this form.Please enable JavaScript in your browser to complete this form. Name * FirstLast Work Email *Company Name *Your Project Type *– Please select –Car, SUV, MPVBus, coach, trainLCV (pickup truck, light-duty truck, etc.)HCV (heavy-duty truck, tractor, trailer, concrete mixer, etc.)Construction machinery (excavator, forklift, crane, bulldozer, loader, etc.)Vessel, boat, ship, yacht, etc.Others (please write it in the note)Your Interested Solutions *– Please select –Motore-AxleBatteryChassisAuxiliary inverterOBC / DCDC / PDUAir brake compressorEPS / EHPS / SbW / eRCBBTMSOthers (please write it in the note)Do you have other contact info? (Whatsapp, Wechat, Skype, etc.)Please introduce your project and your request here. * Checkbox * I consent to receive updates on products and events from Brogen, and give consent based on Brogen’s Privacy Policy. Submit

electric light truck project in south korea
Light Commercial Vehicles

Electric Light Truck Project in South Korea With Our EV Systems

Leave a Comment / Light Commercial Vehicles /

Electric Light Truck Project in South Korea With Our EV Systems Project Overview In 2021, an electric truck manufacturer in South Korea approached us for EV systems to support their electric light truck project. After a thorough analysis of their vehicle requirements and specifications, we recommended a range of EV systems including air conditioning compressors, water pumps, DC/DC converters, and EHPS. We then customized these systems to perfectly align with their vehicle platform. By 2023, the prototype had successfully entered mass production, and we continued to supply additional systems to meet their growing needs. Challenges Faced During the project, the client considered changing their voltage platform, which would have required adjustments to our products.  However, after careful evaluation by engineers from both sides, it was concluded that maintaining the original voltage platform would be more beneficial. The client ultimately accepted this recommendation and kept the original platform unchanged. Another challenge was the client’s requirement for the CAN protocol to be based entirely on their standard frame, whereas some of our systems used extended frames. To ensure the project’s success, our engineers customized the CAN protocol, adjusting both the content and communication speed to meet the client’s standards. Preparing the shipment to the client How We Worked To ensure our systems work well on the client’s electric light truck, we modified the water pump bracket to fit the electric light truck chassis. During vehicle installation testing, our engineers provided remote technical support, assisting the client in modifying the software protocol and completing the full vehicle testing. Systems in This Project DC/DC Converter Dimension: 300x185x73 mm Weight: ≤ 5 kg Efficiency: 94% Input voltage range: 450 – 750 VDC Rated input voltage: 640 VDC Rated output voltage: 14 VDC Output current range: 0 – 214 A Explore more DC/DC converters Air Conditioning Compressor Refrigerating capacity (max.): 2.9 kW, 9900 BTU/hr Input power: 1.5 kW Current: 4.8 A Displacement: 18.0 cc/rev Oil charge: 100 cc Speed range: 1500 – 6000 rpm Relief pressure: 4.0 MPa (G) Inquiry Now EHPS Controller voltage range: 10 – 15 VDC Rated voltage: 12 VDC Rated speed: 3000 rpm Rated power: 0.5 kW Peak power: 1.5 kW Protection level: IP67 Discover Electric Power Steering Solutions Result In the end, our systems successfully operated on the client’s prototype vehicle and passed all tests. In 2023, the client placed bulk orders for our EV systems and is expected to continue with further mass production plans in 2024. Contact Us Get in touch with us by sending us an email, using the Whatsapp number below, or filling in the form below. We usually reply within 2 business days. Email: contact@brogenevsolution.com Respond within 1 business day Whatsapp: +8619352173376 Business hours: 9 am to 6 pm, GMT+8, Mon. to Fri. LinkedIn channel Follow us for regular updates > YouTube channel Ev systems introduction & industry insights > ContactFill in the form and we will get in touch with you within 2 business days.Please enable JavaScript in your browser to complete this form.Please enable JavaScript in your browser to complete this form. Name * FirstLast Work Email *Company Name *Your Project Type *– Please select –Car, SUV, MPVBus, coach, trainLCV (pickup truck, light-duty truck, etc.)HCV (heavy-duty truck, tractor, trailer, concrete mixer, etc.)Construction machinery (excavator, forklift, crane, bulldozer, loader, etc.)Vessel, boat, ship, yacht, etc.Others (please write it in the note)Your Interested Solutions *– Please select –Motore-AxleBatteryChassisAuxiliary inverterOBC / DCDC / PDUAir brake compressorEPS / EHPS / SbW / eRCBBTMSOthers (please write it in the note)Do you have other contact info? (Whatsapp, Wechat, Skype, etc.)Please introduce your project and your request here. * Checkbox * I consent to receive updates on products and events from Brogen, and give consent based on Brogen’s Privacy Policy. Submit

electric pickup truck development
Industry Insight, Light Commercial Vehicles

Optimizing Electric Pickup Truck Development: E-Axles Benefits

Leave a Comment / Industry Insight, Light Commercial Vehicles /

Optimizing Electric Pickup Truck Development: E-Axle Benefits The Unique Requirements of Electric Pickup Trucks Pickup trucks, primarily commercial vehicles, have a chassis design more aligned with light commercial vehicles than with passenger cars or SUVs. Directly using passenger car electric powertrains in electric pickup trucks can increase costs and fail to meet the specific demands of pickup truck usage. A truck-style rear axle design is an economical and effective solution that meets the essential requirements of electric pickup trucks, such as traction, payload capacity, durability, and off-road capability. Additionally, it ensures superior towing performance. Electric Drive Axle Technology for Electric Pickup Trucks The axle is a critical element in the strength and durability of pickups and light trucks. The electric drive axle technology integrates the electric motor directly with the axle, allowing seamless integration with existing truck structures without the need for specialized suspension, chassis, or braking systems. This setup enables electric pickup trucks to retain the towing capacity of traditional fuel-powered vehicles while also accommodating higher payloads. The highly concentrated power system of the electric drive axle simplifies vehicle battery placement and features an integrated structure that adapts to the unique operating conditions of fully electric vehicles. Flexibility in E-Powertrain Configurations In addition to rear-wheel drive, pickup manufacturers can integrate a standard electric drive system into the front axle of their electric pickup trucks, achieving an electric four-wheel drive configuration. For the ultimate solution, a three-motor setup, including a front axle motor, offers the highest level of performance for electric pickup trucks. However, manufacturers can opt for a simpler rear-drive system or a lower power output axle, such as a 115 kW rear axle motor, which is generally suited for fully electric vehicles with a GVWR of 4.5 to 6 tons. The 150 kW electric drive axle is suitable for larger fully electric commercial vehicles. Benefits for OEMs This approach allows electric pickup trucks and light commercial vehicles to maintain their performance without compromising payload or towing capacity, all without requiring a complete redesign of the existing truck platform. These advantages make it easier for OEMs to transition to electrification. Additionally, the reduced number of moving parts in the powertrain translates to lower maintenance and servicing needs. High-Power Electric Drive Axles for Pickup Trucks Our high-power output electric drive axles feature the PMSM motor, offering peak power options ranging from 90 kW to 165 kW, with a top speed of up to 110 km/h. This makes it ideal for pickup trucks and light commercial vehicles. The use of finely ground gears results in lower noise levels and a more comfortable driving experience. With an IP68 protection rating, the system includes features like active gear speed monitoring, real-time brake disc temperature control, and friction pad wear alerts, ensuring enhanced safety. Explore E-Axles for LCV

60kW _ 100kW electric motor assembly
Light Commercial Vehicles, Technologies

60kW / 100kW Electric Motor for Pickup Truck, Light Truck, Van

Leave a Comment / Light Commercial Vehicles, Technologies /

60kW / 100kW Electric Motor Assembly for Pickup Truck, Light Truck, Van This 60kW / 100kW e-powertrain system integrates the 60kW / 100kW electric motor, gearbox, and motor controller into one single compact unit. By utilizing shared housing, wiring harnesses, and other components, the system achieves reduced weight, lower costs, and higher efficiency. The integrated e-drive system eliminates the need for separate wiring connections between parts, which also reduces electromagnetic interference. With a three-phase direct connection, the system is simple and reliable. The compact design gives more flexibility in vehicle layout, making it easier for automotive manufacturers to create modular and scalable vehicle platforms. This helps speed up product development, lower costs, and improve efficiency. Additionally, the lower center of gravity improves handling, while increasing torque capacity and the overall efficiency of the e-powertrain system. How It Works This system is used as the drive system for electric vehicles. It’s powered by a PMSM, with high-precision torque and speed control achieved through the software control of an MCU. The system converts high-voltage DC power into an adjustable AC source with variable amplitude and frequency to control and drive the PMSM, ensuring high precision and efficiency. A single-stage reduction gearbox amplifies the torque and reduces the speed. The torque is transmitted via the reduction gearbox flange to the vehicle’s front and rear axles, achieving the desired veehicle propulsion and control. This system is suitable for applications in light commercial vehicles (LCVs), including pickup trucks, vans, light duty trucks. Technical Parameters Motor Parameters Rated voltage: 380 V Rated power: 60 kW Peak power: 100 kW Rated torque: 120 N.m Peak torque: 280 N.m @min Peak speed: 12000 rpm Protection level: IP67 Weight:52 kg Dimension: φ261×339 mm Motor Controller Short-time working current: 420 A Continuous working current: 190 A Operating voltage range: 250 V – 450 V Weight:8 kg Reducer Maximum input torque: 350 N.m Maximum input speed: 12000 rpm Speed ratio: 3.04 E-Powertrain Efficiency Map 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

3-ton electric pickup truck proejct with our e-powertrain in Thailand
Light Commercial Vehicles

3-ton Electric Pickup Truck in Thailand With Our E-Powertrain

Leave a Comment / Light Commercial Vehicles /

3-ton Electric Pickup Truck in Thailand With Our E-Powertrain System Project Overview: Our client, a technology company specializing in electric vehicle conversion in Thailand, approached us in 2022 with a specific requirement for their electric pickup truck project. They needed an e-powertrain system featuring an electric motor with a rated power of 60 kW. After a detailed assessment of their project specifications and vehicle requirements, we proposed two optimized e-powertrain systems to them. The client ultimately selected the system that best met the demands of their electric pickup truck project. Client testing the pickup truck on the road Solution and Implementation Once our e-powertrain system was integrated into the client’s electric pickup truck, they conducted rigorous testing, including water wading, high-speed performance, and other essential assessments. Our system successfully passed all tests, resulting in the client being highly satisfied with the performance of their upgraded electric pickup truck. Expansion of Partnership Due to the successful outcome of the electric pickup truck project, the client expanded their collaboration with us, requesting e-powertrain solutions for additional vehicles, including their 6-ton medium-duty trucks and 25-ton heavy-duty trucks. Throughout this collaboration,  we also supplied key systems such as onboard chargers and battery thermal management systems. Ongoing Collaboration This partnership has now flourished over the past two years, with our solutions continuously meeting the client’s high standards of their electric vehicle conversions. The strong relationship between our companies continues to grow as we support their efforts to electrify a wider range of vehicles. E-Powertrain System Used in This Project Motor Parameters Rated power: 60 kW Peak power: 115 kW Rated torque: 143 N.m Peak torque: 325 N.m Rated speed: 4000 rpm Peak speed: 12000 rpm Reducer Parameter Speed ratio: single – 3.037 Controller Parameter Voltage range: 200 – 450 V Rated voltage: 336 VDC Current module:384 A Rated current: 174 A At Brogen, we provide EV solutions for commercial vehicles, including buses, vans, light-duty trucks, heavy-duty trucks, mining trucks, vessels, and other construction machinery. If you’re looking for an EV solution for your project, you can contact 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