Author name: brogenevsolution.com

Battery Thermal Management for Electric Buses: An Overview This article explores the structure and working principles of common battery thermal management in battery electric buses (BEB), offering valuable insights for their design. The performance of the traction battery system is a key factor in a battery electric bus’s overall efficiency, range, and reliability. Since battery temperature directly affects performance, lifespan, and safety, a well-designed thermal management system is crucial for optimizing operation and ensuring long-term durability. 1. Different Types of Battery Thermal Management Effective battery thermal management ensures optimal performance and safety by regulating temperature under varying conditions. This includes cooling the battery during high temperatures to prevent overheating and heating it in low temperatures to maintain efficiency and reliability. 1.1 Battery Cooling Methods Battery cooling is essential for maintaining performance and safety in electric buses. The most common cooling methods for EV  batteries include natural air cooling, forced air cooling, liquid cooling, and direct refrigerant cooling. The air cooling method features a simple structure, lightweight design, low cost, and no risks of harmful gas accumulation or liquid leakage. However, its drawbacks include low heat dissipation efficiency, difficulty in sealing design, and poor dustproof and waterproof performance. Depending on whether additional devices are used to introduce cooling air, the air cooling system is divied into natural air cooling and forced air cooling: Natural Air Cooling & Forced Air Cooling Natural Air Cooling: It’s a method of utilizing the wind generated by the vehicle’s movement to flow through a diversion pipe and directly cool the battery pack. This approach requires no auxiliary motors, offers a simple structure, and is easy to use. However, the cooling airflow is subject to instability due to fluctuations in vehicle speed, resulting in variable cooling performance. Additionally, air has low heat capacity and thermal conductivity, which limits the efficiency of heat transfer. Natural air cooling is best suited for vehicles with low discharge rates and minimal heat generation in their power batteries. Forced Air Cooling: It directly introduces cabin air, natural air, or external convection air into the battery compartment to cool the battery pack. This cooling method has relatively poor performance, the largest system volume, and a high risk of water ingress. However, it is lightweight, easy to control, has low energy consumption, relatively low system costs, is relatively easy to implement, and offers high process reliability. Liquid Cooling Liquid Cooling: It utilizes convective heat transfer through a coolant to dissipate the heat generated by the battery, effectively lowering its temperature. It’s currently the most widely adopted cooling solution in the market. Compared to air cooling, liquid cooling systems – using coolant as the heat transfer medium – offer significantly higher specific heat capacity and thermal conductivity. Additionally, in low-temperature environments, the system can also provide heating for the battery pack. However, the primary drawbacks of liquid cooling include increased structural complexity, added battery system weight, and higher overall system costs. Direct Refrigerant Cooling Direct Refrigerant Cooling: Also known as direct cooling or refrigerant-based cooling, integrates the battery thermal management system with the vehicle’s air conditioning system. In this approach, an evaporator in the refrigerant loop functions as the battery’s direct cooling plate, simplifying the overall system. It minimizes heat exchange losses, resulting in a rapid thermal response. And the design eliminates the need for a separate battery cooling loop, reducing components like the coolant pump, piping, and chiller, leading to a more space-efficeint, lightweight thermal management system. A comparison of different cooling methods is as follows: Comparison Item Natural Cooling Forced Air Cooling Liquid Cooling Direct Cooling Working Principle Natural air convection Forced air convection Forced liquid convection Phase-change cooling Heat Transfer Coefficient (W/m²K) 5-25 25-100 500-15000 2500-25000 Heat Dissipation Efficiency Poor High High Very High Temperature Uniformity Good without external heat sources, otherwise poor Poor (especially at inlet and outlet) Good Good Installation Environment Adaptability Poor (requires external insulation and ventilation) Fair (dependent on inlet and outlet air structure) Good Good Suitability for High/Low Temperatures Poor (conflict between auxiliary heating/insulation and heat dissipation) Poor (conflict between auxiliary heating/insulation and heat dissipation) Good (capable of both heating and cooling) Poor (requires additional auxiliary heating, difficult to control heat pump) Complexity Simplest Moderate Complex Complex Energy Consumption None High Low (easy to implement insulation) Low (high efficiency) Cost Low Relatively High High (can be optimized) High 1.2 Battery Heating Methods To maintain optimal performance in cold conditions, EV traction batteries require heating. The most common battery heating methods include: Integrated Electric Heating Film: A thin electric heating film integrated inside the battery pack directly heats the battery cells. Performance: Above 0°C: works well, requires no additional space, consumes no energy when inactive, and is cost-effective. Below 0°C: heating efficiency drops significantly, making it unsuitable for extremely cold environments. Advantages: Space savings and easy to implement; low system cost and no additional control needed. Limitations: Ineffective in freezing temperatures, leading to limited adoption in colder climates. Liquid-Based Heating System: An electric liquid heater is integrated into the thermal management system’s coolant circuit to heat the antifreeze, which then circulates to warm the battery pack. Performance: Provides efficient and uniform heating, making it the preferred method in colder regions. Advantages: Compact system design with minimal space requirements; mature and reliable technology with well-established control mechanisms; high heating efficiency, ensuring stable battery operation in low temperatures Limitations: Higher system cost compared to electric heating films. Due to its efficiency and reliability, liquid heating is currently the most commonly used battery heating solution. Comparison Item Electric Heating Film Liquid Heating Heating Characteristics Constant power heating Convective/conductive heating Space constraints (Thickness) 0.3~2 mm Integrated into the liquid heating system Heating Rate 0.15~0.3°C/min 0.3~0.6°C/min Uniformity (Battery Temperature Difference) ≈8°C ≤5°C 2. Structure and Working Principles of Battery Thermal Management Systems To maintain optimal performance and longevity, EV traction batteries in electric buses operate within an ideal temperature range of 25°C ± 5°C, regardless of seasonal variations. In winter, the battery thermal management system heats the coolant to maintain the target

This 120kW/240kW electric motor is designed for 10-12 meter battery-electric buses and 8-10 meter electric coaches.

80 kW / 160 kW Electric Axle for Bus, Coach, Truck This 80 kW / 160 kW electric axle for bus integrates a high-speed electric motor, gearbox, and rear axle into a compact, lightweight system, optimizing both vehicle efficiency and chassis layout flexibility. Featuring a two-stage helical gear transmission, it achieves an impressive 70% energy recovery efficiency. By eliminating the driveshaft and spiral bevel gears, the system significantly reduces weight, further enhancing energy efficiency and overall vehicle performance. Email: contact@brogenevsolution.com Get Custom Quote Key Features of Brogen 160 kW Electric Axle for Bus Compact Design The motor, gearbox, and axle utilize a highly integrated parallel-axis design, resulting in a lightweight system with high transmission efficiency. Improved NVH Performance The gearbox is engineered for all operating conditions, featuring in-house manufactured DIN 4-grade high-precision gears, ensuring low noise levels. Flexible Vehicle Layout By eliminating the driveshaft, the chassis provides additional space for battery placement, allowing for a more flexible vehicle layout. Technical Parameters The specific parameters vary depending on the configuration. For more details, please contact us: contact@brogenEVsolution.com Model OEEA85 Load 8500 kg Rim mounting distance 1838 mm (adjustable) Speed ratio 20.475 Maximum output torque 9214 N.m Type of hub bearing Maintenance-free Brake specification Pneumatic disc type 19.5″ Rated / Peak power 80 kW / 160 kW Rated / Peak torque 200 N.m / 450 N.m Rated / Maximum speed 3600 rpm / 12000 rpm Weight 525 kg More Power Options Model OEEA30 OEEA50 OEEA60 OEEA95 OEEA100 Load 3000 kg~ 3500 kg 4000 kg ~ 5500 kg 6000 kg 9500 kg 10000 kg Rim mounting distance 1605 mm (adjustable) 1760 mm (adjustable) 1515 mm (adjustable) 1916 mm (adjustable) 1832 mm (adjustable) Speed ratio 12.665 16.141 16.473 19.220 Gear 1: 55.2 Gear 2: 17.24 Maximum output torque 4433 N.m 5730 N.m 7412 N.m 14415 N.m 41400 N.m Type of hub bearing Maintenance-free Maintenance-free Maintenance-free Maintenance-free Maintenance-free Brake specification Hydraulic disc-type two-cylinder φ43 Pneumatic disc type 17.5″ Pneumatic disc type 17.5″ Pneumatic disc type 19.5″ Pneumatic disc type φ410 Rated / Peak power 65 kW / 120 kW 65 kW / 120 kW 80 kW / 160 kW 200 kW / 320 kW 200 kW / 320 kW Rated / Peak torque 160 N.m / 350 N.m 170 N.m / 355 N.m 235 N.m / 450 N.m 350 N.m / 750 N.m 350 N.m / 750 N.m Rated / Maximum speed 3580 rpm / 12000 rpm 3600 rpm / 12000 rpm 4100 rpm / 12000 rpm 4093 rpm / 12000 rpm 4093 rpm / 12000 rpm Weight 205 kg 255 kg 300 kg 583 kg 887 kg Brogen 160 kW Electric Axle for Bus – Solution Advantages Central Direct Drive Powertrain for Bus Brogen Electric Drive Axle for Bus Higher Efficiency & Stronger Performance – A highly integrated two-stage helical gear transmission shortens the drivetrain, reduces axle load, and improves energy recovery efficiency by 10% compared to traditional central electric drive systems. Lightweight Design & Lower Energy Consumption – Removing the driveshaft and spiral bevel gears simplifies the system, significantly reducing weight and further enhancing energy efficiency. Improved NVH & Quieter Operation – Eliminating the driveshaft eliminates issues like shaft angles and dynamic balancing, reducing noise at the source for a smoother and quieter ride. Case Study – 8.5-meter City Bus As public transport operators face growing challenges and evolving industry demands, efficiency and service quality have become critical for sustainable operations. To meet these needs, a public transport company deployed the  8.5-meter battery electric city buses featuring our high-speed motor + high-speed gearbox + rear axle in an advanced 3-in-1 e-drive system.  Enhanced Safety & Reliability The axle head is welded using internationally advanced friction welding technology, ensuring superior strength and durability. The electric powertrain system has successfully passed a 1-million-kilometer durability test, guaranteeing long-term reliability for intensive daily operations. Optimized Space & Weight The integrated e-powertrain system reduces space usage by 25% and weight by 50% compared to conventional setups. The overall vehicle weight is reduced by 2,000 kg, cutting energy consumption by 10%, which extends driving range without increasing battery capacity. Improved Accessibility A single-step entry reduces passenger boarding and alighting time, improving operational efficiency. A fully flat floor design increases standing capacity, enhances layout flexibility, and eliminates interior steps, reducing step-related passenger injuries by 46%. 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 Public Transport Electrification Solutions Electric Axles for Buses 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

This 190 kW / 320 kW electric portal axle for bus is characterized by its highly compact design, incorporating dual motors.

110 kW / 180 kW Steering Electric Portal Axle for Bus, Trolleybus This 110 kW / 180 kW steering electric portal axle is designed for public transport vehicles such as battery electric buses (BEBs) from 8 meters to 10 meters or trolleybuses. It adopts the distributed drive technology, allowing for precise torque and speed control of each wheel independently. Due to its unique features, this product enables highly customizable configurations for buses and provides passengers with greater convenience through its fully low-floor and wide-passenger aisle design. Email: contact@brogenevsolution.com Get Custom Quote Key Features of Brogen Electric Portal Axle Distributed Drive Adopts the distributed drive technology for the precise control of torque and speed of each wheel independently. Compact & Lightweight​ The compact layout integrates the motor, suspension system, and drive axle, reducing the need for complex components and space required by traditional drivetrains. Independent Suspension​ The four-airbag independent suspension structure results in lower noise and more stable steering. Technical Parameters Model OEEA1100K Motor Type PMSM Motor Power (Rated / Peak) 2×55 kW / 2×90 kW Maximum Motor Speed 9500 rpm Motor Output Torque (Rated / Peak) 2×140 N.m / 2×350 N.m Rated Voltage 540 VDC IP Rate IP67 Axle Weight 850 kg Rated Axle Load 9000 kg Maximum Wheel Speed 540 rpm Gear Ratio 17.55 Rim Size 22.5 inch Tire Size 305/70R22.5 385/65R22.5 Brake Air disc brake Maximum Steering Angle ±18° Basic Structure The four-airbag double wishbone design offers reduced unsprung mass for a smoother ride with improved comfort and stability. With high torque and power density, the dual motors provide a strong and reliable output. The reducer  reduces the motor output speed to increase torque. The Motor Controller controls the motor to operate at the desired speed, angle, direction, and response time. Other Electronic Components: accelerator pedal sensors, brake pedal sensors, Hall-effect wheel speed sensors, Hall-effect steering angle sensors, roll angle sensors, yaw rate sensors, and controller hardware. Working Principle The VCU calculates the total torque demand based on the driver’s acceleration or deceleration intent.  The electric drive control unit (DCU) allocates the total torque between the left and right drive motors based on the steering angle, vehicle posture sensors, and road surface traction coefficients.  The left and right motor controllers (or 2-in-1 integrated motor controller), upon receiving the instructions, convert the energy from the battery to the necessary power for the drive motors, ensuring the vehicle’s stability and handling. Solution Benefits Low-Floor Design Adapts to the fully flat low-floor design and allows for easy one-step entry, providing a spacious aisle and reducing the risk of passenger falls. IP67 Protection An IP67 protection rating effectively prevents the intrusion of dust and water, providing enhanced performance in challenging conditions. Lower Maintenance Costs Utilizes maintenance-free wheel hub units, lowering maintenance costs. The advanced EDS ensures tire replacement intervals exceed 100,000 kilometers. Core Technology – Distributed Drive Electric Powertrain Traditional Electric Powertrain Solution Centralized Drive → Poor driving maneuverability Centralized Brake → Long braking distance Centralized Steering → Large turning radius Long Mechanical Transmission Chain Significant energy transmission losses; Poor applicability across vehicle models; Insufficient passenger space Distributed Drive Electric Powertrain Solution Drive / Brake Decoupling Distributed Drive → Enhanced control on complex surfaces Distributed Brake → Reduced braking distance on complex surfaces Distributed Steering Four-wheel Independent Steering → Reduces turning radius; enables lateral movement and zero-radius turns; significantly enhancing maneuverability Eliminates Mechanical Transmission → Increases user space; reduces energy transmission losses Our Projects Our distributed electric drive axle systems have been successfully implemented in city buses across Europe, the Middle East, Asia, and other regions. Incorporating advanced design concepts and control strategies, we prioritize the safety and reliability of our systems, delivering profitability for public transport vehicle manufacturers. Hydrogen buses with 320 kW eaxles Buses with the low-floor design Airport shuttle bus with 14T eaxles Pur electric buses with our eaxles 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 Public Transport Electrification Solutions Distributed Drive Electric Portal Axle for E-Buses Electric Axles for Buses 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

20 kW Onboard Charger for Truck, Bus, Municipal Vehicle, Air-Cooled This 20 kW onboard charger (OBC) is engineered for electric commercial vehicles, including buses, trucks, and construction machinery. It supports three-phase AC input, with an adjustable DC output voltage range, poviding flexibility to meet diverse charging requirements. Enhanced Charging Efficiency: The adjustable DC output voltage range ensures compatibility with various battery types, optimizing charging efficiency and reducing downtime. Improved System Robustness: The digital control and comprehensive protection features contribute to a more resilient charging system, minimizing the risk of damage and maintenance needs. Flexible Integration: The CAN interface communication allows for integration with existing vehicle monitoring systems, facilitating easy parameter adjustments and system monitoring. Cost-Effective Operation: The air-cooled design reduces the need for complex cooling systems, lowering operational costs and simplifying maintenance procedures. Technical Parameters Model Input Voltage Range Rated Output Power Rated Output Voltage Output Voltage Range Output Current Range TR3621 152-456 VAC 20 kW 80 VDC 0-105 VDC 0-240 A TR3622 152-456 VAC 20 kW 108 VDC 0-135 VDC 0-180 A TR3623 152-456 VAC 20 kW 144 VDC 0-180 VDC 0-132 A TR3624 152-456 VAC 20 kW 360 VDC 0-500 VDC 0-54 A TR3625 152-456 VAC 20 kW 540 VDC 0-720 VDC 0-36 A TR3626 152-456 VAC 20 kW 700 VDC 0-850 VDC 0-24 A Relevant Solutions All Posts Autonomous Vehicles Charger & Converter EV Industry EV Motor Heavy Transport Industry Insight Light Commercial Vehicles Marine Electrification Public Transportation Specialty Equipment Technologies   Back EV Motor EV On Board Charger & DC-DC Converter Combo Public Transport Electrification Solutions Heavy-Duty Truck Electrification Solutions Contact Us Get in touch with us by sending us an email, using the Whatsapp number below, or filling in the form below. We usually reply within 2 business days. Email: contact@brogenevsolution.com Respond within 1 business day Whatsapp: +8619352173376 Business hours: 9 am to 6 pm, GMT+8, Mon. to Fri. LinkedIn channel Follow us for regular updates > YouTube channel Ev systems introduction & industry insights > ContactFill in the form and we will get in touch with you within 2 business days.Please enable JavaScript in your browser to complete this form.Please enable JavaScript in your browser to complete this form. Name * FirstLast Work Email *Company Name *Your Project Type *– Please select –Car, SUV, MPVBus, coach, trainLCV (pickup truck, light-duty truck, etc.)HCV (heavy-duty truck, tractor, trailer, concrete mixer, etc.)Construction machinery (excavator, forklift, crane, bulldozer, loader, etc.)Vessel, boat, ship, yacht, etc.Others (please write it in the note)Your Interested Solutions *– Please select –Motore-AxleBatteryChassisAuxiliary inverterOBC / DCDC / PDUAir brake compressorEPS / EHPS / SbW / eRCBBTMSOthers (please write it in the note)Do you have other contact info? (Whatsapp, Wechat, Skype, etc.)Please introduce your project and your request here. * Checkbox * I consent to receive updates on products and events from Brogen, and give consent based on Brogen’s Privacy Policy. Submit

SbW System in Electric Vehicles: Detailed Explanation The Steer-by-Wire (SbW) system is a cutting-edge technology that significantly improves the steering mechanism in modern vehicles, particularly in the realm of electric vehicles. Traditional steering systems are mechanical, where the driver manipulates the steering wheel, transforming movement to the steering wheels via linkages and steering mechanisms. The SbW system, however, eliminates this mechanical connection, relying entirely on electrical signals to control the steering. This technological shift unlocks new possibilities for vehicle design and performance, enabling more precise, customizable steering characteristics and greater vehicle safety. 1. Overview of the SbW System The SbW system consists of three core components: steering wheel assembly, steering actuator assembly, and main controller (ECU). Additional systems, such as fail-safe mechanisms and power supply systems, support the overall functionality and reliability of the system. 2. How the SbW System Works The SbW system operates by detecting the driver’s steering intentions through sensors. These data points are then transmitted via a data bus to the vehicle’s ECU, which processes the information and sends feedback commands to the steering actuator system. This system controls the movement of the wheels, ensuring they reach the required angles. The steering angle and torque feedback are sent back to the system, completing the cycle of control. 3. Key Features of the SbW System 1. Enhanced Automotive Safety Performance The SbW system removes mechanical components like the steering column, reducing the risk of injury during collisions. The intelligent ECU continuously monitors the driving conditions, adjusting the system to ensure optimal safety. In extreme conditions, the system can stabilize the vehicle automatically. 2. Improved Handling and Maneuverability The SbW system dynamically adjusts the steering ratio based on driving parameters such as speed, traction, and road conditions. At low speeds, the steering ratio is reduced, requiring less wheel rotation for tight turns and parking. At higher speeds, the ratio increases for improved stability and handling during straight-line driving. 3. Enhanced Road Feel for Drivers Without a mechanical connection between the steering wheel and the wheels, the SbW system uses simulated feedback to provide drivers with a realistic “road feel.” This feedback is derived from the vehicle’s actual driving and road conditions, ensuring that only useful information is relayed to the driver, resulting in a more natural driving experience. 4. Advantages of the SbW System Improved Handling Stability: The SbW system synchronizes the steering wheel and actuator, allowing for more responsive and precise control, which enhances driving stability. Enhanced Comfort: By eliminating vibrations caused by uneven surfaces or imbalances in the steering mechanism, the SbW system provides a smoother, more comfortable ride. Energy Efficiency: The SbW system only activates during steering input, optimizing energy consumption and contributing to improved fuel efficiency and eco-friendliness. Increased Passive Safety: In the event of a collision, the SbW system significantly reduces the impact force transmitted through the steering column, enhancing driver safety. Weight Reduction: By eliminating the mechanical linkages, the SbW system reduces vehicle weight by approximately 5 kg, contributing to vehicle light-weighting efforts. 5. Challenges for the SbW System Power Requirements: The SbW system requires high-power actuators and complex algorithms to ensure accurate force feedback and steering control. Reliability and Safety Concerns: As with any new technology, improving the safety and reliability of the SbW system remains a critical focus for automotive manufacturers. Increased Cost: The inclusion of redundant components and advanced sensors can increase the cost and weight of the system, which may present challenges in mass adoption. 6. Future Trends of the SbW System The rise of intelligent driving technologies and the growing popularity of electric vehicles positions the SbW system as a key component in future vehicle designs. With advancements in autonomous driving and smart vehicle technologies, SbW is expected to become a mainstream solution, offering drivers a more accurate, safe, and comfortable driving experience. Ongoing research and development by automotive manufacturers will continue to drive innovations in SbW technology, unlocking new possibilities for the automotive industry. Brogen Steer-by-Wire Technology At Brogen, we offer a customized steer-by-wire system specifically developed for autonomous vehicles, adaptable to multiple operating modes (mechanical mode, power-assisted mode, and angle control mode). Our solutions are designed to meet the diverse needs of different customers, offering various design options such as electric power assistance and intelligent driving. Our series of SbW products feature high intelligence and integration, making them ideal for applications in human-machine collaboration, autonomous driving scenarios, and various layout configurations. Currently, our SbW products are being utilized in low-to-medium speed autonomous vehicle chassis, supporting commercial applications in driverless logistics and autonomous urban distribution. Support seamless transitions between human-machine collaboration modes in autonomous vehicles. Deliver rapid steering response with a latency of less than 50 ms. Manage steering angle overshoot effectively. Ensure precise steering control accuracy. Allow for steering angle and angular velocity control commands to be transmitted via bus communication, independent of manual electromechanical systems. Learn more here: https://brogenevsolution.com/steer-by-wire-sbw-system-oem-odm-manufacturer/ Business inquiry: contact@brogenEVSolution.com Contact Us Get in touch with us by sending us an email, using the Whatsapp number below, or filling in the form below. We usually reply within 2 business days. Email: contact@brogenevsolution.com Respond within 1 business day Whatsapp: +8619352173376 Business hours: 9 am to 6 pm, GMT+8, Mon. to Fri.   LinkedIn channel Follow us for regular updates >   YouTube channel Ev systems introduction & industry insights > ContactFill in the form and we will get in touch with you within 2 business days.Please enable JavaScript in your browser to complete this form.Please enable JavaScript in your browser to complete this form. Name * FirstLast Work Email *Company Name *Your Project Type *– Please select –Car, SUV, MPVBus, coach, trainLCV (pickup truck, light-duty truck, etc.)HCV (heavy-duty truck, tractor, trailer, concrete mixer, etc.)Construction machinery (excavator, forklift, crane, bulldozer, loader, etc.)Vessel, boat, ship, yacht, etc.Others (please write it in the note)Your Interested Solutions *– Please select –Motore-AxleBatteryChassisAuxiliary inverterOBC / DCDC / PDUAir brake compressorEPS / EHPS / SbW / eRCBBTMSOthers (please write it in the note)Do you have other contact info? (Whatsapp,

Top 4 Trends in Automotive Steering Systems in 2025 Steering systems are one of the most essential components of any vehicle, impacting safety, control, and efficiency. As automotive technology continues to evolve, so do the demands on them, particularly with the rise of electric vehicles (EVs). Let’s explore the current trends shaping the future of automotive steering systems, with a focus on Electric Power Steering (EPS), Steer-by-Wire (SbW), and innovations designed to improve vehicle performance, safety, and comfort in 2025 and beyond. 1. Widespread Adoption and Optimization of Electric Power Steering (EPS) The adoption and optimization of Electric Power Steering (EPS) will become a mainstream trend in the automotive industry. With the growing popularity of electric vehicles, EPS will see expanded use due to its high efficiency and energy-saving features. In the coming years, EPS technology will be further refined to reduce energy consumption and enhance response speed. Additionally, EPS will be integrated more deeply with other vehicle electronic systems, such as brakes and suspension, for more efficient coordinated control. Moreover, Steer-by-Wire technology, which replaces traditional mechanical connections with electronic signals, will also make significant advancements. This will improve steering precision and response times, while providing safer steering control for autonomous vehicles. 2. Intelligent and Adaptive Steering Systems The trend towards intelligent and adaptive steering systems will play a critical role in the future of automotive technology. Steering systems will evolve to automatically adjust steering force and feedback based on driver habits, road conditions, and vehicle speed, offering a more personalized driving experience. By integrating sensor technology and artificial intelligence (AI), these systems will be able to detect real-time road conditions, such as slippery surfaces or obstacles, and automatically adjust steering strategies to improve safety. These adaptive systems will be deeply integrated with autonomous driving technologies, enabling precise path tracking and obstacle avoidance. Additionally, redundant designs will ensure that these systems continue to function effectively even if part of the system fails, enhancing both safety and reliability. 3. Focus on Energy Efficiency, Sustainability, and Personalized Comfort As environmental concerns and fuel efficiency remain at the forefront of automotive development, future steering systems will place increased emphasis on energy efficiency and sustainability. Steering systems will be designed to reduce the load on vehicle powertrains, particularly in electric vehicles, which require maximum battery efficiency. Moreover, eco-friendly materials will be incorporated into the design of steering systems to minimize environmental impact. Beyond energy conservation, personalized comfort will be a key focus. Steering systems will allow drivers to choose from different steering feedback modes, such as sport or comfort, based on personal preference. In addition, smarter power assistance will help reduce driver fatigue, especially during long drives. On the safety front, steering systems will be equipped with fault detection and self-repair capabilities. These systems will also be integrated with ADAS (Advanced Driver Assistance Systems) to offer lane-keeping, automatic obstacle avoidance, and other active safety features. 4. Advanced Materials, New Manufacturing Processes, and Vehicle Connectivity The application of new materials and advanced manufacturing processes will play a pivotal role in the continued innovation of steering systems. Lightweight, high-strength materials such as carbon fiber and aluminum alloys, along with cutting-edge technologies like 3D printing, will enable the creation of more complex and reliable steering components, leading to enhanced performance. Additionally, steering systems will benefit from increased vehicle-to-vehicle (V2V) and vehicle-to-infrastructure (V2X) connectivity, enabling collaborative steering control across connected vehicles. Cloud-based data analysis will allow for real-time optimization of steering strategies, adapting to various driving environments and enhancing overall performance and safety. Conclusion: Steering Systems in 2025 and Beyond By 2025, automotive steering system will be more intelligent, efficient, and sustainable than ever before. From the widespread adoption of Electric Power Steering (EPS) to the breakthrough advancements in Steer-by-Wire technology, the future of steering is set to offer a more responsive, personalized, and safe driving experience. The integration of AI, adaptive features, and eco-friendly materials will redefine how we interact with vehicles, while vehicle connectivity and advanced manufacturing processes will push the boundaries of steering performance and reliability. As the automotive industry moves toward greater sustainability and automation, steering systems will continue to evolve, playing a pivotal role in shaping the future of electric mobility and autonomous driving. How Can We Help? At Brogen, we specialize in the development, production, and sales of electric power steering solutions for the automotive industry since 2007. Our power steering system range has expanded from hydraulic systems to electric solutions like EHPS, eRCB, EPS, and SbW, with over 2,500 models for both traditional and electric vehicles. In response to the growing demand for commercial vehicle steering upgrades, we’ve focused on developing EPS systems for light, medium, and heavy commercial vehicles, achieving mass production through continuous R&D innovation. Brogen EPS Factory Energy efficient Light and responsive steering Flexible system layout Low noise, high comfort, and active safety Fast matching and rapid development Compatibility with ADAS and autonomous driving Learn more here: https://brogenevsolution.com/electric-power-steering-solutions/ Business inquiry: contact@brogenEVSolution.com Contact Us Get in touch with us by sending us an email, using the Whatsapp number below, or filling in the form below. We usually reply within 2 business days. Email: contact@brogenevsolution.com Respond within 1 business day Whatsapp: +8619352173376 Business hours: 9 am to 6 pm, GMT+8, Mon. to Fri.   LinkedIn channel Follow us for regular updates >   YouTube channel Ev systems introduction & industry insights > ContactFill in the form and we will get in touch with you within 2 business days.Please enable JavaScript in your browser to complete this form.Please enable JavaScript in your browser to complete this form. Name * FirstLast Work Email *Company Name *Your Project Type *– Please select –Car, SUV, MPVBus, coach, trainLCV (pickup truck, light-duty truck, etc.)HCV (heavy-duty truck, tractor, trailer, concrete mixer, etc.)Construction machinery (excavator, forklift, crane, bulldozer, loader, etc.)Vessel, boat, ship, yacht, etc.Others (please write it in the note)Your Interested Solutions *– Please select –Motore-AxleBatteryChassisAuxiliary inverterOBC / DCDC / PDUAir brake compressorEPS / EHPS / SbW / eRCBBTMSOthers (please write it in the note)Do you have

Electronic Differential Lock (EDL/EDS): Technology Overview What is Electronic Differential Lock or System (EDL/EDS)? An Electronic Differential Lock or System (EDS/EDL) refers to the use of electronic control to manage the speed of the left and right wheels, enabling them to rotate at different speeds. This system adjusts the speed or torque of the drive motors independently for each wheel, allowing the vehicle to steer effectively while turning. Essentially, EDS optimizes torque distribution between wheels for efficient and stable maneuvering, particularly in vehicles with distributed drive systems. Different Ways to Achieve Electronic Differential and Their Pros & Cons The key challenge in differential steering is ensuring the wheel rotational speed matches the speed of the wheel‘s axle to prevent skidding or dragging. In traditional central-drive vehicles, mechanical differentials coordinate the wheel speeds. However, distributed drive vehicles, where the left and right drive wheels are not mechanically connected, rely on electronic differential control to solve this problem. There are two primary methods for implementing EDS: Wheel Speed-Based Control: This method controls the wheel speed and can use the Ackermann-Jeantand steering model. It calculates the theoretical speed of the left and right drive wheels in real time and controls them accordingly. This approach is simple but has significant limitations and can cause vehicle instability and excessive tire wear. When driving on uneven terrain, the suspension’s vertical movement can cause a mismatch between the real and theoretical wheel hub speeds, which degrades the control effect, resulting in inconsistencies in the wheel speed control and potential slip or drag. Additionally, during high-speed turns, tire lateral slip characteristics significantly change compared to low-speed scenarios, making the Ackermann model unsuitable for control, and wheel speed control can impact vehicle stability. Ackermann-Jeantand steering model Wheel force Motor Torque-Based Control: This method uses the drive wheel motor torque as the control variable, instead of controlling wheel speed, allowing the wheels to rotate freely according to their load. Since each drive wheel can rotate independently, as long as the wheel-tire-road friction does not exceed the limit, the friction force on the road will balance the driving force. In the stable range of tire attachment characteristics, road friction is a monotonous function of slip ratio, meaning there is a direct correspondence between friction force and slip ratio. As long as the motor torque does not exceed the attachment limit, the slip ratio remains within the stable region of tire attachment characteristics, and no differential issue arises, preventing wheel slip or drag. When the motor torque exceeds the friction limit, wheel slip will occur, and anti-slip control will be activated. This method can implement adaptive differential steering, where the control system outputs motor torque commands based on the vehicle’s motion state, and the wheel speed is determined by the tire force balance. This method, combined with anti-slip control, performs well for electronic differential functions, but its control algorithms become more complex as driving conditions change. Increasingly, researchers prefer using motor torque as the control variable, which is closely linked to anti-slip research. Electronic differential research based on torque control and anti-slip technology is an integrated field, and many scholars worldwide have explored this from the perspective of vehicle dynamics control. Current Development of Commercial Vehicles Compared to passenger cars, the advantages of distributed drive systems are more evident in commercial vehicles. First, the high integration of distributed drive systems enables low-floor, wide-passenger designs for city buses, facilitating quick and barrier-free transit, especially in large and medium-sized cities with an aging population, making distributed drive buses increasingly popular. Additionally, by eliminating mechanical differentials and drive shafts, lightweight independent suspension and single-tire configurations can be used, improving system efficiency. Lastly, distributed drive systems allow for independent, precise, and continuous control of drive and braking forces for each drive wheel, fully utilizing tire-road friction characteristics and enabling traction control, anti-lock braking, and stability control. Based on these advantages, the promotion of distributed drive technology in city buses is on the rise. Engineering Development Process for Distributed Drive Electronic Differential Lock The engineering development process for distributed drive electronic differential control technology follows the V-model, from initial function definition and requirement analysis to final application and mass production. The V-model emphasizes collaboration and speed in software algorithm development, integrating algorithm implementation and verification, shortening the development cycle while ensuring high-quality software algorithms. The development process consists of two phases: the software algorithm development phase and the product testing phase. At the start of software algorithm development, requirements are defined, including market demands and product functionalities. After understanding these requirements, designers can proceed with system architecture and product functionality design. The algorithm development team will then create models and simulations, using Matlab for algorithm design. Offline simulations, including model-in-loop and software-in-loop simulations, are performed before downloading the algorithm to rapid prototyping devices for online simulation and algorithm verification.  After this, the software-generated C code is tested with the ECU on a test bench. Once the software and hardware are tested, control parameters are optimized during real-world road testing. This includes calibrating the vehicle’s performance to its best state and conducting reliability tests over a set distance. After completing the above steps, the product can be mass-produced and launched into the market, with continuous feedback for algorithm optimization and upgrades. Each step in the process is crucial for ensuring reliable products and functionality. Project Development Personnel, Timeline, and Budget 6.1 Personnel Compared to traditional central drive systems, the development of distributed drive systems involves more complexity due to the harsh operating environment of the motors. This requires a broader range of expertise. For example, the development of the new energy system involves roles such as: 2 people for gearbox design 2 people for motor design 1 person for motor controller matching 1 person for power system performance and efficiency matching 2 people for vehicle control strategy development 1 person for vehicle calibration, etc. In the chassis design, roles include: 1 person for axle design 2 people for suspension design 1 person for brake design 1 person

Electric Bus Powertrain: Wheel-Side Drive Motor – Introduction and Analysis Electric buses have traditionally relied on centralized drive systems. Two main configurations have dominated the market: Direct-Drive Motor System In these systems, the electric motor directly replaces the internal combustion engine. This approach offers a simple and straightforward system architecture, with mature vehicle structural design technology that has made it the mainstream configuration for battery electric buses. Motor + Gearbox Systems This configuration, which combines an electric motor with an Automatic Manual Transmission (AMT) gearbox, delivers superior performance on steep slopes, meeting the demands of mountainous or scenic areas. Although it borrows extensively from conventional fuel vehicle technology and is relatively mature, including an automatic shifting mechanism can compromise reliability, leading to practical challenges in real-world operations. As electric bus powertrain systems evolve toward higher speeds, greater integration, and lightweight designs, distributed electric drive technology—exemplified by wheel-side drive motors—has begun to enter the practical stage. Compared with centralized drive systems, wheel-side drive configurations eliminate the need for transmission shafts, main reduction gears, and differentials. This results in a shorter power transmission chain, higher transmission efficiency, and a more compact structure.  In addition, precise control of wheel-side motor speed and torque enables integrated functions such as vehicle propulsion, braking, differential action, and energy recovery. Owing to its high degree of freedom and functional expandability, the wheel-side drive system has become a focal point in the research and development of pure electric bus powertrain systems. In addition, precise control of wheel-side motor speed and torque enables integrated functions such as vehicle propulsion, braking, differential action, and energy recovery. Owing to its high degree of freedom and functional expandability, the wheel-side drive system has become a focal point in the research and development of pure electric bus powertrain systems. Electric Bus Powertrain: Wheel-Side Motor Drive Configurations Wheel-side motor solutions for battery electric buses bridge the gap between centralized and hub motor designs. They typically integrate a motor with a fixed-ratio reducer mounted on the chassis, directly driving the wheels via short axles. Two primary configurations exist: A. Fixed-Motor Configuration The fixed-motor configuration usually takes the form of an integrated wheel-side drive axle. In this design, the conventional axle housing and half-shafts are eliminated, and the drive motor is mounted adjacent to the wheel. Despite maintaining a rigid axle structure, this design can employ either steel leaf springs or a combination of air springs and coil-over shock absorbers.  Brogen wheel-side drive system with fixed motors Key advantages: Reduced Weight and Space: By removing the axle housing, casing, and half-shafts, the overall structure is significantly lighter and more compact. High-Speed Motor Integration: With the use of high-speed motors paired with high reduction ratios (often through a planetary gear structure), the design minimizes motor volume and weight while increasing power density. Robust Performance: Our integrated wheel-side drive axle, for example, features two high-speed motors mounted on either side of the axle. With a two-stage reduction system, it delivers enhanced torque and is capable of handling high axle loads—ideal for heavy-duty, low-floor city buses. B. Swing-Motor Configuration In the swing-motor configuration, the traditional rigid axle is abandoned in favor of an independent air suspension system. Here, both the drive motors and reducers are mounted directly on the suspension, and the reducer can be designed as either a two-stage or planetary gear system. Brogen wheel-side drive system with swing motor and independent suspension Key advantages: Lower Unsprung Mass: The elimination of the rigid axle structure reduces unsprung mass. A well-designed suspension can effectively transfer the motor’s mass to the vehicle body, improving ride comfort and handling. Enhanced Cabin Design: This configuration enables increased interior space, a wider aisle, and lower floor heights—critical factors in the design of modern low-floor city buses. Benefits of Wheel-Side Drive Motors in Electric Buses The adoption of a wheel-side drive motor for an electric bus powertrain – where flexible electrical connections replace some mechanical linkages – offers significant benefits in electric bus design and performance. Below are the primary advantages:  1. Increased Cabin Space and Lower Floor Height Low-floor city buses are a growing trend. In these designs, the area from the front passenger door to the last axle forms a continuous, step-free zone. Lowering the interior floor not only reduces the number and height of steps – making boarding and movement inside the bus easier, safer, and more accessible for all passengers – but also increases headroom in key areas. For instance, the structural dimensions of an integrated wheel-side drive axle can reduce floor installation height by approximately 70 mm, achieving a floor clearance as low as 290 mm. This enhanced design meets both interior space and passenger safety requirements. 2. Vehicle Lightweighting Reducing the overall vehicle weight directly contributes to lower energy consumption. Research indicates that a 10% reduction in vehicle weight can lead to a 6% – 8% reduction in energy consumption. The wheel-side drive motor configuration achieves significant weight savings through: High-speed motor design: Increased motor speeds allow for lower torque requirements, which in turn reduces cost and weight. System integration: Consolidating components (motor, reducer, controller) into an integrated design reduces the need for additional attachments and cabling, thereby lowering both the weight and cost of the powertrain. 3. Enhanced Vehicle Dynamics Mainstream single-motor direct-drive configurations often struggle with steep climbs and mid-to-high-speed acceleration, while dual-motor systems face challenges in weight and cost. Additionally, motor+AMT configurations can suffer from power interruptions during gear shifts. In contrast, the wheel-side motor configuration: Dual-Motor Advantage: By deploying two motors, the power demand on each unit is reduced while maintaining overall system performance. Elimination of the Main Reducer: Replacing the main reducer with a high-reduction ratio gear system (using helical gears) not only simplifies the transmission patch but also improves strength, reduces manufacturing complexity, and lowers costs. 4. Improved Transmission Efficiency Eliminating the traditional main reducer and differential from the electric bus powertrain means that power is transmitted through a shorter chain – enhancing efficiency. The use of helical gears in the