Author name: brogenevsolution.com

3-in-1 on-board charger (OBC) + DCDC+ PDU
Industry Insight

Everything You Need to Know About The On Board Charger for Electric Vehicles

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Everything You Need to Know About The On Board Charger for Electric Vehicles What is an on-board charger? An On Board Charger (OBC) is a device that converts AC power into DC power. It transforms the AC voltage from charging stations into the DC voltage required by the battery. OBCs are installed in electric vehicles (EVs) and plug-in hybrid electric vehicles (PHEVs). They enable these vehicles to be charged using AC power from residential or public charging stations. The output power of an OBC typically ranges from 3.3 kW to 22 kW. A significant advantage of OBCs is their ability to charge electric vehicles using standard household outlets. What are the different methods of charging an electric vehicle? Electric vehicle charging stations can be broadly categorized into two types: AC charging stations and DC charging stations. AC Charging Stations As the name suggests, AC charging stations provide alternating current (AC) from the electrical grid to electric vehicles. The onboard charger then converts the AC to direct current (DC) to charge the vehicle’s battery. These stations, also known as Level 1 and Level 2 chargers, are used in residential and commercial applications. The advantage of AC charging stations is that the OBC can adjust the voltage and current according to the vehicle’s needs. This eliminates the need for the charging station to communicate with the electric vehicle. However, the disadvantage is their low output power. It results in longer charging times. AC power from the grid is delivered directly to the OBC via an Electric Vehicle Supply Equipment (EVSE), which then converts it to DC and charges the battery via the Battery Management System (BMS). DC Charging Stations DC chargers take AC power from the grid and convert it to DC, bypassing the OBC to charge the battery pack directly. These chargers typically deliver high voltages up to 600V and currents up to 400A. Unlike AC chargers, which take 8-16 hours to charge a vehicle, DC charging stations can fully charge an electric vehicle in approximately 30 minutes. These stations are also known as Level 3 chargers, with the chargers referred to as DC Fast Chargers (DCFC) or Superchargers. The main advantage of DC chargers is their fast charging time. However, they are technically complex and need to communicate with the electric vehicle to charge it efficiently and safely. As shown in the typical DC charging system diagram, the EVSE bypasses the OBC and delivers DC power directly to the battery pack. The standard capacity of a DC charging station ranges from 50 kW to 300 kW. It’s more than 6 times the capacity of a single-phase on-board charger. However, AC charging through the OBC has less impact on the battery and minimizes battery aging. What are the functions of the onboard charger? The primary function of the OBC is to manage the charging process from the power grid to the vehicle’s battery. The OBC is designed to charge the battery as quickly as possible while minimizing battery degradation. It offers two charging methods: constant current charging and constant voltage charging. Constant current charging: this method charges the battery faster, but cannot fully charge the vehicle. Constant voltage charging: also known as trickle charging, this method charges the battery more slowly but with greater control, allowing the vehicle to reach a full charge. To optimize charging speed, the OBC uses constant current charging at the beginning of the charge cycle and switches to constant voltage charging toward the end. The OBC also plays a critical role in the bi-directional charging mode available in some vehicles. This capability allows it to convert DC power from the high-voltage battery pack back to AC power, supporting AC loads (Vehicle to Load, V2L), grid power (Vehicle to Grid, V2G), and even home power (Vehicle to Home, V2H). Hardware architecture of the OBC The OBC primarily consists of the following hardware components: Input Voltage Measurement Circuit: Measures the input voltage to control the conversion circuit. Input Filter: Suppresses internal noise or noise from external devices. Full-Wave Rectification Circuit: Converts AC voltage to DC voltage. Power Factor Correction (PFC) Circuit: Improves power efficiency degraded by waveform phase shifts. Voltage Conversion Circuit: Converts voltage using components such as an isolation transformer and field-effect transistor (FET) switches. Output Filter: Suppresses noise generated internally. Output Voltage Measurement Circuit: Measures the output voltage to control the conversion circuit. Control Circuit: Manages the conversion circuit and other components. DC/DC Converter: Provides power to the control circuit. Communication Interface: Facilitates communication with external devices. What are the trends and challenges in OBC development? The OBC is a critical component for both battery electric vehicles (BEVs) and plug-in hybrid electric vehicles (PHEVs). As the number of electric vehicles increases, the number of vehicles equipped with OBCs will also increase. At the same time, more electric vehicles will be equipped with DC fast charging capabilities.Key trends and challenges in OBC development include: Adaptation to 800V High-Voltage Platforms: OBCs will be compatible with these high-voltage systems. Increased Output Power: As 800V platforms become more common and battery capacities grow, OBCs will need to provide higher output power. Future OBCs will need to feature high voltage (high withstand voltage), high current, low loss, high heat resistance, and compact size. Bidirectional Charging Capability: OBCs will need to support bidirectional charging, allowing the conversion of DC power from high-voltage battery packs into AC power to support external AC loads. Use of Discrete High-Voltage Components: These components will be widely used in OBCs to enhance performance. Increased Power Requirements: The trend towards fast charging will significantly increase the power requirements of OBC topologies. Our On Board Charger Systems Engineered for top-tier power conversion efficiency and remarkable power density, our chargers cover a broad power spectrum, ranging from 3.3 kW to 40 kW. Whether you’re driving a passenger car, bus, van, or LCV, or require upfit power supply for specialized vehicles, our comprehensive solutions ensure seamless integration and optimal performance.  Applicable for both PHEV and BEV Wide input range, 1 phase

mining truck-1
Heavy Transport, Specialty Equipment

Pure Electric Mining Truck Project

Leave a Comment / Heavy Transport, Specialty Equipment /

This collaborative project enabled our client, a leading construction equipment manufacturer, to replace diesel mining trucks with its own line of purpose-built, all-electric mining truck models designed specifically for rugged, mountainous terrain. These innovative electric mining trucks offer many advantages, including ample battery capacity, reliable performance, and adaptability in a variety of working environments. This strategic shift has not only resulted in fuel cost savings but has also made a significant dent in carbon emissions. As a result, it represents a win-win scenario that offers both economic benefits and environmental stewardship – an offer that has been enthusiastically embraced by our client’s customer base. Project Overview Project timeline: 2021 Offered products: E-powertrain system (dual motor power uninterrupted solution) Application: 120-ton to 180-ton mining truck Provided services: Pre-sales consultation; solution planning; technical coordination; product testing; shipping; post-sales technical support; onsite debugging Challenge Our client, a seasoned manufacturer of construction equipment, places a strong emphasis on thorough, scientifically supported research prior to making any significant decisions. They recognize that establishing trust is the pivotal first step in our partnership. They also highlight that relying solely on branded core components does not guarantee consistent equipment quality, especially with the introduction of novel electric technologies requiring heightened caution. In addition, design integrity is fundamental. How effectively we address challenges has a significant impact on our customers’ perceptions. Our commitment extends beyond product delivery; we’re entrusted with ensuring the smooth flow of their vehicle production operations. Our Approach To meet the demanding power requirements of steep-grade applications, we introduce our dual-motor electric powertrain system. Designed to excel under continuous heavy loads, it delivers an impressive power output of up to 540 kW at rated capacity and 800 kW at maximum, equivalent to over 1000 horsepower. Even on a daunting 30% grade, it rises to the challenge, effortlessly pulling heavy loads while maintaining rapid movement, significantly improving transportation efficiency. Beyond design, our customer appreciates our proactive approach to problem-solving. In particular, they praise our “delivery is the beginning of service, not the end of sales” ethos. We don’t just provide products; we provide comprehensive green transportation solutions. Our commitment extends beyond the mere delivery of equipment; we ensure seamless production operations for our users. Providing dedicated field service personnel is just the beginning. When faced with complex challenges, we mobilize our R&D and quality teams and go the extra mile to support our customers’ production needs. Solutions We’ve Provided Motor 1 & Motor 2 Parameters Gearbox Parameters Gear 1 3 5 2 4 6 Speed ratio 9.16 3.02 1.22 5.27 2.17 1 System Parameters Contact If you’re seeking an EV solution for your project, feel free to fill out the following form. You can also write to us at contact@brogenevsolution.com Our experts will promptly respond within 2 business days, crafting a tailored EV system to empower your projects.

Brogen epowertrain-motor 100kW Electric Motor
Industry Insight, Light Commercial Vehicles

What Are The Benefits of Direct Drive System for Electric LCVs?

Leave a Comment / Industry Insight, Light Commercial Vehicles /

Two Major E-Powertrain Solutions for LCVs Electric power has become the primary driving force for new energy light trucks. These trucks typically employ two main power layouts: one utilizes a traditional drive motor paired with a gearbox and rear axle, while the other employs a combination of a motor and an electric drive axle. Initially, many automakers adopted the former approach to capitalize on emerging opportunities driven by policies and market demands. This involved directly modifying the architecture of conventional fuel-powered light trucks to create pure electric models, maintaining consistency with traditional fuel-based layouts. Developing an entirely new platform for new energy light trucks entails significant investments in manpower and finances, along with lengthy product validation processes. The “gas-to-electric” conversion model streamlines this process by simply replacing the original engine and transmission assembly with a motor and single-stage reducer. This not only reduces development time but also simplifies post-vehicle maintenance, resulting in lower costs. Moreover, the motor + reducer + rear axle combination closely resembles the power structure of diesel vehicles. The electric drive axle represents a novel technical solution that integrates components like the motor, reducer, and differential, enabling the axle to generate power output. Its major advantages lie in reducing vehicle weight and significantly increasing chassis space due to its high integration, thereby enhancing overall efficiency. Currently, traditional “gas-to-electric” new energy LCVs remain the preferred choice for EV builders due to their lower procurement and maintenance costs. Although they may be less technologically advanced than electric LCVs utilizing e-axle technology, their minor modifications to traditional power layouts ensure stronger reliability and stability by retaining the original vehicle structure. Brogen’s Direct Drive System for EV LCVs At Brogen, we offer both direct drive systems and electric axle systems. For our direct drive motor systems, in addition to single motor + controller systems, we also offer high-speed motor + controller + reducer systems, available in both high voltage and low voltage platforms. MCU, DCDC, Brake DCAC, Steering DCAC, and PDU functions are integrated into the high-voltage controller. Benefits include Example Configurations Motor + Controller Motor + Gearbox + Controller More EV Systems for LCVs Contact Struggling to find the perfect EV solution for your project? No need to fret! Simply fill out the form below, and we’ll tailor a solution to suit your needs. Alternatively, you can reach out to us directly at contact@brogenevsolution.com. Rest assured, we strive to respond promptly within 2 business days to ensure the seamless progress of your EV program. Let’s work together to make your electric vehicle vision a reality!

portugal project (1)
Heavy Transport

40-ton Electric Heavy Truck Project in Portugal

Leave a Comment / Heavy Transport /

40-ton Electric Heavy Truck Project in Portugal Introduction This project marks a significant milestone as we partnered with a new energy company in Portugal to successfully deliver their first all-electric heavy-duty truck, signaling a decisive step towards zero carbon emissions. It embodies our mission and underscores our commitment to accelerating the transition to green renewable energy, advancing humanity’s journey to carbon neutrality, and driving societal progress. Project Overview Project timeline: 2021 Offered solutions: e-powertrain system, power steering system, braking system, 3-in-1 auxiliary converter Application model: 40-ton pure electric heavy duty truck Provided services: pre-sales consultation, solution planning, technical coordination, product testing, post-sales technical support, remote debugging Challenge Collaborating with this company on their first electric heavy-duty truck project presents both exciting prospects and challenges for both parties involved. For them, embarking on their first electric heavy truck endeavor poses a learning curve. Given their parent company’s background in construction and energy storage, their newly established new energy department may lack the technical expertise needed for designing and developing comprehensive EV solutions. Additionally, the R&D costs could be substantial, potentially leading to longer project timelines and delayed vehicle launches. For us, our foremost task is to establish clear lines of communication and grasp a thorough understanding of their requirements, preferences, and expectations for the heavy truck project. From there, we must devise tailored EV solutions to precisely meet their needs. Effective collaboration with their team is paramount to address any technical hurdles, tackle challenges head-on, and ensure seamless project execution. Our Approach In assisting this company in its EV truck project, our approach has been anchored in robust communication from inception to completion, ensuring a thorough understanding of our client’s needs. We’ve tailored the EV solution precisely to their specifications, guiding them through any technical challenges encountered along the way. Furthermore, we extend ongoing remote technical support and engage in cooperative discussions with their team to address any lingering technical concerns. Solutions We Have Provided 1. E-Powertrain (Electric Motor + Gearbox) We’ve equipped the truck with our 350 kW 2-in-1 integrated e-powertrain system, seamlessly combining the EV motor and gearbox alongside an independent MCU. The electric motor used in this project System Parameters Rated / peak power: 220 / 350 kW Rated voltage: 618 V Rated / peak speed: 1400 / 3000 rpm Rated / peak torque: 1500 / 2500 N.m Rated / peak current: 340 / 610 A Protection level: IP67/H Cooling method: liquid cooling Applicable models: heavy truck System Features The electric powertrain system with the gearbox Integrated motor: a streamlined design for convenient vehicle layout, eliminating phase harness EMC radiation while minimizing energy loss. Real-time weight measurement: ensures precision within 10%, while dynamic slope measurement boasts an accuracy of ±0.2° and static accuracy of ±0.1°. Adaptive shift timing: responds to factors like vehicle weight, slope, and driver input, including throttle system, pedal depth, and acceleration, adjusting shift points dynamically. Shift time clocks in at under 0.7s. Digital intelligent shifting: employs an electronically controlled shifting system for precise gear changes, enhancing overall performance. The electric powertrain system efficiency map 2. Power Steering System (Electric Hydraulic Power Steering) We have supplied the 4 kW electric hydraulic power steering system (EHPS) on the truck. The integrated design combines a motor, steering pump, ECU, DC power processing, and oil tank into a single unit, which maximizes space utilization, simplifies system integration, and offers compact size and light weight. The EHPS for this project System Parameters Rated power: 4 kW Rated voltage: AC 380 V Rated current: 7.4 A Rated torque: 34.2 N.m Rated speed: 1200 rpm Peak power: 10.75 kW Back EMF (rated speed): 140 V/krpm Peak current: 19.2 A Peak torque: 85.6 N.m Peak speed: 1281 rpm Controlled flow: 18±2 L/min Insulation class: H Rated efficiency: 92% Line resistance (20°C): 1.88Ω Phase resistance (20°C): 0.9Ω Working frequency: 80 Hz Protection class: IP67 Pole pairs: 4 Q-axis inductance: 9.3 mH D-axis inductance: 12.5 mH 3. Braking System (Air Brake Compressor) We have supplied the 4 kW oil-free air brake compressor for the electric heavy truck. With the latest technology, our air compressor delivers air that’s entirely oil and water-free, eliminating concerns of oil emulsification, leaks, and fire hazards. Its innovative structural design minimizes energy waste during compression, optimizing efficiency. The air brake compressor used in this project System Parameters Rated exhaust: 380 L/min Rated exhaust pressure: 1 Mpa Exhaust pressure: 1.2 Mpa Dimensions: 560*335*370 mm Motor power: 4 kW Weight: 65 kg Operating temperature: -40°C ~ + 60°C Protection class: IP67 4. Auxiliary Inverter We have used the 3-in-1 auxiliary inverter for the project, which consists of a DC/DC converter, a DC/AC oil pump, and a DC/AC air compressor. This integrated and lightweight design significantly reduces system weight and size. It not only offers a lightweight solution but also delivers substantial space, wiring, and cost savings for electric commercial vehicles. Result The e-powertrain system installed on the truck Our systems performed exceptionally well on the client’s 40-ton electric heavy trucks, earning high satisfaction from the client. As a result, they promptly initiated another project involving a 26-ton logistics truck (AGV) for port operations, utilizing our systems to efficiently transport goods between sites. Our Customizable Solution for Heavy-Duty Trucks For heavy commercial vehicles, we offer an extensive range of EV systems, including e-powertrains, batteries, chassis, braking systems, steering systems, and more. Our comprehensive solutions are designed to enhance fleet operational efficiency and elevate safety standards in heavy-duty transportation. Discover HCV 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

E-axles that integrates motors, MCU , transmission system electric drive axle
Heavy Transport, Technologies

Introduction of the Electric Drive Axle for Heavy Duty Trucks

Leave a Comment / Heavy Transport, Technologies /

Introduction of the Electric Drive Axle for Heavy Duty Trucks Sales of electric trucks have continued to rise in 2023 compared to 2022, driven by strong and ambitious government policies. For heavy-duty vehicle manufacturers, adopting a reliable and powerful electric powertrain system is crucial to staying competitive in this rapidly expanding market. As demand for sustainable transportation grows, integrating advanced electric systems will be key to their long-term success. The Evolution of the Electric Drive Axle for Heavy Duty Trucks The evolution of heavy-duty trucks has gone through three distinct phases, with a vision of the future of electric mobility shaping the landscape. First, traditional fuel-powered trucks dominated the roads, with cabs that were flat and high drag coefficient. These trucks relied on engine-based power systems located at the bottom of the cab. The next phase saw the emergence of gas-electric heavy-duty trucks, which retained the central drive model but swapped the engine for electric motors. However, these vehicles retained conventional propulsion systems that were bulky, inefficient, and compromised cargo space due to rear-mounted battery boxes. Today, all-electric heavy-duty trucks typically use the electric axle as the e-powertrain system. EV solutions with electric drive axles provide increased transmission efficiency and space flexibility. At the same time, cabin structures are redesigned to lower the center of gravity and improve aerodynamics. Why The Electric Drive Axle is a Better Choice for Battery-Electric Trucks Building on the advanced design of the electric axle drive system, the structural design of the chassis for pure electric heavy-duty trucks can be further optimized, resulting in more efficient use of space. For example, all-electric heavy-duty trucks using our e-axle solution can eliminate traditional driveshafts, allowing the chassis structure to be redesigned to accommodate the battery spread flat across the chassis. This layout has many advantages: Placing the battery flat at the bottom allows for a larger battery capacity, extending the range while minimizing intrusion into the cargo area. By using a box-shaped beam frame structure, the battery pack is placed within the box frame structure, ensuring both battery safety and full utilization of the chassis load capacity. Lowering the vehicle’s overall center of gravity reduces the risk of rollover during cornering and improves driving stability and maneuverability. The overall appearance of the vehicle is improved. Analysis of Different Electric Powertrain Systems for Heavy Trucks At present, the primary e-powertrain configurations for electric heavy trucks encompass several distinct forms: Different configurations of electric powertrains for heavy-duty trucks Analysis of configuration characteristics of different electric drive axles Comparison of dual-motor central drive and dual-motor distribute drive systems An Example of Our Electric Drive Axle for Heavy Duty Trucks Let’s take our 360 kW eAxle as an example, which is suitable for 6×4 and 4×2 tractors and heavy-duty trucks. Compared to similar eAxle products on the market, our eAxle integrates two motors, providing higher system power and torque with a smaller footprint, and has 100% regenerative braking capability, eliminating mechanical differentials. This results in lower space requirements, weight, and cost. Our electric drive axle installed on the heavy-duty truck Additional Safety Redundancy In addition, our distributed drive system minimizes layout losses, reduces weight, and incorporates fault and safety strategies. The two drive systems are completely independent, consisting of a motor + 2-speed AMT and wheel-side reducer, using electronic differential technology and independently controlling the left and right drive systems. In the event of a single motor failure, the other motor can continue to operate normally, ensuring system safety. 23% System Weight Reduction Weight of different electric powertrain solutions for heavy trucks In contrast to the central drive system, our distributed drive system has achieved a weight reduction of 23.6%. Similarly, compared to the motor gearbox integration system, our distributed drive system has managed to reduce weight by 23.9%. Good Passability The distributed drive system boasts a 7.3% increase in ground clearance compared to the central drive system. Moreover, it achieves an even greater elevation of 11.7% when compared to the motor gearbox integration system. Higher Transmission Efficiency Compared to the central drive system, our distributed drive system demonstrates a 6% enhancement in overall transmission efficiency. High Security Currently, heavy-duty trucks are only equipped with ABS and lack ASR, ESC, and EDL. With our EV motor’s electronic differential system strategy control, heavy trucks can be equipped with ASR/ESC safety configurations, improving vehicle traction, stability, and safety. Technical Parameters for Brogen Electric Drive Axle for Heavy Duty Vehicles Our e-axle for heavy trucks showcased at Automechanika Shanghai 2023 Motor power (peak/rated): 2×180 kW / 2×80 kW Motor speed (max.): 9500 rpm Motor torque (peak/rated): 2×520 N.m / 2×260 N.m Maximum output torque: 50000 N.m Rated voltage: 540 VDC Axle weight: 950 kg Rated axle load: 13000 kg Wheel speed (max.): 620 rpm Gear ratio: 49.4/15.3 Solution Advantages The dual motor structure ensures uninterrupted power during gear shifts. Reduces vehicle weight by 300 kg, boosting loading capacity. A compact design saves chassis space and lowers the center of gravity for better stability. Maximum output torque of 50,000 N.m, ideal for 4×2 tractors. Passed 1 million load-bearing tests with 2.5 times load capacity, ensuring reliability. Equipped with ASR function for enhanced grip on slippery surfaces, ensuring safer driving. Relevant Solution All Posts EV Industry EV Products EV Projects Electric Axle for Heavy-duty Truck Read More Contact Us Get in touch with us by sending us an email, using the Whatsapp number below, or filling in the form below. We usually reply within 2 business days. 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,

electric power steering system for bus
Public Transportation, Technologies

R-EPS System for (Hybrid) Battery Electric Bus

Leave a Comment / Public Transportation, Technologies /

R-EPS System for (Hybrid) Electric Buses Introduction In 2023, an OEM (automotive manufacturer) for buses enlisted our expertise for the electric power steering system implementation in their buses. We recommended our latest R-EPS solution, specifically engineered for large commercial vehicles like buses. Our R-EPS (Rack-assist Electric Power Steering) system operates as a pure electric power steering system, regulating the power steering motor’s operation and torque output. This control is facilitated through the processing and calculation of inputs from the vehicle’s driving speed, steering torque, and steering angle, managed by the steering electronic control unit (ECU). The system serves as a pivotal device, optimizing the power steering effect to ensure smooth and precise vehicle maneuverability. Technical Features of Our R-EPS System for Buses Here are the key features of our R-EPS system for buses: Streamlined modification process and excellent adaptability to the recirculating ball hydraulic steering system layout. Reduced component count ensures high assembly efficiency. Responsive steering and exceptional maneuverability. High-efficiency design with low friction and operating noise. High product integration and compact structure for space optimization. Utilizes non-contact sensor with angle signal for precision. Equipped with overheating and under-voltage protection for enhanced reliability. Maintains steering assistance even during normal failure modes. Features IP67 protection for robust performance in varied conditions. Tailored to meet the demands of ADAS and automatic driving, particularly for large steering-by-wire chassis applications. Installation of the R-EPS on the Battery Electric Bus We’ve successfully integrated our EPS into the 8.5-meter pure electric bus, which has a maximum front axle load capacity of 4500 kg. Our electric power steering system has replaced several electro-hydraulic steering components originally present in the bus. Real Vehicle Calibration and Testing Our EPS system has undergone real vehicle calibration, ensuring optimal performance and functionality. Power Supply: Aligning with the original low-voltage wiring harness of the vehicle chassis, the power line is routed to the 24V battery, which then supplies power to the EPS. CAN Communication Integration: Receives vehicle speed signals in accordance with the vehicle CAN communication protocol. Activation of EPS System: Initiate the vehicle by shifting to the START gear, thereby entering the ready mode. Steering Function Implementation: Experience enhanced maneuverability with our EPS system’s responsive steering capabilities. From spot steering to normal road driving, our EPS provides noticeable power assistance, resulting in lighter steering torque and precise steering response. Active Return to Center Functionality: While navigating urban roads, our system ensures a smooth and seamless return to the center position when the steering wheel is released after turning to any angle, enhancing the overall driving experience and safety. Learn More About This R-EPS System All Posts EV Industry EV Products EV Projects Electric Power Steering for Hybrid & Full Electric Buses July 12, 2024/No Comments Electric Power Steering System for Bus Our rack-assist type electric power steering system (R-EPS) for large commercial vehicles like buses… Read More Contact Us Get in touch with us by sending us an email, using the Whatsapp number below, or filling in the form below. We usually reply within 2 business days. 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

turkey electric bus project with our battery system
Public Transportation

Brogen’s EV Battery Solution Powers Turkey’s Battery Electric Bus Project

Public Transportation /

8-Meter and 12-Meter Battery Electric Bus Project in Turkey Project Overview Project Start Time: 2022 Project Vehicle Types: 8-meter and 12-meter battery electric bus Country: Turkey Systems We Provided: battery packs, PDU (with BMS), BTMS, EVCC Project Introduction In response to Turkey’s growing environmental initiatives, a well-established Turkish commercial vehicle manufacturer embarked on an electric bus project, focusing on 8-meter and 12-meter models. Leveraging our expertise in electric bus battery systems, we delivered a tailored solution that included a 280 kWh battery system, a custom BMS, and a cooling unit. This case study outlines our approach to overcoming technical challenges and providing comprehensive support throughout the project. Client Background The client, a prominent commercial vehicle manufacturer in Turkey, has a strong reputation for producing traditional fuel-powered buses. In 2022, motivated by Turkey’s environmental policies, the company shifted its focus to electric buses, initiating a new product for 8-meter and 12-meter electric models. Given our history as their supplier of EHPS and air brake compressors, they entrusted us with developing a high-quality electric bus battery system for their new fleet. Challenges Customized Battery System Design: The 8-meter and 12-meter electric buses required different battery capacities and layouts, necessitating a bespoke approach for each vehicle size. Unique Voltage Requirements: The battery-electric buses were equipped with a 700 V high-voltage motor, which is not a common voltage for battery packs, posing a challenge in designing a compatible system. Space Optimization: The battery packs needed to be efficiently integrated into the limited space within the buses while meeting energy requirements. Preparing for the shipment of the battery systems How We Worked Initial Consultation and Design Conducted detailed simulations and calculations based on the client’s vehicle specifications, including speed, range, and certification requirements. Designed custom battery packs with different capacities to meet the distinct needs of the 8-meter and 12-meter buses. Technical Development Developed a specialized BMS tailored to the buses’ specifications. Created circuit diagrams and optimized the internal and external wiring to fit the vehicle layouts. Carefully selected connectors, considering power currents and interlock requirements. Ensured compatibility between the charging infrastructure and the battery system, adhering to European standards. Testing and Validation Conducted joint testing with the client to verify the charging system’s functionality. Provided technical support during the installation and initial operation phases, including software updates and remote troubleshooting. Systems We Provided Battery modules BMS PDU Power output wiring harness Vehicle communication wiring harness CCS charging seat wiring harness Battery input harness Power wire harness between the battery boxes Communication wiring harness between the battery boxes EVCC Charge harness Battery Packs Used in This Project Our standard battery pack Our battery factory The battery packs used in this project Other Systems in This Project 8 kW BTMS BMS with PDU Wiring harness Brogen Standard EV Battery Pack Solution Independent secondary control: facilitates easy installation and maintenance. Integrated liquid cooling: strong adaptability to high-temperature environments. Full aluminum casing: lightweight design. High energy density. Protection level: IP67. Standard charging: 1C. Standard equipped with heating film. Parameters C Box C Box C Box C Box Dimension 1060*630*240 mm Battery cell 105 Ah 173 Ah 230 Ah 280 Ah Grouping 2P48S 1P63S 1P48S 1P36S System capacity 210 Ah 173 Ah 230 Ah 280 Ah Rated system voltage 153.6 V 202.86 V 153.6 V 115.2 V System energy 32.256 kWh 35.095 kWh 35.328 kWh 32.256 kWh Battery System Configuration Example Based on Our Standard Battery Packs Battery System Parameters Note System nominal voltage 614.4 V The monomer is 3.2 V System operating voltage range min 480 V Monomeric 2.5 V~3.65 V max 700.8 V System rated capacity 460 Ah 25 ± 2℃, 1 / 3C, 100% DOD, the shipment capacity is not less than 98% of the rated capacity System storage energy 282.62 kWh 25 ± 2℃, 1 / 3C, 100% DOD, the shipped power is not less than 98% of the rated power System life end remdual capacity ≥368 Ah 5 years, not less than 80% of the rated capacity System group mode 2P192S Series and parallel connection Battery system weight About  1920 kg Specific energy of the system About 150 Wh/kg Maximum continuous charging current 230 A Maximum duration of 0.5C Maximum pulse charging current (30s) 460 A 30s max. 1C Maximum continuous discharge current 460 A Maximum duration of 1C Maximum pulse discharge current (30s) 920 A 30s maximum of 2C Maximum allowable feedback charging current (10s) 920 A 50% SOC, 20 – 55℃ / 10s max 2C SOC working range 10~100 % Insulation requirements ≥200 MΩ 500 VDC, total positive / negative against the shell Protection level of the battery box body IP67 System cooling mode water cooling system System heating mode water cooling system Charge on shipment (SOC) 20%~50% The SOC status is consistent with the same batch of shipment Download Brochure 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

Spain-Electric-Boat-EV-Project-With-EV-Batteries
Marine Electrification

Brogen EV Batteries Power Spain’s First All-Electric Boat Project

Marine Electrification /

In 2023, Brogen partnered with a prominent shipbuilding company in Spain to pioneer the country’s first all-electric boat, championing a zero-emission agenda and combating marine pollution while advancing efforts to decarbonize ports. Charged with providing a robust propulsion system for the electric boat, our engagement with Spain’s esteemed electric boat manufacturer marked a significant milestone in the field of green marine transportation. Our involvement spanned the design and implementation phases, where our team of experts demonstrated unwavering professionalism and an unwavering commitment to service excellence. At the outset, our pre-sales team worked diligently with the company to fully understand its requirements. Our engineers then meticulously designed a custom electric propulsion system to meet the unique specifications of their all-electric vessel project, working seamlessly with their technical staff to fine-tune the systems. After six months of project completion, we were pleased to receive a letter of commendation from the company’s President, recognizing our commitment to excellence and innovation. Our contributions not only facilitated the seamless implementation of the project but also ensured its continued performance and reliability. Remarkably, even six months after completion, our system continues to perform flawlessly, exceeding expectations across multiple metrics. Praise from the company “Your team’s ability to address challenges with professionalism and efficiency has been a major factor in the project’s success. This experience has not only strengthened our professional relationship but also reinforced our trust in you as a valuable and reliable partner.” said the President. At Brogen, our commitment is to provide customizable EV solutions supported by new technologies that help EV companies succeed while promoting environmental sustainability. Talk to our experts to find out how we can empower your EV project: contact@brogenevsolution.com We usually respond within 2 business days. Click the button below to learn more about our EV battery solutions for commercial vehicles such as trucks, buses, vessels, and construction machinery.

blade-battery-project light duty truck
Light Commercial Vehicles, Technologies

Mini Truck Project Powered by Blade Battery Solution

Light Commercial Vehicles, Technologies /

Discover our EV battery solution for urban delivery with innovative Blade battery technology. This all-electric light-duty truck, powered by the Blade battery pack, is ideal for urban delivery. With zero emissions and exceptional performance, it offers a sustainable solution for urban logistics. With a 45 kWh Blade battery pack, it achieves a range of 280 km, and even 260 km at half load, ensuring reliable and efficient transportation. Compared to traditional EV battery packs, our blade battery packs offer higher energy density by eliminating the battery module, which significantly increases volume utilization. In addition, they prioritize safety by passing the nail penetration test without flame or explosion, ensuring reliable quality and stability. In the urban delivery market, electric commercial vehicles offer unmatched advantages over conventional fuel trucks, with operating costs as low as $0.03 to $0.05 per kilometer. This new generation of electric trucks offers superior battery technology, capacity and range, as well as superior flexibility, chassis load capacity and driving comfort. More parameters about this electric truck: At Brogen, we offer comprehensive EV solutions for commercial vehicles, including motors, e-axles, batteries, chassis, and more, designed to electrify your fleet and reduce operating costs. Contact us at contact@brogenevsolution.com to discuss how we can empower your EV project. Click the button below to explore our blade battery solution.

axial flux motor on mixing tank
Heavy Transport, Specialty Equipment

Concrete Mixer’s Mixing Drum Electrification Project

Heavy Transport, Specialty Equipment /

Client:  A concrete company Demand:  An EV solution for their 22 concrete mixer trucks to save fuel costs Introduction:  In 2022, a concrete company approached us and wanted an EV solution for their concrete mixer trucks to reduce the fuel costs.   Challenges Faced by the Concrete Company:  In the concrete mixer industry, as long as the mixing tank is turning, the engine cannot be turned off. This has been a persistant challenge, leading to high fuel consumption. Between 36% and 70% of the operating conditions for concrete mixers involve idling. Although they operate for 12 to 14 hours a day, only half of that time is spent in actual motion. Prolonged idling not only significantly increases fuel consumption but also necessitates frequent engine maintenance, reducing the lifespan of the vehicles. The Axial Flux Motor Solution for Concrete Mixer:  Starting in 2022, they implemented our EV system using axial flux motors. The system replaced the traditional hydraulic transmission of concrete mixers with an electrically powered attachement, achieving a separation of engine power and mixing drum power. During loading, unloading, or normail driving, the system’s onboard power battery provides the rotating power for the mixing drum autonomously, eliminating the reliance on engine power. Consequently, during vehicle idling, engine shutdown no longer affects the drum’s rotation, allowing the air conditioning system to function normally and resulting in a significant reduction in fuel consumption. Morever, the system incorporates an energy-efficient loop mechanism that automatically collects surplus power from the engine during vehicle operation to recharge the battery. As a result, the system minimally draws on the engine’s power, further enhancing fuel efficiency. Result:  After almost a year of practical application, the results speak volumes: some trucks have achieved monthly fuel cost savings of up to $1000. Despite the inital investment required for the system, the company anticipates a swift return on investment, with costs recovered within a few months. Contact us 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 fleet, you can contact us at contact@brogenevsolution.com. We usually respond within 2 business days.

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