Author name: brogenevsolution.com

hybrid suv project with brogen onboard charger
Light Commercial Vehicles

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

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

electric light truck project in south korea
Light Commercial Vehicles

Electric Light Truck Project in South Korea With Our EV Systems

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

electric pickup truck development
Industry Insight, Light Commercial Vehicles

Optimizing Electric Pickup Truck Development: E-Axles Benefits

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

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

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

60kW / 100kW Electric Motor Assembly for Pickup Truck, Light Truck, Van This 60kW / 100kW e-powertrain system integrates the 60kW / 100kW electric motor, gearbox, and motor controller into one single compact unit. By utilizing shared housing, wiring harnesses, and other components, the system achieves reduced weight, lower costs, and higher efficiency. The integrated e-drive system eliminates the need for separate wiring connections between parts, which also reduces electromagnetic interference. With a three-phase direct connection, the system is simple and reliable. The compact design gives more flexibility in vehicle layout, making it easier for automotive manufacturers to create modular and scalable vehicle platforms. This helps speed up product development, lower costs, and improve efficiency. Additionally, the lower center of gravity improves handling, while increasing torque capacity and the overall efficiency of the e-powertrain system. How It Works This system is used as the drive system for electric vehicles. It’s powered by a PMSM, with high-precision torque and speed control achieved through the software control of an MCU. The system converts high-voltage DC power into an adjustable AC source with variable amplitude and frequency to control and drive the PMSM, ensuring high precision and efficiency. A single-stage reduction gearbox amplifies the torque and reduces the speed. The torque is transmitted via the reduction gearbox flange to the vehicle’s front and rear axles, achieving the desired veehicle propulsion and control. This system is suitable for applications in light commercial vehicles (LCVs), including pickup trucks, vans, light duty trucks. Technical Parameters Motor Parameters Rated voltage: 380 V Rated power: 60 kW Peak power: 100 kW Rated torque: 120 N.m Peak torque: 280 N.m @min Peak speed: 12000 rpm Protection level: IP67 Weight:52 kg Dimension: φ261×339 mm Motor Controller Short-time working current: 420 A Continuous working current: 190 A Operating voltage range: 250 V – 450 V Weight:8 kg Reducer Maximum input torque: 350 N.m Maximum input speed: 12000 rpm Speed ratio: 3.04 E-Powertrain Efficiency Map Contact Us Get in touch with us by sending us an email, using the Whatsapp number below, or filling in the form below. We usually reply within 2 business days. Email: contact@brogenevsolution.com Respond within 1 business day Whatsapp: +8619352173376 Business hours: 9 am to 6 pm, GMT+8, Mon. to Fri. LinkedIn channel Follow us for regular updates > YouTube channel Ev systems introduction & industry insights > ContactFill in the form and we will get in touch with you within 2 business days.Please enable JavaScript in your browser to complete this form.Please enable JavaScript in your browser to complete this form. Name * FirstLast Work Email *Company Name *Your Project Type *– Please select –Car, SUV, MPVBus, coach, trainLCV (pickup truck, light-duty truck, etc.)HCV (heavy-duty truck, tractor, trailer, concrete mixer, etc.)Construction machinery (excavator, forklift, crane, bulldozer, loader, etc.)Vessel, boat, ship, yacht, etc.Others (please write it in the note)Your Interested Solutions *– Please select –Motore-AxleBatteryChassisAuxiliary inverterOBC / DCDC / PDUAir brake compressorEPS / EHPS / SbW / eRCBBTMSOthers (please write it in the note)Do you have other contact info? (Whatsapp, Wechat, Skype, etc.)Please introduce your project and your request here. * Checkbox * I consent to receive updates on products and events from Brogen, and give consent based on Brogen’s Privacy Policy. Submit

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

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

3-ton Electric Pickup Truck in Thailand With Our E-Powertrain System Project Overview: Our client, a technology company specializing in electric vehicle conversion in Thailand, approached us in 2022 with a specific requirement for their electric pickup truck project. They needed an e-powertrain system featuring an electric motor with a rated power of 60 kW. After a detailed assessment of their project specifications and vehicle requirements, we proposed two optimized e-powertrain systems to them. The client ultimately selected the system that best met the demands of their electric pickup truck project. Client testing the pickup truck on the road Solution and Implementation Once our e-powertrain system was integrated into the client’s electric pickup truck, they conducted rigorous testing, including water wading, high-speed performance, and other essential assessments. Our system successfully passed all tests, resulting in the client being highly satisfied with the performance of their upgraded electric pickup truck. Expansion of Partnership Due to the successful outcome of the electric pickup truck project, the client expanded their collaboration with us, requesting e-powertrain solutions for additional vehicles, including their 6-ton medium-duty trucks and 25-ton heavy-duty trucks. Throughout this collaboration,  we also supplied key systems such as onboard chargers and battery thermal management systems. Ongoing Collaboration This partnership has now flourished over the past two years, with our solutions continuously meeting the client’s high standards of their electric vehicle conversions. The strong relationship between our companies continues to grow as we support their efforts to electrify a wider range of vehicles. E-Powertrain System Used in This Project Motor Parameters Rated power: 60 kW Peak power: 115 kW Rated torque: 143 N.m Peak torque: 325 N.m Rated speed: 4000 rpm Peak speed: 12000 rpm Reducer Parameter Speed ratio: single – 3.037 Controller Parameter Voltage range: 200 – 450 V Rated voltage: 336 VDC Current module:384 A Rated current: 174 A At Brogen, we provide EV solutions for commercial vehicles, including buses, vans, light-duty trucks, heavy-duty trucks, mining trucks, vessels, and other construction machinery. If you’re looking for an EV solution for your project, you can contact us at contact@brogenevsolution.com. Contact Us Get in touch with us by sending us an email, using the Whatsapp number below, or filling in the form below. We usually reply within 2 business days. Email: contact@brogenevsolution.com Respond within 1 business day Whatsapp: +8619352173376 Business hours: 9 am to 6 pm, GMT+8, Mon. to Fri. LinkedIn channel Follow us for regular updates > YouTube channel Ev systems introduction & industry insights > ContactFill in the form and we will get in touch with you within 2 business days.Please enable JavaScript in your browser to complete this form.Please enable JavaScript in your browser to complete this form. Name * FirstLast Work Email *Company Name *Your Project Type *– Please select –Car, SUV, MPVBus, coach, trainLCV (pickup truck, light-duty truck, etc.)HCV (heavy-duty truck, tractor, trailer, concrete mixer, etc.)Construction machinery (excavator, forklift, crane, bulldozer, loader, etc.)Vessel, boat, ship, yacht, etc.Others (please write it in the note)Your Interested Solutions *– Please select –Motore-AxleBatteryChassisAuxiliary inverterOBC / DCDC / PDUAir brake compressorEPS / EHPS / SbW / eRCBBTMSOthers (please write it in the note)Do you have other contact info? (Whatsapp, Wechat, Skype, etc.)Please introduce your project and your request here. * Checkbox * I consent to receive updates on products and events from Brogen, and give consent based on Brogen’s Privacy Policy. Submit

electric pickup truck axle - 1
Industry Insight, Light Commercial Vehicles

Electric Pickup Truck Axle: Understanding the Difference Between Flexible and Rigid Axles

Electric Pickup Truck Axle: Understanding the Difference Between Rigid and Flexible Axles Recently, BYD launched its first hybrid pickup truck: BYD SHARK in Mexico, showcasing its latest advancements in hybrid technology on a global stage. This vehicle, built on the DMO platform, features an off-road specific longitudinal EHS hybrid system in the front and a globally pioneering rear-drive electric powertrain at the rear. What sets this pickup apart is its “flexible axle” rear design, a significant departure from traditional pickups. As we enter the era of electric and hybrid pickups,  could traditional “rigid axles” become a thing of the past? What Are “Rigid Axles” and “Flexible Axles”? To understand this concept, it’s essential to know what an axle is. An axle, also known as a drive axle, connects the suspension to the vehicle’s frame or chassis, with wheels mounted at either end. It transmits power and supports the vehicle’s weight. Axles can be classified into two types based on their suspension structure: solid and independent. A solid axle, commonly known as a “rigid axle,” features a rigid beam that connects the wheels, ensuring they move in unison. On the other hand, a “flexible axle” uses an independent suspension system where the wheels can move independently, providing more flexibility and better ride comfort. The Shift to Flexible Axles in Electric Pickup Trucks In traditional pickup trucks, especially those with rear-wheel drive, the rear axle is typically a rigid axle because it needs to be rigid to handle the load. However, as pickups evolve into more passenger-friendly and electric-powered vehicles, many are transitioning to flexible axles. This allows the half-shafts between the differential and wheels to flex, offering better ride comfort and versatility. The BYD SHARK, mentioned earlier, is a prime example of this shift. Other electric pickup trucks, like the Radar RD6, Horizon, and various American models, also use flexible axles. The Tesla Cybertruck, Hummer EV, Ford F-150 Lightning, and Rivian R1T are all examples of electric trucks that have adopted this design. Even Toyota’s recently announced electric Hilux is expected to feature a flexible axle. Are Rigid Electric Pickup Truck Axles Becoming Obsolete? While many new electric pickup trucks are adopting flexible axles, some still use rigid axles, especially those designed for heavy-duty or off-road use. For instance, the Jiangling Daoda EV features a world-first high-performance oil-cooled coaxial electric drive axle, which is essentially a rigid axle integrated with an electric motor. This design offers superior load capacity, making it ideal for heavy-duty applications. Similarly, the Changan Hunter EV uses a hard axle structure for its electric drive axle. The single-motor rear-wheel-drive version delivers a maximum power of 110 kW and a torque of 300 Nm, retaining the characteristics of traditional solid axles while incorporating electric drive technology. Pros and Cons of Flexible and Rigid Electric Pickup Truck Axles Each type of axle has its advantages and disadvantages. Flexible axles, with their independent suspension, offer better ride comfort and are well-suited for light-duty, household, and light off-road use. However, they may compromise ground clearance, which can be a drawback on rough terrain. Additionally, the complex structure of flexible axles can limit customization options and increase the risk of damage when subjected to extreme conditions. Rigid axles, on the other hand, provide consistent ground clearance, making them more suitable for off-road and heavy-duty applications. They offer greater load capacity and are better suited for modifications. However, the added weight of a rigid axle, especially when integrated with an electric motor, can affect handling and reduce ride comfort. The Future of Electric Pickup Truck Axles While flexible axles are becoming more common, rigid electric drive axles remain essential for heavy-duty and off-road electric trucks. These axles provide consistent ground clearance, superior load capacity, and enhanced durability, making them ideal for demanding applications. Our rigid electric drive axles are designed to integrate seamlessly with electric powertrains, offering the strength and reliability needed for tough environments. As the market for electric trucks grows, hard axles will continue to be crucial for those who prioritize performance and durability. Learn more about our electric drive axle systems here.

DC_DC converters
Industry Insight

DC-DC Converter: Unlocking the Energy Code of Electric Vehicles (EV)

DC-DC Converter: Unlocking the Energy Code of Electric Vehicles Introduction to the DC-DC Converter The onboard DC-DC converter is a crucial component in electric vehicles (EVs). It’s primarily responsible for converting the high-voltage DC power from the battery into the low-voltage DC power needed by various electronic components and control systems within the vehicle. The operation of a DC-DC converter involves multiple modules, including power conversion, driving, and control, ensuring that energy is safely and efficiently transferred. Functions of the DC-DC Converter In electric vehicles, the DC-DC converter plays several key roles. First, it provides the necessary power for systems like power steering, air conditioning, and other auxiliary equipment, ensuring the vehicle operates smoothly. Additionally, since many of the electronic components and control systems in a pure electric vehicle use low-voltage power, the DC-DC converter ensures that the low-voltage battery is sufficiently charged. In some systems, the DC-DC converter even replaces the traditional 12V alternator, becoming the primary power source for recharging the high-voltage battery and supplying the 12V power load. DC-DC Converter Types There are various types of onboard DC-DC converters, including boost, buck, and buck-boost converters, which can be selected and configured based on specific needs. When selecting a converter, factors such as the vehicle’s top speed, acceleration, weight, maximum torque, and power requirements must be considered to ensure the converter’s power capacity meets the vehicle’s needs. Future Trends It’s worth noting that as EV technology continues to evolve, onboard DC-DC converters are also being optimized and upgraded. In the future, with the rise of higher voltage systems and the adoption of 48V systems, DC-DC converters will play an even more critical role in providing stable and efficient power to vehicles. Key Specifications of the Onboard DC-DC Converter The main specifications of onboard DC-DC converters cover several key parameters and characteristics, which not only impact the converter’s performance but also directly affect the stability and reliability of the vehicle’s electrical system. Here’s a detailed look at these key specifications: Output Current Capability: This refers to the maximum output current that the DC-DC converter can provide. This parameter directly determines whether the converter can meet the power demands of the vehicle’s electronic systems. It’s crucial to ensure the converter’s output current capability is robust enough to handle various load conditions. Conversion Efficiency: This indicates how efficiently the DC-DC converter transforms input power into output power. Higher efficiency means less energy loss, which is essential for improving the overall energy efficiency of the vehicle’s electronic systems. Therefore, when choosing a converter, preference should be given to products with high conversion efficiency. Power Rating: The power rating of the DC-DC converter is a critical specification, determining the scale of power the converter can handle. Different vehicle types often have varying power needs, so it’s important to select a converter with a power rating that matches the vehicle’s configuration and actual requirements. Size and Weight: Given the limited space inside electric vehicles, the size and weight of the DC-DC converter are important factors to consider. Smaller and lighter converters help save space and optimize vehicle layout. Thermal Performance: Thermal performance is key to the stability of the DC-DC converter. In high-temperature environments, good thermal performance ensures that the converter operates normally and avoids damage due to overheating. Therefore, the converter’s cooling method and effectiveness should be considered when selecting a unit. Electrical Safety Performance: The electrical safety performance of the DC-DC converter is also critical. This includes compliance with input-output wiring standards, grounding resistance requirements, and specifications for electrical clearance and creepage distance, all of which are necessary to ensure safe operation. Electromagnetic Compatibility (EMC): EMC refers to the DC-DC converter’s ability to operate without exceeding specified electromagnetic interference (EMI) levels, while also being resilient to external interference. This is vital for maintaining the stability and reliability of the vehicle’s electrical system. Reliability: Reliability reflects the DC-DC converter’s stability and durability during long-term operation. A highly reliable converter reduces the likelihood of faults and enhances the overall performance of the vehicle.   Topologies of the Onboard DC-DC Converter The topology of a DC-DC converter is a key factor in its design and performance. The topology determines the path and method of energy conversion, significantly impacting the converter’s efficiency, reliability, and cost. Here are some common topologies of onboard DC-DC converters: Non-Isolated Bidirectional DC-DC: Simple structure with direct component connections and no extra energy loss, leading to high efficiency. High capacitor requirements on the boost side. Main circuit structures include bidirectional half-bridge boost-buck circuits, bidirectional buck-boost circuits, bidirectional buck circuits, and bidirectional Zeta-Sepic circuits. Isolated Bidirectional DC-DC: Adds a high-frequency transformer to the non-isolated design, achieving electrical isolation. The circuit topology on both sides of the high-frequency transformer can be full-bridge, half-bridge, or push-pull types. Utilizes more power switches, offering a broader voltage range and the advantage of electrical isolation. Boost Converter Topology: Used to step up the input voltage to a higher voltage. Basic structure includes an inductor, switch, diode, and output filter capacitor. Buck Converter Topology: Used to step down the input voltage to a lower voltage. Simple structure with high efficiency, commonly used in automotive applications. Buck-Boost Converter Topology: Capable of both stepping up and stepping down the input voltage, suitable for situations where the input voltage varies widely. Can convert input voltage that is greater than, equal to, or less than the output voltage. Flyback Converter Topology: Suitable for low-power, high-voltage applications. Converts voltage through the storage and release of energy in a magnetic field. Half-Bridge Converter Topology: Another topology for converting input voltage to output voltage. Basic structure includes two switches, a pair of diodes, and an output filter capacitor. Brogen’s DC-DC Converter Systems At Brogen, we offer a comprehensive range of DC-DC converters designed to meet diverse needs. Our converters cover power options from 0.6 kW to 6 kW and are available with natural cooling, air cooling, and liquid cooling options. We provide both step-down and step-up configurations, with input voltage ranges from 40 – 700

electric axle system electric truck axle electric axle for lcv
Light Commercial Vehicles, Technologies

60 kW / 115 kW Electric Axle For Truck

60 kW / 115 kW Electric Axle for Truck This 60/115 kW electric axle for truck is specifically designed and developed for light commercial vehicles. It features a lightweight design, high efficiency, intelligence, low noise, and integration. Compared to traditional direct-drive systems, this electric truck axle assembly reduces overall weight by more than 100 kg and decreases energy consumption by over 5%. It is suitable for light commercial vehicles such as pickup trucks, light trucks, vans, buses, etc. Whatsapp: +8619352173376 Email: contact@brogenevsolution.com Download Brochure Get Custom Quote We Offer Best Features Lightweight The highly integrated drive system optimizes the chassis layout. The electric motor features a high rotation speed and compact size, resulting in a lightweight assembly that reduces the e-powertrain system by over 100 kg. Energy-Efficient This electric truck axle features a short drive chain, offering a 2% increase in transmission efficiency and 5% decrease in energy consumption compared to traditional direct drives. Lower Maintenance Costs The oil change interval for the main reducer extends to 100,000 km, resulting in higher uptime and lower maintenance costs – maximizing savings for fleet operators and drivers. System Advantages 100 kg reduce in weight compared to direct drive systems. 5% reduce in power consumption compared to direct drive systems. 350 N.m maximum torque for robust power during climbing. 100% counter torque for increased cruising range. Lower than 70 dB noise for a more pleasant driving experience. Technical Parameters Model 5PE A5PE (steering drive) Rated Axle Load 3500 kg 3500 kg 2700 kg Maximum Torque 5400 N.m 5800 N.m 5400 N.m Gear Ratio 15.58/16.60 16.60 15.58 Motor Voltage 360 V / 540 V 360 V / 540 V 360 V / 540 V Motor Rated / Peak Power 60 kW / 115 kW 60 kW / 115 kW 60 kW / 115 kW Motor Rated / Peak Torque 135 N.m / 325 N.m 135 N.m / 350 N.m 135 N.m / 350 N.m Motor Rated / Peak Speed 4244 rpm / 12000 rpm 4244 rpm / 12000 rpm 4244 rpm / 12000 rpm Explore More E-Axle Solutions Applications Contact Us Get in touch with us by sending us an email, using the Whatsapp number below, or filling in the form below. We usually reply within 2 business days. Email: contact@brogenevsolution.com Respond within 1 business day Whatsapp: +8619352173376 Business hours: 9 am to 6 pm, GMT+8, Mon. to Fri. LinkedIn channel Follow us for regular updates > YouTube channel Ev systems introduction & industry insights > ContactFill in the form and we will get in touch with you within 2 business days.Please enable JavaScript in your browser to complete this form.Please enable JavaScript in your browser to complete this form. Name * FirstLast Work Email *Company Name *Your Project Type *– Please select –Car, SUV, MPVBus, coach, trainLCV (pickup truck, light-duty truck, etc.)HCV (heavy-duty truck, tractor, trailer, concrete mixer, etc.)Construction machinery (excavator, forklift, crane, bulldozer, loader, etc.)Vessel, boat, ship, yacht, etc.Others (please write it in the note)Your Interested Solutions *– Please select –Motore-AxleBatteryChassisAuxiliary inverterOBC / DCDC / PDUAir brake compressorEPS / EHPS / SbW / eRCBBTMSOthers (please write it in the note)Do you have other contact info? (Whatsapp, Wechat, Skype, etc.)Please introduce your project and your request here. * Checkbox * I consent to receive updates on products and events from Brogen, and give consent based on Brogen’s Privacy Policy. Submit

250 kW electric motor (1)
Public Transportation, Technologies

120 kW / 250 kW Electric Motor for Bus, Truck, Rail Transit Vehicle

120 kW / 250 kW Electric Motor for Buses, Trucks, Rail Transit Vehicles This 250 kW electric motor is designed for larger commercial vehicles, such as buses ranging from 9 to 18 meters, rail transit vehicles, and trucks. Utilizing permanent magnet materials, the drive system is lightweight, achieving higher power density and optimal space utilization. Coupled with advanced motor control technology, it ensures precise speed, position, and torque control, perfectly matching the requirements of modern high-precision equipment. The application of the MES system (including visualized control of production progress, fine control of product quality, and full lifecycle management of equipment) ensures product consistency and stability. 250 kW Electric Motor Performance Curves 250 kW Electric Motor Parameters Rated power: 120 kW Peak power: 250 kW Rated torque: 1200 N.m Peak torque: 2800 N.m Rated speed: 955 rpm Peak speed: 2500 rpm DC BUS voltage: 540 V Rated efficiency: ≥96% Protection level: IP67 Peak current: 520 A Cooling method: liquid cooling Motor Control Unit Rated input voltage: DC 540 V Rated power: 200 kW Input voltage range: DC 350 V – 750 V Rated output current: 380 A Maximum output current: 570 A Output frequency range: 0 – 300 Hz Protection level: IP67 Cooling method: liquid cooling Discover Other EV Motor Solutions All Posts EV Industry EV Products EV Projects Electric Motors for Commercial Vehicles Electric Motors for Commercial Vehicles Our electric motors for commercial vehicles are ideal for buses, trucks, municipal vehicles, construction equipment,… Read More Contact Us Get in touch with us by sending us an email, using the Whatsapp number below, or filling in the form below. We usually reply within 2 business days. Whatsapp: +8619352173376 Email: contact@brogenevsolution.com ContactFill in the form and we will get in touch with you within 2 business days.Please enable JavaScript in your browser to complete this form.Please enable JavaScript in your browser to complete this form. Name * FirstLast Work Email *Company Name *Your EV Project Type *– Please select –BusLight-duty truckHeavy-duty truckConstruction machineryVesselOthers (please write it in the note)Your Interested Solutions *– Please select –MotorBatteryChassise-AxleAuxiliary inverterOBC / DCDC / PDUAir compressorEPS / EHPSBTMSOthers (please write it in the note)Do you have other contact info? (Whatsapp, Wechat, Skype, etc.)Please introduce your EV project and your request here. * Checkbox * I consent to receive updates on products and events from Brogen, and give consent based on Brogen’s Privacy Policy. Submit

heavy duty electric truck
Heavy Transport, Industry Insight

18-Ton Heavy-Duty Electric Truck – E-Powertrain Configuration

18-Ton Heavy Duty Electric Truck: E-Powertrain Configuration As electric vehicles continue to rise in popularity, pure electric light trucks and tractors are gaining traction due to their efficiency and cost-effectiveness. However, heavy trucks can also benefit from electrification. This 18-ton heavy duty electric truck features a powerful 322 kWh battery, providing an estimated range of approximately 460 kilometers under consistent driving conditions. This makes it an excellent choice for urban logistics and intercity transportation across various regions. 322 kWh EV Battery System This vehicle is equipped with a liquid-cooled battery systems boasting an impressive capacity of 322 kWh. The battery pack is securely integrated within the chassis frame, offering excellent protection and leaving ample space on both sides for additional installations, such as toolboxes. 160 kW Electric Drive Axle This vehicle is equipped with a two-speed electric drive axle, featuring a drive motor with a peak power of 160 kW and a maximum output torque of 27,600 N·m. The integration of the electric drive axle eliminates the need for components like the driveshaft and universal joints, enhancing overall efficiency and performance. Compact and Lightweight Design For cargo trucks, curb weight has always been a major concern, as it directly affects the vehicle’s loading capacity and consequently, the profitability of each trip. Even though this vehicle is equipped with a large 322 kWh battery system, its curb weight control is still quite impressive. The chassis has an unladen weight of only 7800 kg, with a gross vehicle weight of 18,000 kg. Conclusion Given the current competitive landscape in the logistics industry, businesses and individuals are continually striving to reduce costs and improve operational efficiency. With their outstanding economic performance and efficient transportation capabilities, pure heavy duty electric trucks have become a new choice for urban distribution and intercity transportation. Our Solution for Heavy Duty Electric Trucks At Brogen, our customizable EV systems accelerate heavy-duty electric truck development by reducing R&D costs and time, boosting efficiency, and providing a competitive advantage for EV manufacturers in the rapidly expanding market. Electric Axle 165 kW – 360 kW Explore Traction Battery Customizable Explore Auxiliary Inverter DC/DC, DC/AC, PDU Explore Contact Us Get in touch with us by sending us an email, using the Whatsapp number below, or filling in the form below. We usually reply within 2 business days. Whatsapp: +8619352173376 Email: contact@brogenevsolution.com ContactFill in the form and we will get in touch with you within 2 business days.Please enable JavaScript in your browser to complete this form.Please enable JavaScript in your browser to complete this form. Name * FirstLast Work Email *Company Name *Your EV Project Type *– Please select –BusLight-duty truckHeavy-duty truckConstruction machineryVesselOthers (please write it in the note)Your Interested Solutions *– Please select –MotorBatteryChassise-AxleAuxiliary inverterOBC / DCDC / PDUAir compressorEPS / EHPSBTMSOthers (please write it in the note)Do you have other contact info? (Whatsapp, Wechat, Skype, etc.)Please introduce your EV project and your request here. * Checkbox * I consent to receive updates on products and events from Brogen, and give consent based on Brogen’s Privacy Policy. Submit

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