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

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

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 electric motors for light commercial vehicles

EV Motor, Light Commercial Vehicles

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

60 kW / 100 kW Electric Motor for Light Truck, Van, Pickup This 60 kW / 100 kW e-powertrain system integrates the 60 kW / 100 kW 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 Model OECE1T10004 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 Reducer Maximum Input Torque 350 N.m Maximum Input Speed 12000 rpm Speed Ratio 3.04 E-Powertrain Efficiency Map Relevant Solutions All Posts Autonomous Vehicles EV Industry EV Motor Heavy Transport Industry Insight Light Commercial Vehicles Marine Electrification Public Transportation Specialty Equipment Technologies Back EV Motor Light Commercial Vehicle Electrification Solutions Electric Motors for Light Commercial Vehicles 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

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. Brogen Electric Pickup Truck Axle Solutions 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. At Brogen, we provide modular, scalable e-beam axle solutions tailored for electric pickup trucks. Our e-beam axle solution integrates a lightweight welded differential, die-cast aluminum housing, offset coaxial gearbox, and welded insert tube technology. These engineering optimizations significantly reduce axle mass, minimize the size of the center drive unit, and enhance overall vehicle dynamics compared to conventional designs. Discover our e-Beam axle solution for electric pickup trucks here: https://brogenevsolution.com/e-beam-axle/ We also offer parallel-axis e-axles for light commercial vehicles (LCVs): https://brogenevsolution.com/electric-axle-for-light-truck/ Discover our full range of LCV EV system solutions: https://brogenevsolution.com/light-commercial-vehicle-electrification-solutions/ Business inquiry: contact@BrogenEVSolution.com or you can fill in the form below to get in touch with us. 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

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

60 kW / 115 kW Electric Axle For Truck

60 kW / 115 kW Electric Axle for Light Truck, Bus, Pickup 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. Email: contact@brogenevsolution.com 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. 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. 5% reduce in power consumption compared to direct drive systems. Technical Parameters Model OEEP5 OEEP5A(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 Applications 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 Light Commercial Vehicle Electrification Solutions Public Transport Electrification Solutions Electric Axles for Light Truck, Van, Minibus, Municipal Vehicle 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

Public Transportation, Technologies

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

120 kW / 250 kW Electric MotorFor Bus, Coach, Truck, and Rail Transit Vehicle 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 Parameters 250 kW Electric Motor Performance Curves 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 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 Bus Motor / Integrated Electric Bus Powertrain 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

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

Industry Insight, Specialty Equipment

How to Choose the Right Electric Forklift Battery: The Complete Guide

How to Choose the Right Electric Forklift Battery: The Complete Guide Introduction For businesses that rely on forklifts, the choice of electric forklift battery can significantly impact overall operational efficiency and, in the long run, influence substantial time and financial costs. By selecting the appropriate forklift battery, forklift manufacturers can ensure the safety and performance of their products in a competitive market. This guide will walk you through the various types of electric forklift batteries, their key differences, price ranges, and how these battery options can affect your business’s daily operations. Quick Access Types of Electric Forklift Batteries Electric Forklift Battery Lifespan Electric Forklift Battery Maintenance Requirements for Forklift Battery Charging Stations Safety Comparison Price How to Determine if Lithium-Ion Batteries are Suitable for Your Forklifts How to Choose the Right Electric Forklift Battery Brogen’s Electric Forklift Battery Solutions Contact Us Types of Electric Forklift Batteries There are two primary battery types powering electric forklifts: lead-acid and lithium-ion. Lead-Acid Batteries As the traditional choice for forklift power, lead-acid batteries utilize a chemical reaction between lead plates and sulfuric acid to generate electricity. These batteries are characterized by their bulky size, liquid electrolyte, and requirement for regular maintenance. Key components include cells, bars, plates of lead dioxide, cables, and electrolytes. The electrochemical reaction between the lead plates and the electrolyte solution allows for the flow of ions, producing an electric current. Lithium-Ion Batteries (Primarily Lithium Iron Phosphate) Introduced in the early 1990s, lithium-ion batteries, particularly Lithium Iron Phosphate (LFP), have gained significant popularity in the material handling industry. These batteries offer higher energy density and a more compact design compared to lead-acid batteries. They are sealed and require minimal maintenance. Lithium-ion batteries operate on the principle of lithium-ion movement between the anode and cathode through an electrolyte. During discharge, lithium ions move from the anode to the cathode, generating electricity. Electric Forklift Battery Lifespan Like any business expense, electric forklift batteries are a cost that needs to be managed over time. The type of battery a forklift uses determines how often the battery needs to be manually replaced. Lead-acid and lithium-ion batteries have different lifespans: Lead-Acid Batteries: 1000 – 1500 cycles Lead-acid batteries have a longer charging time compared to lithium-ion batteries. They are primarily charged using traditional charging methods, typically overnight after a shift, using a low current charge for approximately 8 to 10 hours until fully charged. After a long charging period, the batteries need to cool for 6 to 8 hours before they can be used again. Traditional charging is mostly done overnight, making it suitable for single-shift operations. This also means that lead-acid batteries typically do not undergo opportunity charging. Doing so can quickly damage the battery, wear it out faster, and reduce the number of cycles. Overall, lead-acid forklift batteries can last 3 to 5 years (or 1000 to 1500 charge cycles) with a normal weekly operation of 40 hours. Lithium-Ion Batteries: 3500 cycles Lithium-ion batteries can be easily charged using opportunity charging because they can be fast-charged. This type of charging involves using a specialized high-current charger to quickly recharge the battery. Opportunity charging can be done as needed or at convenient times, making lithium-ion batteries more efficient. If properly maintained, lithium-ion forklift batteries can last 2000 to 3000 cycles, or approximately 7 to 10 years (assuming 300 working days per year). Electric Forklift Battery Maintenance To ensure that lithium-ion and lead-acid batteries perform at their best, proper maintenance is essential. Without appropriate forklift battery maintenance, their lifespan can be significantly reduced. To maximize lifespan and overall battery capacity, users of both types of batteries should follow certain practices. However, lead-acid batteries require more care and attention compared to lithium-ion batteries. Lead-Acid Forklift Battery Maintenance Requirements Equalization (Battery Balancing): In traditional lead-acid batteries, internal acid, and water can often stratify (separate horizontally, with more concentrated acid near the bottom). This can lead to the formation of sulfate crystals at the bottom of the battery, reducing its ability to hold a charge. Equalization helps break down these crystals, but if the battery is left too long, the crystals may not break. Temperature Control: Lead-acid batteries must be kept within a certain temperature range to avoid shortening their lifespan. They can become very hot during charging, requiring a temperature-controlled space for charging and storage. Typically, using lead-acid batteries requires a significant fixed space to store the batteries. Water Level Management: These batteries need to be checked approximately every 10 charge cycles to ensure they have enough water. “Watering” the battery can be a tedious and time-consuming task for individual batteries. Lithium-ion Batteries Maintenance In comparison, lithium-ion batteries require much less maintenance. They come equipped with a Battery Management System (BMS) that automatically balances the cells, operate well at higher temperatures (making temperature control less of an issue), and do not require any water level management. Requirements for Forklift Battery Charging Stations Lead-Acid Forklift Battery Lead-acid forklift batteries must be completely removed from the forklift and placed onto a separate forklift battery charger. Many of these chargers can perform equalization. If there are many forklifts in operation, multiple chargers are needed, and sufficient space is required for cooling several units after charging. This process involves employees using specialized lifting equipment to swap out discharged batteries for charged ones regularly. While not physically demanding, this task can be time-consuming and may impact operational efficiency for those looking to optimize productivity. Additionally, lead-acid batteries require dedicated charging areas with proper ventilation and temperature control. This is because they can become very hot and release harmful fumes during charging. Lithium-ion Battery In contrast, lithium-ion forklift batteries do not require separate charging spaces, cooling, or a fully charged backup battery when another is fully discharged—they can be plugged directly into the charger without needing to be removed from the forklift, making the charging process straightforward with no further actions required. Safety Comparison Safety Risks of Lead-Acid Forklift Batteries Spillage: Lead-acid batteries contain highly toxic sulfuric acid, which can spill, especially since these

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