EV Industry

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Understanding Electric Power Steering Systems: Types and Key Differences

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

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EV Industry

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

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

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EV Industry

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

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

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Optimizing Electric Pickup Truck Development: E-Axles Benefits

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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

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

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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.

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

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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

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EV Industry

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

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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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EV Industry

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

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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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EV Industry

How to Design a BEV Traction Battery System? – Overview

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Designing Better BEV Traction Battery Systems Brief Introduction Designing a suitable traction battery system for Battery Electric Vehicles (BEVs) is crucial for ensuring optimal performance, safety, and longevity of the vehicle. As BEVs become increasingly popular due to their environmental benefits and efficiency, the demand for advanced battery systems continues to grow. A well-designed traction battery system not only meets the power and range requirements of the vehicle but also addresses critical factors such as safety, cost, and environmental impact. In this blog, we will explore the key aspects of designing a traction battery system, including safety and performance requirements, issues to be addressed, design processes, and the information needed about the vehicle to achieve a perfect design, as well as a detailed case study of designing a battery system. Purpose of the EV Traction Battery System Design To provide a traction battery system with optimal performance based on the design requirements of the entire vehicle. Safety performance requirements Electrical performance requirements Battery selection and system configuration Issues to be Addressed Design structure and process within allowable size and weight to meet the vehicle’s power requirements Find simple and feasible processes Reduce costs Improve technical performance where conditions permit Address and resolve environmental pollution issues EV Traction Battery Design Process Understand vehicle requirements Design system power Design system capacity Thermal design System integration Simulation and validation Parameters to Determine and Issues to Address 1. Electrical Characteristics Nominal voltage and operating voltage range; Nominal capacity and available capacity range; Regular discharge current of the traction battery system; Charging requirements of the traction battery system. 2. Power Characteristics Maximum output power and duration of the traction battery system; Maximum regenerative power and duration of the battery system. 3. Environmental Characteristics Operating temperature range of the traction battery system; Charging temperature range; Storage temperature range. 4. Physical Characteristics Structural and dimensions of the traction battery system; Quality of the traction battery system; Other mechanical performance and protection requirements. 5. BMS Requirements Management and protection functions of the BMS; Determination of battery SOC and SOH; Communication methods and transceiver design requirements; Control requirements and communication protocols. 6. Vehicle Interface Requirements Physical interfaces: battery installation, fixing methods, space orientation of cooling medium, and related pipelines; Electrical interfaces: vehicle harness definition and technical specifications, connector model, and pin definitions; Communication interfaces: communication with the vehicle, internal communication of the BMS, communication with the charger. Information Needed About the Vehicle The more detailed the understanding of the vehicle, the more perfect the traction battery system design will be. Not only the motor and vehicle control strategies but also the vehicle’s mass, dimensions, space, and operating conditions must be thoroughly understood: Vehicle parameters Vehicle motor parameters Required driving range of the vehicle Regenerative power Installation space dimensions of the traction battery system and installation and fixing requirements Quality requirements of the traction battery system Charging methods and interfaces Vehicle operating conditions Operating environment temperature range Charging environment temperature range Power requirements of auxiliary systems Characteristic parameters of the auxiliary battery Traction Battery System Design Steps Determine vehicle design requirements Determine motor requirements Determine power requirements of the traction battery system Determine the voltage range of the traction battery system Determine the type of batteries required for the traction battery system Determine the SOC application range of the traction battery system Determine the effective and actual capacity range of the traction battery system Determine the combined structure of the traction battery system Determine the BMS requirements of the traction battery system Determine the interfaces of the traction battery system Determine other methods such as cooling methods, gas sources, and charging methods Simulation and validation Design optimization Case Study With the following parameters for a BEV, explore how to design a suitable traction battery system to ensure optimal performance, safety, and efficiency. Curb weight: 12600 kg Gross weight: 17150 kg Wheelbase: 5980 mm Frontal area: 7.95 m² Transmission system efficiency: 0.92 Aerodynamic drag coefficient: 0.7 Rolling resistance coefficient: 0.0076+0.000056Vv Required acceleration time: 13 s Required driving range: 200 km (average speed at 40 km/h) Power consumption for electronic accessories and air conditioning: 8 kW Step 1: Determine the vehicle’s power requirements The power balance relationship of an automobile should satisfy: The vehicle power requirement (Pv1) corresponding to the maximum vehicle speed is: The vehicle power requirement (Pv2) corresponding to the maximum climbing grade αm is: The vehicle’s power requirement Pv3 for accelerating from a standstill to a specified acceleration time T is given by the following formula. The required power during full-throttle acceleration is Pv3. The power requirements of the vehicle under different conditions – maximum speed, maximum climbing gradient, and full acceleration – are as follows: 98.7 kW, 91.8 kW, and 65 kW, respectively. Step 2: Determine the system voltage range Based on the selected motor for the vehicle, determine the nominal voltage and voltage application range of the traction battery system. Standards require that the motor and controller safely handle the maximum current within 120% to 75% of the rated voltage. Additionally, the DC bus voltage should not fall below 80% of the motor’s rated voltage. For instance, if the vehicle uses a 384 V motor, the battery system should operate within a voltage range of 300 to 460 V. In this case, a lithium iron phosphate (LiFePO4) battery system with 120 cells connected in series is selected. Step 3: Determine the maximum output power / current of the system Power supply system power requirements: the motor power is 110 kW. Assuming the motor efficiency and controller efficiency are 0.9 and 0.95, respectively, and the power for electronic accessories and air conditioning is 8 kW, the minimum power required by the power supply system is calculated as follows: 110/(0.9×0.95)+8=137 kW Maximum output current: the system’s nominal voltage is 384 V. For high-power output, it’s calculated at 10% below the nominal voltage: Idmax=Pmax/V=137000/(384×0.9)=396 A Duration: the duration should meet the requirements of the entire vehicle, taking into account the SOC requirements (the maximum power demand at 30% SOC). Design redundancy: ensuring a 30%

electric car batteries (1)
EV Industry

How Long Do Electric Car Batteries Last?

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How Long Do Electric Car Batteries Last? The lifespan of electric car batteries is a multifaceted subject influenced by various factors. Here’s a detailed and informative analysis, incorporating relevant figures and information to help you understand how long these batteries typically last. Overview The lifespan of an electric car battery is usually defined not by complete depletion but by the national standard where the battery capacity drops to a specific percentage (e.g. 70%) of its original capacity. Several factors influence the lifespan of EV car batteries, including charging and discharging frequency, depth of discharge, usage duration, environmental conditions, and thermal management. Specific Lifespan for Electric Car Batteries Usage Duration Cycle Life Shelf Life Influencing Factors Electric Car Batteries Maintenance Recommendations Summary The lifespan of these batteries is influenced by various factors. Generally, lithium batteries last between 8 and 10 years, with an effective lifespan of 5 to 7 years. Proper usage and maintenance can extend battery life. Additionally, with ongoing technological advancements, future electric car batteries are expected to have longer lifespans and improved performance. By understanding these factors and following best practices for maintenance, electric car owners can maximize the lifespan and efficiency of their vehicle’s batteries, ensuring reliable performance and cost-effectiveness over time. At Brogen, we provide customizable EV battery solutions. Inquiry: contact@brogenevsolution.com

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