EV Industry

18-Ton Battery Electric Water Truck With Our Electric Truck Axle Introduction This case highlights our collaboration with an EV manufacturer to deliver a highly efficient, 100% electric water truck. Specializing in municipal and specialty vehicles, the EV manufacturer serves an environmental resources company as their end customer. This innovative vehicle incorporates our advanced electric truck axle technology. Application of Our Electric Truck axle Our electric truck axle utilizes the latest e-axle technology, featuring a distributed approach that offers numerous benefits, including low noise, extended cruising range, intelligent control, energy efficiency, and high performance. For instance, the 18-ton water truck in this project is equipped with a 231 kWh EV battery system. Thanks to the energy-saving and efficiency-boosting design, it achieves a cruising range comparable to a similar vehicle with a 280 kWh battery system. This allows up to 8 hours of operation on a single charge, significantly reducing costs for fleet operators. Gross vehicle mass: 18000 kg Chassis curb weight: 9145 kg Loading mass: 8660 kg Maximum vehicle speed: 90 km/h Versatility and Safety of Our Electric Truck Axle Our electric drive axle is also suitable for heavy-duty trucks, tractors, and trailers. The distributed approach enhances safety redundancy, ensuring that even if one motor fails, the other can continue to operate normally. Advanced software technology further ensures vehicles’ safety and reliability. Learn more about our innovative e-axle solutions here. Benefits of Upfit Electrification We also provide electric motors for the upfit of specialty and hybrid vehicles, such as street sweepers, water trucks, and concrete mixers, etc. Upfit electrification separates the power source for retrofitting from the vehicle’s drive systems. This enables specialty vehicles like hybrid concrete mixers to shut off their engines during loading and unloading while maintaining retrofit operations. Drivers can also benefit from air conditioning in hot weather. For fleet operators, this significantly reduces annual fuel costs. Learn more about our electric motor solutions here. Electric Truck Battery Solutions At Brogen, we offer standard LFP EV battery solutions for electric trucks, used in applications such as mining trucks, dump trucks, forklifts, and AGVs. Learn more about our EV battery solutions here. Brogen EV Solutions for Electric Trucks We offer a wide range of customizable electrification solutions for EV manufacturers. Our product lineup includes electric motors, electric axles, EV batteries, on-board chargers, and more. If you are seeking an EV solution for your project, please contact us by filling out the form below or by emailing us at contact@brogenevsolution.com. We typically respond within two business days. Contact Us Get in touch with us by sending us an email, using the Whatsapp number below, or filling in the form below. We usually reply within 2 business days. Email: contact@brogenevsolution.com Respond within 1 business day Whatsapp: +8619352173376 Business hours: 9 am to 6 pm, GMT+8, Mon. to Fri. LinkedIn channel Follow us for regular updates > YouTube channel Ev systems introduction & industry insights > ContactFill in the form and we will get in touch with you within 2 business days.Please enable JavaScript in your browser to complete this form.Please enable JavaScript in your browser to complete this form. Name * FirstLast Work Email *Company Name *Your Project Type *– Please select –Car, SUV, MPVBus, coach, trainLCV (pickup truck, light-duty truck, etc.)HCV (heavy-duty truck, tractor, trailer, concrete mixer, etc.)Construction machinery (excavator, forklift, crane, bulldozer, loader, etc.)Vessel, boat, ship, yacht, etc.Others (please write it in the note)Your Interested Solutions *– Please select –Motore-AxleBatteryChassisAuxiliary inverterOBC / DCDC / PDUAir brake compressorEPS / EHPS / SbW / eRCBBTMSOthers (please write it in the note)Do you have other contact info? (Whatsapp, Wechat, Skype, etc.)Please introduce your project and your request here. * Checkbox * I consent to receive updates on products and events from Brogen, and give consent based on Brogen’s Privacy Policy. Submit

Electric Power Recirculating Ball Steering (eRCB) for Commercial Vehicles Our eRCB installed on hybrid electric trucks As commercial vehicles continue to evolve toward electrification, intelligent control, and system integration, power steering systems are undergoing a fundamental transition from hydraulics to fully electric solutions. The development of commercial vehicle power steering technology has progressed through four key stages: Mechanical steering, Hydraulic power steering (HPS), Electro-hydraulic steering (EHPS), and Fully electric steering systems, represented by Electric Power Recirculating Ball Steering (eRCB). For electric and hybrid commercial vehicles—especially light- and medium-duty platforms—eRCB offers a practical balance between high load capability, energy efficiency, and electronic controllability, while retaining the robustness of traditional recirculating ball steering mechanisms. What is the Electric Power Recirculating Ball Steering (eRCB) System? The Electric Power Recirculating Ball Steering (eRCB) system is an electrically assisted steering solution based on a traditional recirculating ball steering gear, enhanced with an integrated electric motor and reduction mechanism at the input shaft. Unlike purely mechanical systems, eRCB actively generates steering assist torque through motor control rather than hydraulic pressure. The system processes: Steering torque signals Vehicle speed signals Active control commands Based on these inputs, the controller drives the electric motor to deliver adaptive steering assistance and enable advanced steering functions, while maintaining the durability and load-bearing advantages required by commercial vehicles. How Does the Electric Power Recirculating Ball Steering Work? When the driver turns the steering wheel: Torque SensingA torque sensor detects the steering input via a torsion bar inside the steering shaft. As the driver applies force, the torsion bar twists, and the twist angle is measured.The detected torque is directly proportional to the torsion bar’s angular deformation. Vehicle Speed InputA vehicle speed sensor sends speed signals (typically square-wave signals) to the steering controller. Control and Motor ActuationThe controller processes both torque and speed signals using a predefined assist characteristic model.It then regulates the motor current accordingly. Torque Amplification and AssistanceThe motor output torque is amplified through the reduction mechanism and applied directly to the steering gear, assisting the driver’s steering input. This closed-loop control architecture enables speed-sensitive assistance, stable high-speed handling, and precise low-speed maneuverability. Key Advantages of Electric Power Recirculating Ball Steering Systems Compared with traditional hydraulic power steering solutions, eRCB offers clear system-level advantages for commercial vehicles: 1. Lower System Procurement Cost for Electric Vehicles Electric vehicles using hydraulic steering require an additional electric motor and controller to replace the engine-driven hydraulic pump.This increases both system complexity and cost. By contrast, eRCB integrates assistance directly into the steering gear, resulting in lower overall system cost. 2. Fewer Components and Reduced System Weight Hydraulic steering systems require multiple components, including hydraulic pumps, motors, and controllers, and oil hoses and reservoirs. The eRCB system eliminates these components through full electrical integration, reducing assembly complexity. Overall system weight can be reduced by approximately 50%, improving vehicle packaging flexibility and safety. 3. Extended Driving Range and Improved Energy Efficiency Hydraulic steering systems typically require a continuously operating motor with power ratings of 2 kW or higher, leading to constant energy consumption. In contrast, eRCB operates on 12V or 24V electrical systems; typical motor power demand is around 400 W; energy is consumed only during steering events. Vehicle tests show that eRCB can improve driving range by over 25% compared to hydraulic steering systems. 4. Adaptive Steering Feel and High-Speed Stability The eRCB system dynamically adjusts steering assistance based on vehicle speed, light, and responsive steering at low speeds; firm and stable steering feel at high speeds. This improves vehicle controllability, driver comfort, and operational safety—especially for commercial vehicles operating under varying load conditions. 5. No Hydraulic Oil, No Leakage Risk By eliminating hydraulic fluid, eRCB removes the risk of oil leakage, reduces environmental impact, and simplifies maintenance and servicing. 6. High Reliability and Maintenance-Free Operation The fully electric design ensures high system reliability, stable performance in low-temperature environments, and maintenance-free operation over the vehicle lifecycle. 7. Broad Vehicle Applicability The eRCB system is suitable for internal combustion engine vehicles, hybrid vehicles, and pure electric commercial vehicles. It is particularly well-suited for light- and medium-duty electric platforms requiring high steering loads and electronic controllability. Brogen’s eRCB Solutions We provide electric power recirculating ball steering (eRCB) systems designed specifically for commercial vehicle applications, with a focus on functional safety, system integration, and future-ready electronic architectures. System Functions Speed-sensitive power assistance Active return Dampling compensation function Friction compensation function Rack end protection function Inertia compensation function Temperature management Motor thermal protection System Advantages Provides eRCB products supporting L2 autonomous driving Configurable interfaces, compatible with various TAS sensor types Supports CAN/CANFD interface Supports Cybersecutiry hardware encryption Supports OTA upgrades Example System Configuration *Specifications are for reference only. For specific vehicle platforms, please contact us to discuss requirements with our engineering team. ITEM Parameters Steering Gear Type Electricc Power Recirculating Ball Steering Gear Steering Operation Mode Manned Drivinng Worm Shaft Rotation Direction Left-hand Rotation Maximum Steering Gear Output Torque 1500 N.m EPS Functions Speed-sensitive power assist; active return-to-center 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

30 kW / 60 kW Electric Motor for Light Truck, Van, Pickup This 30 kW / 60 kW electric motor is designed for light commercial vehicles, such as battery-electric light vans, light trucks, pickup trucks, and minibusses. Featuring a PMSM motor with high energy efficiency, it has been deployed in over 10,000 electric vehicles globally and is currently in mass production.  Technical Parameters Model OETZ180XS-30-02 Maximum Power 60 kW Rated Power 30 kW Maximum Torque 223 N.m Rated Torque 90 N.m Maximum Speed 9000 rpm Rated Speed 3183 rpm Maximum Phase Current 260 Arms Rated Phase Current 120 Arms Cooling Method Liquid Cooling Benefits of Our 30 kW / 60 kW Electric Motor for EV LCVs This system is designed to address customer requirements and is tailored for the microvan and micro truck market. It boasts exceptional safety, a compact and lightweight design, high power density, superior efficiency, and outstanding reliability, making it an ideal solution for modern vehicle applications in this segment. Built-in ASR (Anti-Slip Regulation) Improves overall vehicle safty by preventing wheel slippage. Compact and Lightweight Controller Design 5 L, 5 kg, power density 21.5 kW/L High EMC Design Meets Class 4 standards for electromagnetic compatibility. High System Efficiency Achieves up to 95% peak efficiency. Comprehensive Safety Strategies Includes active vibration suppression, hill start assist, slope operation, and regenerative coasting. ASR Function Overview Developed in-house, the ASR module eliminates the need for additional hardware or sensors. By leveraging precise road surface recognition and wheel slip rate calculations, the system optimizes motor and motor controller performance based on finely tuned calibrations. This enhances both the safety and drivability of vehicles, particularly during straight-line driving or cornering under slippery conditions. Efficiency Map Motor Power Map Motor Efficiency Map Simulation Conditions: Battery Voltage DC628V, Peak Current 285Arms, Magnet Temperature 130°C Output Power at Different Torque-Speed Operating Conditions External Characteristics Under Different Voltage Platforms and Different Operating Modes Peak external characteristics at rated operating voltage in electric mode Peak external characteristics at rated operating voltage in regenerative mode Peak external characteristics at minimum operating voltage in electric mode Peak external characteristics at minimum operating voltage in regenerative mode Peak external characteristics at maximum operating voltage in electric mode Peak external characteristics at maximum operating voltage in regenerative mode Gallery 60 kW electric motor Vans with our motor 60 kW electric motor Vans with our motor 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

Electric Truck Powertrain: Central Drive Motor vs. Rear Electric Drive Axle For modern battery-electric trucks, selecting the right electric truck powertrain is critical for balancing efficiency, payload, and reliability. Two main approaches dominate today’s EV truck market: traditional central drive systems and integrated rear electric drive axles (e-axles). Traditional Truck Powertrain Structure – Central Drive System A central drive system typically features an EV motor coupled with a reducer (gearbox) that amplifies torque before transmitting power through a driveshaft to the rear axle. This setup resembles conventional truck powertrains and is well-suited for heavy-duty applications requiring high torque and flexible gearing. How It Works: Motor output: The EV motor generates high-speed, low-torque power. Torque amplification: The reducer increases torque for heavy-duty operations. Power transmission: Torque travels through a driveshaft to the rear axle. Final drive: The rear axle delivers power to the wheels. While reliable and mature, central drive systems add weight and occupy chassis space, which can reduce available room for batteries or other vehicle components. Electric Drive Axle (E-Axle) The e-axle integrates the EV motor, rear axle, transmission, and differential into a single compact unit, representing a modern electric truck powertrain solution. Key Advantages: Weight reduction: Eliminates the driveshaft and separate reducer, allowing higher payloads. Improved efficiency: Direct power delivery to the axle reduces energy loss and extends vehicle range. Space optimization: Frees chassis space for additional batteries or systems. Simplified design: Fewer mechanical components reduce maintenance needs and improve reliability. Considerations: E-axles are optimized for efficiency and simplicity but may have lower peak torque compared to central drive systems with large reducers. High-power e-axles require careful design and thermal management. Choosing the Right Electric Truck Powertrain Fleet operators and OEMs should select the appropriate electric truck powertrain based on operational needs: Central drive systems excel in heavy-duty applications requiring high torque and multi-speed gearing. E-axles are ideal for medium-duty and logistics trucks where weight savings, efficiency, and packaging flexibility are critical. Understanding these trade-offs ensures that electric trucks achieve optimal peformance, range, and uptime. Brogen Electric Truck Powertrain Solutions At Brogen, we offer a comprehensive range of electric truck powertrain solutions, tailored for various vehicle models and applications. Explore our central drive solutions here: https://brogenevsolution.com/electric-motors-for-truck/ Explore our electric truck axle solutions here: https://brogenevsolution.com/electric-axle-for-truck/ Business inquiry: contact@BrogenEVSolution.com Contact Us Get in touch with us by sending us an email, using the Whatsapp number below, or filling in the form below. We usually reply within 2 business days. Email: contact@brogenevsolution.com Respond within 1 business day Whatsapp: +8619352173376 Business hours: 9 am to 6 pm, GMT+8, Mon. to Fri.   LinkedIn channel Follow us for regular updates >   YouTube channel Ev systems introduction & industry insights > ContactFill in the form and we will get in touch with you within 2 business days.Please enable JavaScript in your browser to complete this form.Please enable JavaScript in your browser to complete this form. Name * FirstLast Work Email *Company Name *Your Project Type *– Please select –Car, SUV, MPVBus, coach, trainLCV (pickup truck, light-duty truck, etc.)HCV (heavy-duty truck, tractor, trailer, concrete mixer, etc.)Construction machinery (excavator, forklift, crane, bulldozer, loader, etc.)Vessel, boat, ship, yacht, etc.Others (please write it in the note)Your Interested Solutions *– Please select –Motore-AxleBatteryChassisAuxiliary inverterOBC / DCDC / PDUAir brake compressorEPS / EHPS / SbW / eRCBBTMSOthers (please write it in the note)Do you have other contact info? (Whatsapp, 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

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

Electric Drive Axle for Truck: Introduction to Heavy-Duty Truck E-Powertrain Technology Sales of electric trucks have continued to grow, driven by ambitious government policies and increasing demand for clean transportation. For heavy-duty truck manufacturers, adopting a reliable and high-performance electric drive axle for truck applications is essential to stay competitive in this fast-growing market. The Evolution of the Electric Drive Axle for Heavy-Duty Trucks The evolution of heavy-duty trucks has gone through three distinct phases, with a vision of the future of electric mobility shaping the landscape. First, traditional fuel-powered trucks dominated the roads, with cabs that were flat and high drag coefficient. These trucks relied on engine-based power systems located at the bottom of the cab. The next phase saw the emergence of gas-electric heavy-duty trucks, which retained the central drive model but swapped the engine for electric motors. However, these vehicles retained conventional propulsion systems that were bulky, inefficient, and compromised cargo space due to rear-mounted battery boxes. Today, battery-electric heavy-duty trucks typically use the electric axle for truck powertrain architecture. EV solutions with electric drive axles provide increased transmission efficiency and space flexibility. At the same time, cabin structures are redesigned to lower the center of gravity and improve aerodynamics. Why The Electric Drive Axle is a Better Choice for Battery-Electric Trucks With an advanced electric drive axle for truck platforms, manufacturers can redesign chassis structures to maximize space and performance.  For example, battery-electric heavy-duty trucks using our e-axle solution can eliminate traditional driveshafts, allowing the chassis structure to be redesigned to accommodate the battery spread flat across the chassis. This layout has many advantages: Placing the battery flat at the bottom allows for a larger battery capacity, extending the range while minimizing intrusion into the cargo area. By using a box-shaped beam frame structure, the battery pack is placed within the box frame structure, ensuring both battery safety and full utilization of the chassis load capacity. Lowering the vehicle’s overall center of gravity reduces the risk of rollover during cornering and improves driving stability and maneuverability. The overall appearance of the vehicle is improved. Analysis of Different Electric Powertrain Configurations for Heavy Trucks At present, the primary e-powertrain configurations for electric heavy trucks encompass several distinct forms: Different configurations of electric powertrains for heavy-duty trucks Analysis of configuration characteristics of different electric drive axles Comparison of dual-motor central drive and dual-motor distribute drive systems Example: Brogen’s Electric Drive Axle for Heavy-Duty Trucks Let’s take our 360 kW eAxle as an example, which is suitable for 6×4 and 4×2 tractors and heavy-duty trucks. Compared to similar eAxle products on the market, our eAxle integrates two motors, providing higher system power and torque with a smaller footprint, and has 100% regenerative braking capability, eliminating mechanical differentials. This results in lower space requirements, weight, and cost. Our electric drive axle installed on the heavy-duty truck Additional Safety Redundancy In addition, our electric drive axle system minimizes layout losses, reduces weight, and incorporates fault and safety strategies. The two drive systems are completely independent, consisting of a motor + 2-speed AMT and wheel-side reducer, using electronic differential technology and independently controlling the left and right drive systems. In the event of a single motor failure, the other motor can continue to operate normally, ensuring system safety. 23% System Weight Reduction Weight of different electric powertrain solutions for heavy trucks In contrast to the central drive system, our distributed drive system has achieved a weight reduction of 23.6%. Similarly, compared to the motor gearbox integration system, our distributed drive system has managed to reduce weight by 23.9%. Good Passability The distributed drive system boasts a 7.3% increase in ground clearance compared to the central drive system. Moreover, it achieves an even greater elevation of 11.7% when compared to the motor gearbox integration system. Higher Transmission Efficiency Compared to the central drive system, our distributed drive system demonstrates a 6% enhancement in overall transmission efficiency. High Safety Currently, heavy-duty trucks are only equipped with ABS and lack ASR, ESC, and EDL. With our EV motor’s electronic differential system strategy control, heavy trucks can be equipped with ASR/ESC safety configurations, improving vehicle traction, stability, and safety. Our Offerings of Electric Drive Axle for Trucks At Brogen, we provide a comprehensive range of electric drive axle solutions for trucks, from Class 1 to Class 8, and other commercial vehicles, including electrified trailers. Our e-axles feature mature, reliable technology designed for high performance and durability. Discover here: https://brogenevsolution.com/electric-axle-for-truck/ Business inquiry: contact@BrogenEVSolution.com Contact Us Get in touch with us by sending us an email, using the Whatsapp number below, or filling in the form below. We usually reply within 2 business days. Email: contact@brogenevsolution.com Respond within 1 business day Whatsapp: +8619352173376 Business hours: 9 am to 6 pm, GMT+8, Mon. to Fri.   LinkedIn channel Follow us for regular updates >   YouTube channel Ev systems introduction & industry insights > ContactFill in the form and we will get in touch with you within 2 business days.Please enable JavaScript in your browser to complete this form.Please enable JavaScript in your browser to complete this form. Name * FirstLast Work Email *Company Name *Your Project Type *– Please select –Car, SUV, MPVBus, coach, trainLCV (pickup truck, light-duty truck, etc.)HCV (heavy-duty truck, tractor, trailer, concrete mixer, etc.)Construction machinery (excavator, forklift, crane, bulldozer, loader, etc.)Vessel, boat, ship, yacht, etc.Others (please write it in the note)Your Interested Solutions *– Please select –Motore-AxleBatteryChassisAuxiliary inverterOBC / DCDC / PDUAir brake compressorEPS / EHPS / SbW / eRCBBTMSOthers (please write it in the note)Do you have other contact info? (Whatsapp, 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

R-EPS System for (Hybrid) Electric Buses Introduction In 2023, an OEM (automotive manufacturer) for buses enlisted our expertise for the electric power steering system implementation in their buses. We recommended our latest R-EPS solution, specifically engineered for large commercial vehicles like buses. Our R-EPS (Rack-assist Electric Power Steering) system operates as a pure electric power steering system, regulating the power steering motor’s operation and torque output. This control is facilitated through the processing and calculation of inputs from the vehicle’s driving speed, steering torque, and steering angle, managed by the steering electronic control unit (ECU). The system serves as a pivotal device, optimizing the power steering effect to ensure smooth and precise vehicle maneuverability. Technical Features of Our R-EPS System for Buses Here are the key features of our R-EPS system for buses: Streamlined modification process and excellent adaptability to the recirculating ball hydraulic steering system layout. Reduced component count ensures high assembly efficiency. Responsive steering and exceptional maneuverability. High-efficiency design with low friction and operating noise. High product integration and compact structure for space optimization. Utilizes non-contact sensor with angle signal for precision. Equipped with overheating and under-voltage protection for enhanced reliability. Maintains steering assistance even during normal failure modes. Features IP67 protection for robust performance in varied conditions. Tailored to meet the demands of ADAS and automatic driving, particularly for large steering-by-wire chassis applications. Installation of the R-EPS on the Battery Electric Bus We’ve successfully integrated our EPS into the 8.5-meter pure electric bus, which has a maximum front axle load capacity of 4500 kg. Our electric power steering system has replaced several electro-hydraulic steering components originally present in the bus. Real Vehicle Calibration and Testing Our EPS system has undergone real vehicle calibration, ensuring optimal performance and functionality. Power Supply: Aligning with the original low-voltage wiring harness of the vehicle chassis, the power line is routed to the 24V battery, which then supplies power to the EPS. CAN Communication Integration: Receives vehicle speed signals in accordance with the vehicle CAN communication protocol. Activation of EPS System: Initiate the vehicle by shifting to the START gear, thereby entering the ready mode. Steering Function Implementation: Experience enhanced maneuverability with our EPS system’s responsive steering capabilities. From spot steering to normal road driving, our EPS provides noticeable power assistance, resulting in lighter steering torque and precise steering response. Active Return to Center Functionality: While navigating urban roads, our system ensures a smooth and seamless return to the center position when the steering wheel is released after turning to any angle, enhancing the overall driving experience and safety. Brogen Electric Power Steering Solutions At Brogen, we provide a wide range of electric power steering solutions for commercial vehicles. Learn more here: https://brogenevsolution.com/electric-power-steering-system-eps-oem-odm-manufacturer/ Business inquiry: contact@BrogenEVSolution.com Contact Us Get in touch with us by sending us an email, using the Whatsapp number below, or filling in the form below. We usually reply within 2 business days. Email: contact@brogenevsolution.com Respond within 1 business day Whatsapp: +8619352173376 Business hours: 9 am to 6 pm, GMT+8, Mon. to Fri. LinkedIn channel Follow us for regular updates > YouTube channel Ev systems introduction & industry insights > ContactFill in the form and we will get in touch with you within 2 business days.Please enable JavaScript in your browser to complete this form.Please enable JavaScript in your browser to complete this form. Name * FirstLast Work Email *Company Name *Your Project Type *– Please select –Car, SUV, MPVBus, coach, trainLCV (pickup truck, light-duty truck, etc.)HCV (heavy-duty truck, tractor, trailer, concrete mixer, etc.)Construction machinery (excavator, forklift, crane, bulldozer, loader, etc.)Vessel, boat, ship, yacht, etc.Others (please write it in the note)Your Interested Solutions *– Please select –Motore-AxleBatteryChassisAuxiliary inverterOBC / DCDC / PDUAir brake compressorEPS / EHPS / SbW / eRCBBTMSOthers (please write it in the note)Do you have other contact info? (Whatsapp, 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

Brogen Delivering Electric Bus Battery Systems for 8-Meter and 12-Meter Battery Electric Buses (BEBs) in Türkiye Project Overview Project Start Time: 2022 Project Vehicle Types: 8-meter and 12-meter battery electric buses Country: Türkiye Systems Supplied: electric bus battery, PDU (with BMS), BTMS, EVCC Project Introduction In response to Türkiye’s growing environmental initiatives, a well-established Turkish commercial vehicle manufacturer embarked on an electric bus project, focusing on 8-meter and 12-meter models. Leveraging our expertise in electric bus battery systems, we delivered a tailored solution that included a 282 kWh battery system, a customized BMS, PDU, and a BTMS cooling unit, engineered to match the bus architecture and meet European certification requirements. This case study outlines our approach to overcoming technical challenges and providing comprehensive support throughout the project. Client Background The client, a prominent commercial vehicle manufacturer in Türkiye, has a strong reputation for producing traditional fuel-powered buses. In 2022, motivated by Türkiye’s environmental policies, the company shifted its focus to electric buses, initiating a new product for 8-meter and 12-meter electric models. Given our history as their supplier of EHPS and air brake compressors, they entrusted us with developing a high-quality electric bus battery system for their new fleet. Key Challenges Custom Electric Bus Battery System Design: The 8-meter and 12-meter electric buses required different energy capacities, battery layouts, and installation architectures, demanding a fully customized solution for each model. Uncommon High-Voltage Architecture: The buses used a high-voltage e-powertrain, which is not a mainstream specification for electric bus battery packs. This required careful component matching, safety validation, and specialized system design. Space Constraints and System Integration: The battery packs needed to fit within limited chassis space while still delivering the required energy, cooling performance, and safety compliance. Preparing for the shipment of the battery systems How We Designed the Electric Bus Battery Solution Requirement Analysis & System Simulation Conducted detailed simulations and calculations based on the client’s vehicle specifications, including speed, range, and certification requirements. Designed custom battery packs with different capacities to meet the distinct needs of the 8-meter and 12-meter buses. Engineering Development Developed a specialized BMS tailored to the buses’ specifications. Created circuit diagrams and optimized the internal and external wiring to fit the vehicle layouts. Carefully selected connectors, considering power currents and interlock requirements. Ensured compatibility between the charging infrastructure and the battery system, adhering to European standards. Joint Testing & Validation Conducted joint testing with the client to verify the charging system’s functionality. Provided technical support during the installation and initial operation phases, including software updates and remote troubleshooting. Systems We Provided Battery modules BMS PDU Power output wiring harness Vehicle communication wiring harness CCS charging seat wiring harness Battery input harness Power wire harness between the battery boxes Communication wiring harness between the battery boxes EVCC Charge harness Battery Packs Used in This Project Our standard battery pack Our battery factory The battery packs used in this project Other Systems in This Project 8 kW BTMS BMS with PDU Wiring harness Brogen Tailored Electric Bus Battery Solution At Brogen, we provide tailored electric bus battery solutions, covering battery packs, BMS, PDU, BTMS, and related subsystems. Built on mature and highly reliable technology, our solutions use premium battery cells from globally recognized suppliers. Today, our electric bus battery systems are already deployed in mass production across global markets. Learn more here: https://brogenevsolution.com/ev-battery-solutions-for-bus-hcv/ Business inquiry: contact@BrogenEVSolution.com Contact Us Get in touch with us by sending us an email, using the Whatsapp number below, or filling in the form below. We usually reply within 2 business days. Email: contact@brogenevsolution.com Respond within 1 business day Whatsapp: +8619352173376 Business hours: 9 am to 6 pm, GMT+8, Mon. to Fri. LinkedIn channel Follow us for regular updates > YouTube channel Ev systems introduction & industry insights > ContactFill in the form and we will get in touch with you within 2 business days.Please enable JavaScript in your browser to complete this form.Please enable JavaScript in your browser to complete this form. Name * FirstLast Work Email *Company Name *Your Project Type *– Please select –Car, SUV, MPVBus, coach, trainLCV (pickup truck, light-duty truck, etc.)HCV (heavy-duty truck, tractor, trailer, concrete mixer, etc.)Construction machinery (excavator, forklift, crane, bulldozer, loader, etc.)Vessel, boat, ship, yacht, etc.Others (please write it in the note)Your Interested Solutions *– Please select –Motore-AxleBatteryChassisAuxiliary inverterOBC / DCDC / PDUAir brake compressorEPS / EHPS / SbW / eRCBBTMSOthers (please write it in the note)Do you have other contact info? (Whatsapp, 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

Brogen Maritime Battery System Powers Spain’s Electric Boat Project In 2023, we partnered with a leading Spanish shipbuilding company to deliver a battery-electric boat, driving forward zero-emission maritime solutions. By integrating advanced maritime battery technology, this project contributes to cleaner ports, reduced marine pollution, and the decarbonization of marine transport. Project Challenge: Designing a Reliable Maritime Battery System The client required a robust and fully compliant maritime battery solution to power the electric vessel’s propulsion system. Key challenges included: Meeting strict maritime redundancy regulations Ensuring fully independent battery packs with complete isolation across the mechanical structure, electrical architecture, thermal management, and control units Delivering long-lasting, high-performance battery packs capable of supporting continuous vessel operations Our Solution: Custom Maritime Battery & Electric Propulsion To address these requirements, we designed and delivered a custom electric propulsion and maritime battery solution, including: Maritime-grade battery packs with multi-group isolation Advanced BMS with a three-level architecture: slave, master, and supervisory controllers PDU, wiring harnesses, and battery racks Our optimized configuration featured two independent battery groups, each containing two clusters, with 10 battery modules per cluster. This design ensured complete isolation and redundancy, reducing the risk of cell imbalance, overcharging, and over-discharging. The maritime battery system we provided for the client Implementation & Collaboration Throughout the design and implementation phases, our team worked closely with the client’s technical staff to fine-tune the systems. Our pre-sales and engineering teams ensured every detail, from mechanical integration to software configuration, aligned with the unique specifications of the electric boat. Six months after project completion, the system continues to operate flawlessly, demonstrating exceptional reliability, efficiency, and compliance with all maritime safety standards. Results: Seamless Operation & Regulatory Compliance Successful deployment of the company’s first electric boat powered by a reliable maritime battery system High redundancy and isolation meet stringent maritime regulations Sustained, reliable performance six months post-installation Recognition from the client for professionalism, innovation, and technical excellence Praise From The Client “Your team’s ability to address challenges with professionalism and efficiency has been a major factor in the project’s success. This experience has not only strengthened our professional relationship but also reinforced our trust in you as a valuable and reliable partner.” said the President. Brogen Maritime Battery Solutions At Brogen, we provide tailored maritime battery solutions to power vessel electrification with maximum safety, reliability, and sustainability. Our offerings include lithium-ion marine traction battery packs, modular battery clusters, and containerized marine traction battery systems. Explore here: https://brogenevsolution.com/marine-traction-battery/ Looking for an EV solution for your marine electrification project? Reach out to 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

Battery-Electric Concrete Mixer Truck With Axial Flux Motor E-Axles Client: A concrete mixer truck manufacturer Demand: An electric axle solution for their 31-ton heavy-duty battery-electric concrete mixer trucks The electrification trend in commercial vehicles extends to concrete transportation, driven by a dual desire for environmental sustainability and cost savings. Facing the challenge of high fuel costs, concrete mixer truck manufacturers seek innovation solutions to optimize efficiency and reduce operational costs. Description In 2023, a leading concrete mixer truck manufacturer approached us for an EV solution for their 31-ton heavy-duty battery-electric concrete mixer requirements. Understanding the industry’s need for cost-effective electrification, our experienced experts recommended the e-axle solution with axial flux motors for heavy-duty trucks to meet their demands. The 460 kW E-Axle Solution for the Battery-Electric Concrete Mixer Our integrated e-axle system features two axial flux motors, each with 230 kW of power. With the maximum power of 460 kW, the drivetrain system achieves a wheel-end transmission efficiency exceeding 96%, and the maximum gradeability reaches 50%. This also helps effectively increase the cruising range. Benefits of the E-Axle Solution With Axial Flux Motors Enhanced transmission efficiency and range: since the weight and size of the axial flux motor is 50% that of the traditional radial flux motor, this e-axle system uses the three-speed automatic transmission. The first, second, and third gears each have a two-stage transmission. While significantly improving transmission efficiency, the system operates in the high-efficiency range at almost any vehicle speed. Dual-mode shifting: The dual-mode shifting mode can achieve differential shifting between the front and rear axles as well as power compensation. There’s no interruption of power to the vehicle during the shifting process, with a shift response time of less than 0.6 seconds. Optimized vehicle layout: thanks to the use of the axial flux motors, this solution offers a more spacious vehicle layout, allowing the entire vehicle’s traction battery pack to be positioned under the vehicle’s main beams. As a result, the electric concrete mixer truck’s center of gravity is lowered by more than 100 mm compared to conventional gasoline-powered vehicles. And it’s 130 mm lower compared to similar all-electric concrete mixer trucks from other brands. Thus, this fully electric concrete mixer truck has better roll stability, ensuring safer driving. Results The application of the lightweight and more efficient axial flux motor system has enabled this 31-ton new energy concrete mixer truck to achieve a range of 260 km (according to the steady-speed method), with an actual operational range of up to 180 km, significantly outperforming similar products on the market. A driver of this battery-electric concrete mixer truck remarked, “This electric truck has strong power and is comfortable to drive, just like driving a car. Plus, charging it once at night is basically enough for a day’s use, and charging speed is also very fast, almost done in an hour.” Brogen Electric Powertrain Solutions At Brogen, we provide electric powertrain solutions for commercial vehicles, ranging from mature and reliable direct-drive motors to integrated e-powertrains (motor, transmission, and controller) as well as compact, high-efficiency e-axle solutions. Our offerings help EV manufacturers accelerate development and reduce R&D costs for their projects. If you’re looking for a tailored EV solution, don’t hesitate to 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