EV Industry

Electric Truck Axle Guide: How to Choose the Right E-Axle for Heavy-Duty Trucks? https://youtu.be/rakSt-jDAsQ?si=8im9tnZpT0SHnLz6 As electric heavy-duty trucks continue to gain market share, a clear understanding of key drivetrain systems—especially the electric truck axle—is becoming increasingly important for OEMs and commercial EV developers. What types of electric truck axles are available today, and what technical factors should be considered when selecting the right solution? In this article, we explore the core dimensions of electric truck axle selection, including structural layout, motor configuration, transmission stages, and PTO integration. This guide is designed to support engineering and product teams in making informed decisions when developing or sourcing electric heavy truck platforms. Brogen Electric Truck Axle on the Heavy-Duty Truck 1. The Structure of Electric Truck Axle Traditionally, a drive axle consists of four main subassemblies. Axle Housing: As the core load-bearing structure, the housing plays a critical role in supporting the entire axle system. Depending on the manufacturing process, axle housings can be categorized into three main types: Stamped and Welded Steel Plates: Known for their cost-effectiveness and relatively low weight, this method is commonly used in light-duty applications. Hydroformed Structures: This process enables superior lightweight performance, making it ideal for applications with strict weight constraints. Precision Cast Housings: These offer high structural strength and load-bearing capacity, which is essential for heavy-duty operations and demanding terrains. Final Drive (Main Reducer): It converts torque from the driveshaft into torque at the drive wheels. One of the key performance indicators of the final drive is the diameter of its ring gear – the larger the diameter, the greater the vehicle’s load capacity and wheel-end output torque. Additionally, the gear ratio of the final drive is a critical factor affecting the vehicle’s power delivery and energy efficiency. Inside the final drive, there is also a differential, which allows the left and right wheels to rotate at different speeds when the vehicle is running.  Wheel End: This assembly connects directly to the tires and is responsible for high-speed rotation. In older designs, wheel ends required grease lubrication, which routine maintenance typically needed every 50,000 km. Today, most heavy-duty truck axles have adopted maintenance-free wheel ends, significantly reducing service requirements and improving uptime. Braking System: It typically comes in drum or disc configurations. Among drum brakes, there are two common types: S-cam brakes and wedge brakes. Thanks to their simpler structure, faster response, and better space efficiency (especially in tight chassis layouts), wedge-type drum brakes have become the preferred solution in modern heavy-duty trucks. The axle housing, wheel ends, and braking system of this electric drive axle are largely identical to those of a conventional diesel drive axle. From a structural standpoint, electric truck axles are fundamentally similar to traditional diesel axle systems. There are tow primary structural configurations commonly used in the industry: Configuration 1: Integrated Axle Housing Structure This design retains the conventional layout of the axle housing, wheel hubs, and braking system – essentially mirroring a traditional diesel drive axle. The only major difference is the addition of an electric motor and gearbox assembly, which is mounted at the front flange of the axle. The motor delivers torque, which is then stepped down and amplified by the gearbox before being transmitted to the axle to propel the vehicle forward or in reverse. Electric Truck Axle With Integrated Axle Housing The key advantage of this configuration lies in its simplicity. It leverages proven components from diesel truck platforms – including the axle housing, wheel ends, and braking system – which helps reduce development time and keeps costs relatively low. However, there are notable trade-offs. Due to space limitations, it’s difficult to integrate a multi-speed gearbox – typically restricted to two or three gears at most – and there’s usually no room for a PTO. Another major drawback is that the center of gravity of the entire e-axle assembly is offset from the axle line, which can lead to undesirable dynamic behaviors during rapid acceleration or braking. These include pitching motions such as axle lift (front-up) during acceleration and nosedive during deceleration. Configuration 2: Three-Piece Axle Housing Structure Electric Truck Axle With Three Piece Axle Housing Structure This design features square-section axle housings on both sides, with the electric motor and multi-speed gearbox mounted in the center. The three segments are connected via flanges and bolts. The main advantage of this architecture is its compact layout, which allows the gearbox to be designed with 3, 4, or even 6 speeds. This enables improved vehicle performance and energy efficiency, particularly under varying load and terrain conditions. The primary drawback is the increased overall weight due to the bolted flange connections between the three sections. However, the structural integrity of this design is not compromised – the axle can support up to 13 tons, making it fully suitable for heavy-duty applications. Electric Truck With Three-Piece Axle Housing eAxle From a cost perspective, Configuration 1 is more economical and is currently more common in the market. However, from a technological and performance standpoint, the three-piece structure – with its modular layout and support for multi-speed transmissions – is emerging as the mainstream trend in electric axle development for heavy-duty trucks. 2. Choosing the Number of Motors Due to space constraints, electric truck axles typically integrate a single motor. For example, our latest e-axle features a single motor delivering 300  kW peak power (407  hp) and 200  kW rated power (271  hp). It utilizes an oil-cooled system and achieves a maximum output torque of 38,483 Nm. With its integrated axle housing design, it supports a maximum axle load of up to 16,000 kg. Electric Water Truck With Brogen Single Motor Electric Truck Axle To further increase power output, dual-motor configurations are required. These can be arranged in two main ways: Inline configuration: Two motors positioned front and rear, jointly driving the central final drive. Distributed design: Similar to the layout in the Tesla Semi, where the second axle is used as the drive axle. It employs two motors, each driving one half-shaft independently,

Installation Requirements for Onboard Charger (OBC + DCDC) 1. General Requirements The onboard charger layout must take into full consideration its mechanical and electrical characteristics, adhering to principles such as ease of assembly/disassembly, system size, cost minimization, and strong electromagnetic compatibility. 2. Positioning Requirements for the Onboard Charger System-level considerations: The orientation of the OBC should be determined based on its function and characteristics, especially the direction of current flow and coolant piping. Sufficient installation space: A minimum clearance of 10 mm must be maintained between the OBC and surrounding components. Proximity principle: The wiring harness connections between the OBC and components such as the charging port, PDU, traction battery, and auxiliary battery should be as short as possible. Avoid placement near areas of high temperature or excessive moisture. 3. Mounting Requirements for the Onboard Charger The OBC should be mounted in a location that allows convenient removal, preferably without the need to lift the entire vehicle. Adequate tool access space must be reserved around all mounting points. 4. Connector Position Requirements Connectors should be positioned as close as possible to the electrical components they are wired to. The space reserved in the direction of the connector should be at least three times the length of the connector itself, while also ensuring the wiring harness has a sufficient bending radius (greater than 5 times the diameter of the harness). 5. Coolant Circuit Requirements The highest point of the OBC coolant circuit should be lower than the reservoir tank. Inlet and outlet hose positions should be oriented according to the direction of coolant flow and placed as close as possible to the corresponding components. For horizontal installations, either side may serve as the inlet/outlet; for vertical installations, coolant should flow bottom-in, top-out. The OBC should be positioned upstream of the EDS in the cooling loop. 6. Crash Safety Requirements The OBC should be located away from high-risk collision zones. 7. Vibration Requirements The OBC must be positioned away from direct vibration sources such as the engine or suspension system. The vibration standard for the onboard charger (when installed on body-mounted components above dampers) is an RMS acceleration of 30.8 m/s². 8. Dimensional Chain Requirements If the OBC mounting bracket consists of multiple parts and is a newly developed component, dimensional chain analysis must be conducted, and mounting hole specifications should be defined accordingly. For existing (carry-over) parts, the design must control dimensional chain deviations to ensure the mounting hole dimensions meet installation requirements. About Brogen At Brogen, we provide advanced EV solutions for global commercial vehicle manufacturers, enabling them to streamline research and development while capitalizing on cutting-edge technology. Our offerings ensure superior efficiency, extended range, and seamless system integration with proven reliability—empowering our partners to lead in the rapidly evolving green mobility landscape. Currently, our EV solutions have been adopted by vehicle manufacturers in countries and regions such as Canada, Türkiye, Brazil, the Philippines, Indonesia, the Middle East, and more. Discover our Onboard Charger & DCDC solutions here: https://brogenevsolution.com/obc-dcdc-pdu/ Looking for an EV solution for your 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

HVIL Explained: What It Is and Why It’s Critical for High-Voltage Safety With the rapid development of electric vehicles (EVs), especially the increasing demand for fast charging, the operating voltages used in EVs are steadily rising. While some models still use a 200 V platform, the mainstream adopts 400 V systems, and high-end vehicles are increasingly equipped with 800 V architectures. Some OEMs are now developing even higher voltage platforms of 900 V to 1000 V to support ultra-fast 6C charging. As voltage levels increase, concerns about high-voltage safety in EVs grow accordingly. 1. Safety Challenges Associated with High Voltage The primary safety risk associated with high voltage is electric shock, particularly when high-voltage components become exposed. Besides shock hazards, two other major safety issues related to high-voltage operation are switch arcing and high-voltage power loss. 1.1 High Voltage Exposure The generally accepted safety thresholds for human exposure are approximately 50 VAC or 120 VDC. However, actual safety depends heavily on the environment, contact duration, and body resistance. For example, voltages below 36 VAC or 60 VDC are considered relatively safe in dry conditions, but in wet or conductive environments, safe voltages drop to 12 V to 24 V. Mainstream EV high-voltage systems operate around 400 VDC, far exceeding these safety levels. Exposure to such voltages presents serious risks. To mitigate this, all high-voltage components are enclosed in insulated protective covers. These protective covers must remain securely closed during vehicle operation; any unauthorized opening must be detected and addressed immediately. 1.2 Switch Arcing High-voltage switches, such as connectors, can generate electric arcs when opened or closed under load. This occurs because when the voltage exceeds the breakdown voltage of the surrounding gas or insulation medium, electrons accelerate and ionize surrounding particles, causing an avalanche effect that sustains an electric arc. Such arcs can severely damage switch contacts and pose fire hazards to nearby components and personnel. 1.3 High-Voltage Power Cutoff In traditional vehicles, power is provided by an internal combustion engine. When the engine encounters issues – such as high coolant temperature, emission faults, or operational failures – early warnings and appropriate handling are required. In electric vehicles, propulsion is driven by high-voltage electricity from the power battery to the motor. If high-voltage power is suddenly cut off while the vehicle is in motion, it can result in a complete loss of power, posing safety risks to both the vehicle and its occupants. Therefore, early warnings and safety mechanisms must be in place. Issues such as high-voltage exposure, switching arcs, and unexpected high-voltage disconnection must be detected, monitored, and handled effectively to prevent related safety incidents. The High-Voltage Interlock Loop (HVIL) is a safety mechanism capable of addressing all of these concerns simultaneously. 2. Basic Concept of HVIL HVIL stands for High Voltage Interlock Loop – a safety system designed to monitor the integrity of the high-voltage circuit using a low-voltage signal loop. It continuously checks the connection status of all high-voltage components and wiring harnesses, ensuring the entire system remains intact and safe. HVIL systems typically cover critical components such as the battery pack, Battery Management System (BMS), Vehicle Control Unit (VCU), Power Distribution Unit (PDU), Motor Control Unit (MCU), DC/DC converter, PTC heater, wiring harnesses, connectors, and protective covers. When a fault or disconnection occurs anywhere in the HVIL loop, the system triggers alarms and initiates safety measures. 3. How HVIL Works 3.1 Mechanical Structure As previously mentioned, switch arcing is a common issue in high-voltage systems during operation. In electric vehicles, the primary switches that require connection and disconnection are high-voltage connectors, namely, plugs and sockets. If these connectors are plugged or unplugged while live, arcing can easily occur. This problem is addressed through specialized mechanical design. Standard connectors typically have only two terminals: one for the high-voltage positive and one for the negative. HVIL connectors, however, include an additional pair of low-voltage terminals – positive and negative – used by the HVIL system to monitor circuit integrity. These are referred to as HVIL pins. HVIL Connectors As shown in the diagram above, the HVIL connector features four terminals, with two additional HVIL pins located in the center. The illustration on the right further shows that the contact points of the central HVIL pins are not on the same plane as those of the HV pins on either side. The HVIL pins are shorter, which means that during connection, the HV pins make contact first, followed by the HVIL pins. Connection Sequence and Disconnection Sequence The connection process proceeds from left to right: In the left image, all four pins are fully disconnected. In the middle image, the two HV pins on either side make contact first, while the central HVIL pins are not yet connected. In the right image, the HVIL pins complete the connection, finalizing the engagement of all four terminals. If the HVIL pins detect an abnormal condition, the high-voltage circuit is immediately interrupted. When the HVIL pins are not connected, the system is in an open-loop state – considered abnormal – and the internal circuit will cut off the high-voltage supply. Therefore, before the HVIL pins engage, the high-voltage circuit remains open, preventing any voltage presence and eliminating the risk of arcing. This design ensures safety during connector engagement. The disconnection process occurs in reverse order, from right to left: the HVIL pins disconnect first, followed by the HV pins. Once the HVIL pins open the circuit, the high-voltage power is immediately cut off, ensuring that when the HV pins are separated, no voltage is present – thus guaranteeing safe disconnection. 3.2 Electrical Principle While the issue of switch arcing can be addressed through specialized mechanical design, verifying the integrity of the high-voltage circuit requires an electrical solution. Sample Schematic Diagram of the HVIL Circuit The diagram above illustrates a sample HVIL system, which uses a dedicated HVIL monitoring unit. This unit is connected in series with the HVIL pins of the BMs, MDI, and OBC modules, forming a closed monitoring loop.

Development Trends in Battery Electric Heavy-Duty Trucks (e-HDTs) 1. Transition Toward Purpose-Built Development of Electric Heavy Duty Trucks In the current stage of the development of electric heavy-duty trucks (e-HDTs), most models still follow a “diesel-to-electric conversion” approach due to immature technologies and limited production scale. However, in the long run, purpose-built development of dedicated e-HDT platforms will be essential for performance enhancement and is the strategic direction adopted by leading OEMs. Today’s diesel-converted e-HDTs retain the basic layout of their diesel counterparts. The internal combustion engine is replaced with an electric motor, and battery packs are typically mounted behind the cab or on both sides of the chassis. While this transitional approach allows for faster product rollout at controlled costs, it comes with performance compromises, such as inefficient chassis space usage, lower drivetrain efficiency, and limited battery space, reducing cargo capacity and driving range, thus affecting operational effectiveness and cost-efficiency. To achieve large-scale commercialization, industry leaders are moving toward ground-up development of e-HDT platforms, optimizing the e-powertrain, chassis architecture, and vehicle aerodynamics to fully unlock the advantages of electrification. 2. Electric Drive Systems Limitations of Central Drive Architecture Most converted e-HDTs continue to use the central drive architecture typical of diesel trucks – simply replacing the engine with an electric motor. This results in systems that are bulky, heavy, and less efficient. Integrated E-Axles & Distributed Drive Purpose-built e-HDTs allow for deep optimization of the electric drivetrain. As commercial EV powertrains become more integrated, both integrated e-axles and distributed drive solutions are emerging. Although distributed drive systems using hub motors are still in early development, integrated e-axles are currently the mainstream choice. Compared to the central drive, integrated e-axles combine the motor, gearbox, and drive shaft into a compact, highly integrated system. Advantages include: Smaller spatial footprint Higher integration and system efficiency Fewer transmission components Lower vehicle weight and increased usable space These benefits translate into improved performance, energy efficiency, and packaging flexibility. High-Voltage Platforms: The Next Step The trend is shifting from 400V systems (common in passenger EVs) and 600V systems (used in commercial vehicles) toward 800V-1000V high-voltage platforms. Key advantages include: Ultra-fast Charging: Higher voltage enables significantly faster charging, especially critical for commercial vehicles with large battery capacities and tight operational schedules. Enhanced Driving Efficiency: Lower current at higher voltage reduces power losses, increasing overall system efficiency and extending driving range. Porsche first adopted the 800V platform in 2019 with the Taycan. Now, commercial vehicle manufacturers are starting to follow suit. The realization of ultra-first charging requires not only vehicle-side high-voltage systems but also widespread deployment of high-powered charging stations. 3. Fast Charging Technology Evolution The realization of ultra-fast charging requires not only vehicle-side high-voltage systems but also widespread deployment of high-powered charging stations. To support the rising demand for ultra-fast charging: Charging Module Power is steadily increasing – from 7.5 kW (1st gen) to 15-20 kW (2nd gen), and now 30-40 kW (3rd gen) in mainstream systems. Liquid-Cooled Systems are becoming standard for improved heat dissipation, reduced noise, and easier maintenance. Tesla’s V2 Supercharger (2019) and GAC Aion’s A480 (2021) are early adopters of liquid-cooled fast-charging technologies. These trends are expected to transition from passenger to commercial EVs in the near future. 4. Chassis Layout Optimization for Electric Heavy Duty Trucks Diesel truck chassis are traditionally designed with a ladder frame to accommodate a front-engine, rear-drive layout. Retaining this setup in e-HDTs creates challenges, especially in battery packaging, leading to inefficient space use and reduced cargo volume. With a clean-sheet design, purpose-built eHDTs can eliminate the driveshaft and re-engineer the frame to accommodate skateboard-style battery layouts. Benefits include: Higher Energy Density: More battery space improves range without compromising cargo space. Structural Integration: Box-section frames housing the battery enhance structural integrity and load-bearing performance. Lower Center of Gravity: Improves handling, cornering stability, and safety. Sleeker Exterior: Optimized space usage allows for better design flexibility. 5. Aerodynamic and Lightweight Body Design for Electric Heavy Duty Trucks With purpose-built platforms, e-HDTs are no longer limited to the traditional “cab-over” shape. Redesigning the cab structure enables the use of lightweight materials and aerodynamic profiles to reduce drag and improve efficiency. For example, most cab-over trucks in China have a drag coefficient (Cd) between 0.55 and 0.65. In contrast, Tesla’s Semi, which features a bullet-nose design and a single-seat cab, claims a Cd as low as 0.36. Conclusion The electrification of heavy-duty trucks is transitioning from retrofitted solutions to fully purpose-built platforms. From integrated drivetrains and high-voltage architectures to optimized chassis and aerodynamic designs, leading OEMs are paving the way for the next generation of e-HDTs designed for higher efficiency, better performance, and large-scale commercial viability. About Brogen At Brogen, we provide advanced EV solutions for global commercial vehicle manufacturers, enabling them to streamline research and development while capitalizing on cutting-edge technology. Our offerings ensure superior efficiency, extended range, and seamless system integration with proven reliability—empowering our partners to lead in the rapidly evolving green mobility landscape. Currently, our EV solutions for battery electric heavy trucks have been adopted by vehicle manufacturers in countries and regions such as Canada, Türkiye, Brazil, the Philippines, Indonesia, the Middle East, and more. Discover our HCV electrification solution here: https://brogenevsolution.com/heavy-duty-vehicle-electrification-solutions/ Looking for an EV solution for your 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

How the VCU Manages Power-Up and Power-Down in Electric Vehicles: Comprehensive Control Logic Overview 1. Understanding Vehicle Power-Up/ Power-Down Logic Before delving into the vehicle’s power-up and power-down sequences and understand the control strategy via VCU, it’s essential to clarify two fundamental concepts: (1) Why must the VCU control the wake-up of high-voltage component controllers (e.g., BMS, MCU, DCDC, OBC, AC)? Unified vehicle wake-up logic: The vehicle can be awakened via several sources – key ignition, slow charging, fast charging, or remote control. The VCU receives these wake-up signals and subsequently controls the wake-up of other controllers, enabling centralized monitoring and management of the vehicle status while simplifying low-voltage wiring design. Enhanced functionality: By controlling the wake-up of high-voltage components, the VCU facilitates key features such as charging while the vehicle is OFF, remote preconditioning, scheduled charging, and safe sequencing of high-voltage system operations. (2) Key considerations for high-voltage circuits before power-on/off Before power-on: Prevent inrush current: Motor controllers contain large internal capacitors, which allow AC to pass but block DC. At the moment the high-voltage circuit is closed, the capacitors cause the circuit to behave like an AC circuit. If no resistance is present in the circuit (I=U/R), a large inrush current will be generated, potentially damaging high-voltage components. Ensure system safety: Prior to high-voltage activation, safety checks must be performed – verifying proper interlock connections, insulation resistance to prevent electric shock risks, and ensuring there are no high-voltage-related faults. Before power-off: Relay protection: If the system carries a high current during shutdown, opening the relay under load may damage it or cause welding, leading to failure in disconnecting the high voltage. Component protection: Motors can generate back-EMF when rotating. Disconnecting power at high speed can cause voltage spikes (several kV), risking damage to power devices like IGBTs and electric compressors. (3) Diagrams VCU Low-Voltage Schematic Example: Shows typical low-voltage pins used in the VCU; though simplified, it aligns with the overall power control sequence. Vehicle High-Voltage Circuit Example: While layouts vary by manufacturer, the core principles are similar and correspond with the logic described above. 2. Full Vehicle Power-Up and Power-Down Sequence The vehicle’s power-up and power-down process is not a simple on/off switch but a precise system-level operation. When the driver turns the key or presses the start button, the Vehicle Control Unit (VCU) – the vehicle’s central brain – coordinates the initialization of key systems like the MCU, PDU, TCU, and TMS. It manages their low-voltage power-up and sends wake-up signals, ensuring safe and synchronized startup of high-voltage components. Power-Up Sequence: Key On (KL15), VCU wakes up and completes initialization. Wake up high-voltage controllers such as MCU, BMS, DCDC, DCAC, TCU, and TMS. VCU checks the vehicle’s low-voltage system status. If all high-voltage controllers are initialized and there are no HV-related faults, and a high-voltage activation request is present, proceed to step 4; otherwise, stay in step 3. VCU sends a command to close the negative relay. If feedback confirms the relay closed within time t0, proceed to step 5; if not, switch to negative relay disconnection. VCU sends a command to close the positive relay, which is preceded by pre-charge relay activation. After pre-charging, the system confirms that the MCU DC voltage reaches ≥95% of the nominal battery voltage within time t1. If confirmed, proceed to step 6; otherwise, disconnect the positive relay. VCU performs a high-voltage status check. Enables DCDC/DCAC and verifies their operational status. If confirmed, proceed to step 7; otherwise, enter zero torque state. Drive-ready state: VCU enables the MCU and turns on the READY indicator. If the driver shifts into gear, VCU sends torque or speed control commands for driving. If a shutdown request is received, proceed to step 8. Shutdown request received: VCU sends the zero torque command to the MCU to decelerate. Once motor speed<N, torque<T, bus current<A,  and vehicle speed<V or timeout t2 is reached, proceed to step 9. VCU disables DCDC/AC/PTC/DCAC. DCAC, which powers steering/braking assist, is disabled only when the vehicle is stationary to maintain safety. After confirming the shutdown status and that the A/C compressor speed<Nac, or timeout>t3, proceed to step 10. VCU sends command to disconnect the positive relay. Once MCU DC voltage≤ 60V (safe threshold) or timeout>t4, proceed to step 11. VCU sends command to disconnect the negative relay. After confirmation or timeout>t5, proceed to step 12. High-voltage components are powered down. If key=off, VCU proceeds to data storage and sleep; otherwise, return to VCU wake-up.  3. Charging Process and Notes on Power-Up/Down (1) Differences in Charging Process: Wake-up source shifts from ignition to charging signal; If both ignition and charging signals are present, the charging process takes precedence. If the charging cable is connected during READY state, the system performs a shutdown process first, then begins charging. MCU and DCAC are not enabled during charging; driving is not permitted. (2) Key Reminders: During vehicle power-up, low voltage is activated before high voltage. During power-down, high voltage is disconnected before low voltage. For HV activation, negative relay closes before the positive replay. For HV shutdown, positive relay opens before the negative relay. About Brogen At Brogen, we provide advanced EV solutions for global commercial vehicle manufacturers, enabling them to streamline research and development while capitalizing on cutting-edge technology. Our offerings ensure superior efficiency, extended range, and seamless system integration with proven reliability—empowering our partners to lead in the rapidly evolving green mobility landscape. Currently, our EV solutions for battery electric buses and trucks have been adopted by vehicle manufacturers in countries and regions such as Australia, Türkiye, Brazil, the Philippines, Indonesia, the Middle East, and more. Looking for an EV solution for your 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

Five Key High-Voltage Safety Design Principles in Electric Vehicles In battery electric vehicles (BEVs), the propulsion system is powered by high-voltage electric motors. These systems typically operate at very high currents—ranging from tens to even hundreds of amperes—and in the event of a short circuit, the current can spike dramatically. Such high voltages and currents pose significant safety risks to both passengers and vehicle components, including electrical systems and control units. Therefore, the high-voltage electrical system in an EV must not only meet performance and power delivery requirements but also ensure operational safety, personal safety, and safe maintenance. Effective high-voltage safety management involves a combination of technical design, operational protocols, protection mechanisms, and user safety education. Below are five fundamental safety design principles widely adopted in EVs to ensure safe handling and operation of high-voltage systems: 1. Leakage Current Protection Electric vehicles are equipped with leakage current protection devices. If either the positive or negative high-voltage bus comes into contact with the vehicle chassis, the protection device will trigger an alert—or in many cases—automatically shut down the high-voltage supply. This prevents scenarios where the motor casing becomes electrically charged, which could lead to an electric shock if someone touches the opposite pole. Leakage protection also safeguards systems such as the air conditioning unit and DC/DC converters from high-voltage leakage. 2. High-Voltage Interlock (HVIL) All high-voltage connectors are designed to prevent disconnection while the system is energized. However, to guard against human error or unauthorized tampering, high-voltage interlock (HVIL) switches are integrated into connectors. If a connector is unplugged, the interlock circuit is immediately interrupted. The system controller detects this and rapidly disconnects the main relay, cutting off high-voltage power in milliseconds—thereby preventing potential electric shock. HVIL is a critical fail-safe in high-voltage circuit design. 3. Collision Power Cutoff In the event of a collision, onboard crash sensors immediately send a signal to trigger the HVIL system. This automatically disconnects the vehicle’s high-voltage power supply to protect occupants from electric hazards. Some modern systems integrate this function directly into the high-voltage connector modules, combining sensing and cutoff in a compact unit. 4. Insulation Resistance Monitoring Higher system voltages require stricter standards for insulation to prevent dangerous leakages. Insulation resistance is a critical safety parameter, with regulatory standards clearly defining minimum thresholds to mitigate risks of electric shock or component failure. Two common methods are used to monitor insulation resistance: Auxiliary Power Method:A 110V DC auxiliary battery is connected across the high-voltage circuit (positive to negative, and negative to vehicle ground). Under normal conditions, no current flows. If insulation is compromised—due to aging, moisture, etc.—a leakage current forms, triggering an alert and shutting down the system. While effective, this method increases system complexity and cannot easily identify whether the issue lies in the positive or negative lead, limiting its application in EVs. Current Sensor Method:Hall-effect current sensors measure differential current flow by passing both positive and negative cables through the same sensor. When no leakage is present, the outgoing and returning currents cancel out, and the sensor reads zero. If leakage occurs, the imbalance is detected, and the direction of current flow helps identify whether the fault is on the positive or negative side. This method requires the system to be powered during testing but is more commonly used in modern EVs due to its efficiency and precision. 5. Access Panel Monitoring Certain critical high-voltage components in EVs are equipped with cover monitoring mechanisms. If a cover is opened while the high-voltage system is still active, a signal is sent to the main controller. The controller immediately cuts off the main relay and activates a discharge mechanism that rapidly reduces internal voltage to safe levels. This feature ensures safety during servicing or accidental opening of enclosures. Conclusion High-voltage safety is foundational to electric vehicle design. From real-time system monitoring to automatic disconnection features, these protective measures are vital for ensuring the safety of passengers, maintenance personnel, and the vehicle itself. As EV technology continues to evolve, robust safety protocols will remain essential in supporting the growth of safe and reliable electric mobility. About Brogen At Brogen, we provide advanced EV solutions for global commercial vehicle manufacturers, enabling them to streamline research and development while capitalizing on cutting-edge technology. Our offerings ensure superior efficiency, extended range, and seamless system integration with proven reliability—empowering our partners to lead in the rapidly evolving green mobility landscape. Currently, our EV solutions for battery electric buses and trucks have been adopted by vehicle manufacturers in countries and regions such as Australia, Türkiye, Brazil, the Philippines, Indonesia, the Middle East, and more. Looking for an EV solution for your 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

Vehicle Control Unit (VCU) Explained: A Deep Dive into Software Architecture The Vehicle Control Unit (VCU) is often referred to as the “brain” of the vehicle. It plays a pivotal role in managing and coordinating various systems to ensure efficient, safe, and intelligent vehicle operation. At the core of its operation is a well-structured software architecture, typically divided into three key parts: Signal Input, Function Control, and Signal Output. 1. Signal Input – The “Senses” of the Vehicle Control Unit (VCU) The signal input section enables the VCU to perceive the vehicle’s real-time status, much like how human senses gather information from the environment. The VCU collects data from three primary channels: hardwired inputs, the CAN bus (Controller Area Network), and low-level diagnostic signals. Hardwired Inputs: These are like the vehicle’s nerve endings, directly connected to key components. Through these inputs, the VCU gathers critical information such as accelerator position, brake pedal status, ignition key state, and more. This data reflects the driver’s direct commands and helps the VCU respond accordingly. CAN Bus Inputs: Acting as the vehicle’s internal communication highway, the CAN bus connects essential systems such as the battery management system (BMS), motor control unit (MCU), and transmission control unit (TCU). The VCU monitors these systems in real time, allowing precise and coordinated vehicle control. Low-Level Diagnostics: This includes internal controller states, E-flash storage signals, and I/O diagnostics. Think of it as the vehicle’s health report, providing deeper insights to support system reliability and performance monitoring. 2. Function Control – The “Brain” of the Vehicle Control Unit (VCU) This is the core processing layer of the VCU. Based on the inputs received, the VCU makes intelligent decisions to manage vehicle behavior. While features may vary between manufacturers, most VCUs include the following key control functions: Input Signal Processing: Acts as a centralized filter and organizer. It processes signals such as speed, acceleration, braking, gear logic, and vehicle weight. By unifying data at this layer, the VCU improves efficiency and reduces redundant signal processing across different functional modules. Power Management (Power On/Off Control): The VCU coordinates the high-voltage system to manage key processes, including pre-charging, enabling power output, and entering sleep modes. It ensures components are powered on or off in a safe and orderly manner. Additional features like smart battery charging and battery preheating can also be integrated here. Torque Control: One of the VCU’s main roles is controlling the vehicle’s torque output based on driver inputs such as acceleration or braking. This function ensures smooth torque delivery across various drive conditions like cruising, crawling, or rapid acceleration. Single Power Source Vehicles: For vehicles with one drive motor or a conventional ICE powertrain, the VCU arbitrates between different torque demands (e.g., acceleration, crawl, cruise), filters out torque interference (e.g., from gear shifts or stability control), and adjusts torque output for smooth driving. Multi Power Source Vehicles: In EVs with dual motors or hybrid configurations, after determining total torque demand, the VCU distributes torque appropriately between power sources and filters each source’s output to maintain stability and performance. Energy Management: The VCU optimizes energy usage based on the vehicle’s configuration. Battery Electric Vehicles (BEVs): The VCU controls high-voltage components (DCDC, air pumps, HVAC systems) and calculates available power to adjust motor torque output, improving energy efficiency. Fuel Cell or Range-Extended Vehicles: Whether powered by hydrogen or fuel, these systems rely on the VCU to balance energy supply and demand, activate generation systems as needed, and ensure optimal energy use. Fine-tuned control is required to handle differences in startup behavior, power response, noise/vibration (NVH), and energy consumption. Auxiliary Functions: Many VCUs are equipped with additional smart features, such as: Dashboard Display Control: Provides real-time information such as range, average energy consumption, power output, and gear status to the driver. Anti-Theft & Lock Control: Implements features like random key generation, security level control, and key verification for enhanced vehicle protection. PTO (Power Take-Off) Control: Supports operational requirements in special-use vehicles by managing PTO status, speed control, and idle conditions. Auxiliary Systems Management: Oversees the operation of water pumps, cooling fans, vacuum pumps, EPS motors, and air compressors. 3. Signal Output – The “Executors” of VCU Commands This layer handles the transmission of control signals generated by the VCU to the vehicle’s actuators. The output methods include hardwired signals, CAN communication, and data storage: Hardwired Output: Used to enable or wake up components like the BMS, MCU, and TCU. It also provides direct control over specific functions such as pump and fan speed. CAN Output: Enables efficient communication with various high-voltage systems, controlling torque commands, motor speeds, generator activation, relay switching, and more. E-Flash Storage: Stores vital data such as mileage, learned values, and average energy consumption to support diagnostics, analytics, and long-term performance optimization. Conclusion By understanding the structure and function of a Vehicle Control Unit, we can better appreciate the role it plays in enabling intelligent, efficient, and safe vehicle operation. Whether it’s managing torque output, coordinating energy use, or communicating with dozens of subsystems, the VCU lies at the heart of modern vehicle control strategies. About Brogen At Brogen, we provide advanced EV solutions for global commercial vehicle manufacturers, enabling them to streamline research and development while capitalizing on cutting-edge technology. Our offerings ensure superior efficiency, extended range, and seamless system integration with proven reliability—empowering our partners to lead in the rapidly evolving green mobility landscape. Currently, our EV solutions for battery electric buses and trucks have been adopted by vehicle manufacturers in countries and regions such as Australia, Türkiye, Brazil, the Philippines, Indonesia, the Middle East, and more. Looking for an EV solution for your 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

Battery Electric Bus Body: Structural Design and Strength Optimization To advance the adoption of electric vehicles and fully capitalize on the energy-saving and emission-reduction benefits of battery electric buses (BEBs), a lightweight electric bus body design is essential. This article presents an overview of topology optimization theory and explores key material options for electric bus body construction, including high-strength steel, aluminum alloys, and carbon fiber composites. It highlights the advantages of advanced materials in improving structural performance and outlines methodologies for analyzing structural loads, optimizing topology, and ensuring strength and reliability. These insights provide valuable guidance for the development, design, and manufacturing of next-generation electric buses, supporting both performance and sustainability goals. Introduction The electric vehicle (EV) sector is undergoing rapid development, particularly in the public transportation segment, where battery electric buses offer significant advantages such as zero emissions, reduced operating costs, and simpler maintenance. However, one of the primary challenges hindering wider adoption is limited driving range. Reducing curb weight – while maintaining safety and structural integrity – is a proven strategy to extend range and improve overall vehicle efficiency. Since the body structure contributes more than one-third of a bus’s total weight, lightweighting the body is a critical focus. By leveraging topology optimization theory and finite element analysis (FEA), engineers can minimize material use while maintaining required levels of stiffness and strength. This approach not only enhances vehicle range but also contributes to long-term energy efficiency and emission reduction goals. 1. Topology Optimization Principles When applying topology optimization to electric bus body design, shape optimization techniques are used to find the most efficient material layout under one or more loading conditions. This approach targets minimum structural stiffness. It starts with developing a digital base model of the bus body, then uses optimization algorithms to remove unnecessary components while retaining critical structural elements. This improves the structural layout’s rationality and reliability. Basic mathematical model of battery electric bus In practice, topology optimization is performed with the following considerations: Analysis Type: Static analysis Element Types: First-order and second-order tetrahedral elements Material Behavior: Liner elastic, elastoplastic, hyperelastic Loading Conditions: Concentrated force, pressure, torque, gravity Boundary Conditions: Displacement constraints Contact Conditions: Bonded and surface contact Connection Types: Rigid and beam connections Objective Function: Maximize stiffness Design Variables: Topology variables Constraints: Volume fraction If the total number of elements is denoted as a, then each element can be represented as y(i = 1, 2, 3, …, a). During the structural optimization process, if the h-th element is determined to be non-essential, it will be assigned a value of yₕ = 0; if it is essential and should be retained, it will be assigned yₕ = 1. The structural optimization design of a pure electric bus body can be carried out using finite element analysis (FEA) combined with variable design methods. 2. Main Types of Electric Bus Materials The evolution of bus body materials reflects a broader shift toward lightweight and high-performance materials. Initially dominated by steel (over 90% of body structure), the industry has gradually shifted toward aluminum alloys and carbon fiber composites. This shift is driven by the demand for lightweight, energy-efficient, and low-emission vehicles. High-Strength Steel (HSS): Created by adding trace elements to low-carbon steel and undergoing specialized rolling processes. It offers tensile strength up to 420 N/mm² and excellent deep-drawing properties, making it a strong candidate for lightweight structural components. Aluminum Alloys: Compared to steel, aluminum alloys have a lower density (2.7 g/cm³), higher specific strength, good corrosion resistance, thermal stability, and recyclability. These advantages make aluminum alloys widely used for lightweight applications. Carbon Fiber Composites: Composed of carbon fiber bundles and resin, these materials offer exceptional high tensile strength (often over 3500 MPa), high stability, and resistance to deformation during impact. Carbon fiber composites can significantly enhance passive safety and are more than twice as durable as steel. With increasing demand for extended range, pure electric buses have transitioned from using high-strength steel to aluminum alloy bodies, which reduce body weight by 25%-35%. Modern aluminum alloy components are often assembled using rivets and bolts rather than traditional welding, and stamped aluminum parts have replaced conventional steel panels. Aluminum alloys also offer high recyclability, with recovery rates exceeding 85% when vehicles are retired. Skeleton layout of 10.5 m battery electric bus aluminum alloy roof Skeleton layout of 10.5 m pure electric bus aluminum alloy bone around on the left side Skeleton layout of 10.5 m pure electric bus aluminum alloy bone around on the right side 3. Performance and Cost of Advanced Automotive Materials Advanced materials and manufacturing processes are key drivers of automotive innovation. High-Strength Steel: Offers 15%-25% higher strength than standard steel, with better balance and 20% improved corrosion resistance. However, it requires additional anti-corrosion treatments to meet durability requirements. Aluminum Alloys: In a 10-meter bus, switching from steel to aluminum components can reduce body weight by over 450 kg. Aluminum also provides superior thermal insulation and vibration damping compared to steel. Manufacturing methods such as hot forming, die casting, and precision machining enhance part performance and structural integrity. Carbon Fiber Composites: Carbon fiber’s strength and stiffness per unit weight surpass all other commonly used materials. It absorbs 4-5 times more impact energy than steel and can reduce body weight by over 40%, while enhancing safety and aesthetic appeal. However, its high cost restricts its applications to high-end or specialized vehicles. Relative Costs: Steel: Lowest cost Aluminum Alloys: Moderate cost Carbon Fiber Composites: Highest cost   4. Structural Load Analysis and Topology Optimization of Battery Electric Bus Body The structural design of a battery electric bus must comply with the requirements outlined in relevant national standards and the specific design brief. This includes determining the vehicle’s primary exterior dimensions – such as length, width, height, wheelbase, front overhang, and rear overhang – while ensuring a balanced and harmonious overall appearance.  Effective spatial arrangement of the driver’s cabin and passenger area is essential for optimal internal layout. The number, position, and minimum dimensions of passenger doors and emergency

Empowering Innovation: Brogen Electric Truck Axles Drive Our Partner’s Heavy-Duty Electric Trucks As the global push toward decarbonization accelerates, electric truck axles are becoming the heart of next-generation heavy-duty trucks. We are thrilled to share that our partner has officially delivered their first batch of electric heavy trucks, each equipped with our advanced electric axle system, to a renowned logistics company. This milestone highlights how the latest EV technology and vehicle manufacturing come together to enable the electrification of real-world logistics operations, with performance, reliability, and efficiency at the core. Electric heavy trucks equipped with our electric truck axles Brogen Electric Truck Axles – Built for Real-World Logistics This deployment isn’t a concept — it’s a real-world logistics application. The electric trucks are now in service for one of the country’s top logistics providers, handling mid-to-long-distance intercity transportation with high operational frequency. To succeed in such conditions, trucks need powerful, efficient, and reliable drive systems. That’s where our electric truck axles come in: Ultra-low energy consumption of just 1.15 kWh/km, ensuring excellent energy efficiency and reducing per-kilometer transport costs. High torque dual-motor architecture delivers up to 51,480 N·m peak axle output, making it perfect for heavy-duty 4×2 logistics use cases. Intelligent shifting algorithm eliminates power interruption during gear changes — smoother, safer, and better for cargo stability. Symmetrical, compact design maximizes underbody space for additional batteries or storage, extending range and flexibility. Brogen electric truck axle used in this project Designed for Heavy-Duty Transport Our electric axle systems aren’t just about power — they’re about delivering performance under real transport conditions: Passed 1,250 hours of continuous transmission testing Survived 1 million cycles of 2.5× load impact without failure Optimized for NVH performance and oil temperature control, even in high-load, high-speed highway use Whether it’s high-speed expressways or urban delivery corridors, these electric axles are ready for the rigors of commercial transport. Brogen electric drive axle motor testing Why It Matters For logistics companies, transitioning to electric vehicles is no longer just a sustainability goal — it’s a strategic move to reduce TCO, improve fleet uptime, and align with increasingly strict emissions regulations. Our electric axle solutions help vehicle manufacturers and fleets unlock: Simplified electric powertrain architecture Higher payload capacity Lower operational and maintenance costs Cleaner transportation footprint For Truck Manufacturers: Build Better, Faster, Smarter If you’re a truck OEM or EV builder looking to electrify your heavy-duty platforms, our electric truck axle solutions are engineered to give you a competitive edge — from R&D to mass production. Accelerated Development TimelinesOur proven, modular e-axle platforms help reduce your system integration time. Whether you’re building a 4×2 urban logistics truck or a multi-axle long-haul vehicle, we offer tailored technical solutions to help you hit your market timelines faster. Seamless System IntegrationWith deep expertise in high-voltage systems, controllers, gearboxes, and cooling architecture, we support full-stack integration — not just the axle, but the total e-powertrain ecosystem. Flexible Customization & ScalabilityOur systems are field-proven in mass-production EVs with Tier 1 OEMs. From fatigue cycles to thermal and NVH optimization, we engineer for endurance. Discover our electric truck axle solution here: https://brogenevsolution.com/electric-axle-for-truck/ Explore our HCV solutions here: https://brogenevsolution.com/heavy-duty-vehicle-electrification-solutions/ Business inquiry: contact@BrogenEVSolution.com, or you may complete the form below to get in touch with us. Contact Us Get in touch with us by sending us an email, using the Whatsapp number below, or filling in the form below. We usually reply within 2 business days. Email: contact@brogenevsolution.com Respond within 1 business day Whatsapp: +8619352173376 Business hours: 9 am to 6 pm, GMT+8, Mon. to Fri. LinkedIn channel Follow us for regular updates > YouTube channel Ev systems introduction & industry insights > ContactFill in the form and we will get in touch with you within 2 business days.Please enable JavaScript in your browser to complete this form.Please enable JavaScript in your browser to complete this form. Name * FirstLast Work Email *Company Name *Your Project Type *– Please select –Car, SUV, MPVBus, coach, trainLCV (pickup truck, light-duty truck, etc.)HCV (heavy-duty truck, tractor, trailer, concrete mixer, etc.)Construction machinery (excavator, forklift, crane, bulldozer, loader, etc.)Vessel, boat, ship, yacht, etc.Others (please write it in the note)Your Interested Solutions *– Please select –Motore-AxleBatteryChassisAuxiliary inverterOBC / DCDC / PDUAir brake compressorEPS / EHPS / SbW / eRCBBTMSOthers (please write it in the note)Do you have other contact info? (Whatsapp, Wechat, Skype, etc.)Please introduce your project and your request here. * Checkbox * I consent to receive updates on products and events from Brogen, and give consent based on Brogen’s Privacy Policy. Submit

A Comprehensive Guide to CCS Integrated Busbars for EV Battery Packs What is CCS on a Battery? CCS, short for Cells Contact System, refers to an integrated busbar system that combines conductive busbars, control circuits (such as voltage and temperature sensors), and other components into a single modular unit. It plays a critical role in the internal electrical architecture of battery modules. By consolidating multiple functions into one system, CCS enhances the integration, reliability, and safety of battery systems. It also helps reduce assembly complexity, save space, lower production costs, and simplify maintenance. In essence, CCS is an electrical connection structure within the battery module. It integrates data acquisition components, plastic structural parts, copper/aluminum busbars, and more into a single module. This allows it to perform high-voltage series-parallel connections, temperature sensing, voltage sampling, and overcurrent protection, serving as a key component of the Battery Management System (BMS). CCS technology is widely used in electric vehicles (EVs), energy storage systems, and other high-voltage battery applications. Advantages of CCS Busbar for EV Battery Packs High Integration: Multiple functions are integrated into one module, reducing the number of components and wiring complexity. Enhanced Reliability: The integrated design improves system stability and reduces failure rates. Lightweight Design: With compact architecture and lightweight materials, CCS helps lower overall vehicle weight and improve energy efficiency. Improved Production Efficiency: Simplified assembly processes and high automation levels reduce labor costs and improve manufacturing throughput. Ease of Maintenance: Modular design allows for easier maintenance and component replacement, reducing downtime and service costs. CCS Structure and Classifications CCS systems vary based on the type of signal acquisition component used, and include several solutions such as wire harnesses, PCB, FPC, FFC, FDC, and FCC. Various integration techniques are employed, including injection-molded brackets, vacuum-formed plates, hot pressing, and die-cut PET films. The industry currently sees multiple technical paths coexisting and evolving. Common Materials Used in CCS Include: Hot-pressed insulation film Aluminum busbars Vacuum-formed trays Injection-molded structural brackets PCB/FPC/FFC signal acquisition components Type Signal Acquisition Component Common Integration Techniques Wire Harness Traditional Wiring Harness Injection-molded bracket; Thermal riveting process with vacuum-formed tray (blister riveting process) PCB Printed Circuit Board Hot pressing process; Thermal riveting process with vacuum-formed tray (blister riveting process) FPC Flexible Printed Circuit FFC Flexible Flat Cable FDC Flexible Die-cut Circuit FCC FFC connected with FPC or FDC Overview of CCS Variants for EV Batteries Each CCS implementation offers unique benefits depending on the application scenario: 1. Wire Harness Solution Structure: Wire harness + acquisition terminals + NTC sensors + aluminum busbar + injection/vacuum-formed bracket Features: Cost-effective and stable signal transmission, but with lower automation potential. 2. PCB Solution Structure: PCB + nickel strips + aluminum busbar + hot pressing with PET film or vacuum thermal riveting Features: Lightweight, high automation, and excellent signal integrity. 3. FPC Solution Structure: FPC + nickel strips + aluminum busbar + hot pressing with PET film or vacuum-formed plate Features: Ultra-lightweight with high automation and stable signal transmission, though with higher costs. 4. FFC Solution Structure: FFC + nickel strips + aluminum busbar + PET film hot pressing or vacuum thermal riveting Features: Lightweight, low cost, high automation—ideal for long-format battery modules. 5. FDC Solution Structure: Die-cut flexible circuits using rotary die technology Features: Fewer processing steps, low cost, and suitable for mass production. 6. FCC Solution Structure: FFC as the main body with soldered FPC or FDC branches through window openings Features: An emerging cost-effective solution still under evaluation and testing. Key Considerations for CCS Design and Manufacturing 1. Material Selection & Integration Process The choice of conductive (copper, aluminum) and insulating materials, as well as integration techniques like hot pressing and riveting, greatly impacts performance, safety, and durability. 2. Automation & Manufacturing Efficiency High levels of automation are essential for scale and cost control. However, due to differing requirements across battery and vehicle manufacturers, semi-automated processes may offer better return on investment at lower volumes. 3. Signal Transmission Reliability Ensuring stable and accurate transmission of voltage and temperature data is crucial. PCB and FPC solutions perform well in this regard but come at a higher cost. 4. Lightweight Design & Cost Control As electrification continues to grow, CCS must balance performance, weight reduction, and affordability. FFC and FDC solutions offer promising trade-offs, but continuous optimization is necessary. 5. Safety & Protection Features CCS must provide overcurrent protection, corrosion resistance, and thermal stability. Design considerations must include cell-level protection to ensure safe operation under extreme conditions. 6. Thermal Management Proper heat dissipation and thermal balance within the battery pack are vital. CCS design must support efficient thermal management through material selection and structural layout. 7. Quality Control & Testing Rigorous quality assurance is key to reliable CCS performance. This includes testing electrical performance, mechanical durability, and environmental adaptability to ensure consistent results across operating conditions. 8. Market Competition & Innovation With growing competition, CCS manufacturers must innovate in process technologies, improve product quality, and reduce costs to stay competitive. Our CCS Technology for EV Battery Packs Our intelligent integrated CCS technology, featuring a fully integrated design that replaces the traditional complex approach of “wiring harness + BMS + temperature sensors.” By integrating multiple cell state detection components directly into the system, we achieve a streamlined, intelligent solution. Starting from the battery cell level, our CCS system establishes a multidimensional safety architecture—combining active and passive protection mechanisms and system-level thermal runaway risk management. Centered on real user needs, our solution delivers smarter, safer, and more reliable battery management—putting safety at the core. Cost-Effective Standardized integrated systems enhance quality and production efficiency, significantly improving PACK assembly speed while reducing overall costs. The use of standardized components greatly simplifies the assembly process. Ultimate Safety Superior insulation and high-voltage withstand capability reduce the risk of accidents. The design minimizes common issues associated with traditional sampling harnesses, such as insulation failure, aging, breakage, and short circuits. Highly Integrated Combines sampling harnesses, aluminum busbars, temperature sensors, as well as internal PACK components like air pressure sensors, explosion-proof valves, electrolyte