Heavy Transport | Brogen EV Solution | Shanghai OE Industrial Co., Ltd.

Heavy-Duty Electric Truck Axles (504 kW / 620 kW)

Heavy-Duty Electric Truck Axles (504 kW / 620 kW) These heavy-duty electric truck axles feature a dual-motor integrated design and are engineered for high-performance applications. With a rated axle load of 13 tons and a maximum system power output of 504 kW or 620 kW, they are capable of meeting the demanding requirements of various heavy-duty commercial vehicles, including 4×2, 6×4, and 8×4 configurations such as municipal vehicles, semi-trucks, and dump trucks. By delivering strong performance and efficiency under heavy-load conditions, these e-axles help significantly reduce both carbon emissions and overall energy consumption. Email: contact@brogenevsolution.com Get Custom Quote Heavy-Duty Electric Truck Axles: Solution Details 1. Solution Features of Our Heavy-Duty Electric Truck Axles Dual Motor + 4-speed AMT Configuration: Adaptable to multiple use cases, from high-capacity long-haul electric semi-trucks to high-torque construction trucks operating under frequent load shifts. Modular Design for Easier Maintenance: High integration of motors and gearbox enables a compact layout and simplifies service and maintenance processes. Transverse Layout Without Hypoid Gear Set: Eliminates the hypoid gear set to reduce mechanical losses, enhancing transmission and regenerative braking efficiency. One-piece Axle Housing with Aluminum Alloy Casing: Integrated cast axle housing offers higher structural strength and sealing performance; aluminum casing helps reduce overall system weight. 2. Technical Parameters Model OESTEA45000Z-1 OESTEA45000Z-2 E-Powertrain Rated Axle Load 13 T (16 T Under Development) Wheel-End Output Torque 45000 N.m 45000 N.m Assembly Weight 985 kg 990 kg Reference Leaf Spring Distance 1018-1050 mm (Adjustable) Wheel Mounting Distance 1837 mm Compatible Suspension Leaf Spring / Air Suspension Motor Parameters Motor Rated/Peak Power 150/252 kW*2 190/310 kW*2 Motor Rated/Peak Torque 285/550 N.m 280/590 N.m Motor Maximum Speed 9000 rpm Transmission Parameters Speed Ratio 4-speed 1st: main transmission 71.0+auxiliary transmission 46.8 2nd: main transmission 36.3+auxiliary transmission 46.8 3rd: main transmission 20.0+auxiliary transmission 13.2 4th: main transmission 10.2+auxiliary transmission 13.2 Brake Brake Specifications Drum brake φ410*220; disc brake 22.5″ Brake Torque 2*18000 N.m (drum brake); 2*22000 N.m (disc brake) Air Brake Chamber Specifications 30/24 (recommended) Other Options Differential Lock Optional PTO Optional PTO for retrofit 3. Advanced AMT Technology – Built for Smarter, Smoother Electric Trucks This electric truck axle platform features a 4-speed AMT. It enables active speed synchronization between the motor and the transmission input shaft, allowing for rapid and smooth gear shifts. By combining gear profile modification with in-depth analysis of casing and shaft tooth deformation, the system achieves optimal meshing conditions, minimizing transmission error and reducing efficiency loss. Faster gear shifting: Reduced shift time improves drivability, especially under frequent stop-and-go scenarios. Higher drivetrain efficiency: Enhances energy use and supports longer driving range. Lower NVH: Quiet and smooth gear transitions improve driving comfort. Lower maintenance cost: Long-life gear oil with no initial oil chaange required; supports extended intervals of 50,000-200,000 km. 4. Key Performance Data Weight reduction vs. direct drive (dual axle): 22% per set Range improvement vs. direct drive: Up to 20% Energy use: 10% less per 100 km at 49t full load vs. industry average Axial space saving: 40% Deployed units (to date): ~13,000 Projected annual production capacity (2025): Over 10,000 units How We Ensure the Reliability of Our Electric Truck Axles Our electric truck axles undergo a rigorous multi-level validation process to guarantee long-term performance, safety, and durability under real-world operating conditions. Component-Level Testing Over 50 tests are conducted on individual components to verify structural integrity, strength, and consistency. These include: Vibration Salt spray Tensile Torsion Hardness Full-dimension inspections Subsystem-Level Testing More than 90 tests are performed across all core subsystems – including the shifting mechanism, gearbox, motor, high/low voltage controllers, wiring harnesses, and software. These tests fall into six major categories: Module validation Functional testing Performance testing Durability testing Reliability testing Environmental resistance System-Level Testing Over 50 tests are carried out at the system level using specialized test benches and real-vehicle road trials, including: High and low temperature cycling Thermal shock testing Salt spray and corrosion resistance Waterproof and dustproof validation Vibration and noise testing System integration and special-condition simulation R&D and Manufacturing Excellence Comprehensive and Integrated R&D Capabilities The R&D team is built on a robust, cross-functional framework encompassing structural engineering, electronic hardware, system architecture, software development, testing, and manufacturing processes. We maintain a full-spectrum development capability that spans from concept design to real-world validation. With in-house expertise in mechanical design, control unit development, computer-aided simulation, bench testing, and complete vehicle road testing, we are equipped to support rapid iteration and innovation across the entire product lifecycle. Hybrid and pure electric powertrains Transmission systems and controllers Electric motors and motor controllers Shift and clutch actuators Vehicle control units (VCUs) Quality Management & Full Lifecycle Traceability The factory strictly adheres to IATF 16949, ISO 14001, and other international standards, ensuring precise control over every production process and uncompromising quality in every product. The digital management system enables a full lifecycle traceability and control, ensuring that every component is trackable and accountable from production to delivery. In 2025, the e-axle for trucks production capacity is expected to exceed 10,000 units, further demonstrating our ability to scale with quality and consistency. 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

Heavy Transport, Technologies

250kW / 290kW E-Axle for Trucks, Heavy-Duty Truck E-Powertrain

250 kW / 290 kW E-Axle for Trucks Our 250 kW / 290 kW e-axle for trucks integrates a high-efficiency PMSM, transmission, and axle into a compact unit. By leveraging the gear ratio of the integrated transmission, the system delivers high torque output even with a relatively smaller motor. The wheel-end output torque can reach up to 40,000 N.m, making it ideal for 6×4 and 4×2 truck tractors, semi-trailers, water tankers, garbage trucks, dump trucks, and other heavy-duty transport or municipal vehicles. This e-axle system is already in mass production and has been deployed in batch applications on electric semi-trailers. Email: contact@brogenevsolution.com Get Custom Quote E-Axle for Trucks: Solution Details Item Technical Parameters Model OESTEA40000Z-1.5 OESTEA40000Z-1.6 E-Powertrain Axle Load 13 T Wheel-End Output Torque 40000 N.m Assembly Weight 1030 kg Motor Parameters Motor Rated / Peak Power 121 kW / 250 kW 136 kW / 290 kW Motor Rated / Peak Torque 320 N.m / 850 N.m 326 N.m / 860 N.m Motor Peak Speed 10000 rpm Transmission Gear Ratio 13.2/4.4 Axle Wheel-Side Gear Ratio 3.478 Rim Mounting Distance 1822 mm Brake Type Drum Brake / φ410×220 Maximum Brake Torque (0.8MPa) 2×18000 N.m 2×18000 N.m PTO N.A. Optional Differential Lock Optional Solution Features IP67 water and dust protection, along with rigorous high/low temperature and vibration testing, ensures outstanding system reliability. One-piece axle housing provides high load-bearing capacity while maintaining ease of maintenance. Driveshaft eliminated, allowing more space in the chassis for flexible and efficient battery pack installation. Integrated design results in lighter weight, higher efficiency, and better energy savings. Technology Highlights Our e-axle for trucks features a 2-speed AMT. It enables active speed synchronization between the motor and the transmission input shaft, allowing for rapid and smooth gear shifts. By combining gear profile modification with in-depth analysis of casing and shaft tooth deformation, the system achieves optimal meshing conditions, minimizing transmission error and reducing efficiency loss. Shorter gear shifting time Higher transmission efficiency Lower operating noise How We Ensure the Reliability of Our E-Axle for Trucks Our e-axle system undergoes a rigorous multi-level validation process to guarantee long-term performance, safety, and durability under real-world operating conditions. Component-Level Testing Over 50 tests are conducted on individual components to verify structural integrity, strength, and consistency. These include: Vibration Salt spray Tensile Torsion Hardness Full-dimension inspections Subsystem-Level Testing More than 90 tests are performed across all core subsystems – including the shifting mechanism, gearbox, motor, high/low voltage controllers, wiring harnesses, and software. These tests fall into six major categories: Module validation Functional testing Performance testing Durability testing Reliability testing Environmental resistance System-Level Testing Over 50 tests are carried out at the system level using specialized test benches and real-vehicle road trials, including: High and low temperature cycling Thermal shock testing Salt spray and corrosion resistance Waterproof and dustproof validation Vibration and noise testing System integration and special-condition simulation R&D and Manufacturing Excellence Comprehensive and Integrated R&D Capabilities The R&D team is built on a robust, cross-functional framework encompassing structural engineering, electronic hardware, system architecture, software development, testing, and manufacturing processes. We maintain a full-spectrum development capability that spans from concept design to real-world validation. With in-house expertise in mechanical design, control unit development, computer-aided simulation, bench testing, and complete vehicle road testing, we are equipped to support rapid iteration and innovation across the entire product lifecycle. Hybrid and pure electric powertrains Transmission systems and controllers Electric motors and motor controllers Shift and clutch actuators Vehicle control units (VCUs) Quality Management & Full Lifecycle Traceability The factory strictly adheres to IATF 16949, ISO 14001, and other international standards, ensuring precise control over every production process and uncompromising quality in every product. The digital management system enables a full lifecycle traceability and control, ensuring that every component is trackable and accountable from production to delivery. In 2025, the e-axle for trucks production capacity is expected to exceed 10,000 units, further demonstrating our ability to scale with quality and consistency. Application Example This e-axle for trucks has been successfully deployed in 6×4 battery electric semi-trucks, which are now in mass production. Key vehicle specifications include: curb weight: 11 tons; gross vehicle weight:25 tons; maximum towing capacity: 37 tons; top speed: 89 km/h 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

BTMS project - 1 EV thermal management system for electric mining truck

Heavy Transport, Technologies

EV Thermal Management System for Battery Electric Mining Trucks

EV Thermal Management System for Battery Electric Mining Trucks For battery electric mining trucks, it’s critical to maintain the traction battery within an optimal temperature range to ensure both performance and safety. Given the high charge and discharge currents typical of mining operations, the EV thermal management system adopts a liquid cooling technology with superior heat dissipation efficiency. How Does the EV Thermal Management System for Battery Electric Mining Trucks Work? The EV thermal management system for battery electric mining trucks works by actively heating or cooling the coolant to keep the battery operating between 25°C and 35°C, which is considered the ideal thermal range for lithium battery performance. The system is also capable of maintaining the temperature difference between individual cells within 5°C, ensuring consistent operation and extending overall battery lifespan. Operating Principle The heat exchanger inside the EV thermal management system features two flow channels: one channel circulates coolant, the other circulates refrigerant. These channels are alternately arranged:odd-numbered layers carry coolant, while even-numbered layers carry refrigerant. Heat is exchanged between the two media, reducing the temperature of the coolant before it is circulated into the battery pack to absorb and dissipate heat from the cells. In cold environments, a PTC heater is activated to warm the coolant, which in turn heats the battery, ensuring safe operation and charging efficiency at low ambient temperatures. A simplified schematic of the EV thermal management system Our Integrated EV Thermal Management System for Battery Electric Mining Trucks Our integrated EV thermal management system for battery electric mining trucks is designed to address the following key challenges: Cabin climate control Maintain a comfortable temperature and airflow for the driver. Defrost and defog the windshield for clear visibility. Control cabin humidity and air outlet temperature to ensure a clear driving view. Battery temperature regulation Prevent extreme temperatures from affecting charging/discharging rates and battery lifespan. Motor cooling Maintain optimal coolant temperature for efficient motor operation. Limited space constraints Electric commercial vehicles require additional battery cooling, but lack waste heat from an engine. Complex vehicle layout with multiple components. Solution Introduction The integrated EV thermal management solution is engineered to manage both cabin and e-powertrain temperature needs. By sharing core components such as the condensers module and compressor module, the system supports both air conditioning and equipment cooling/heating, ensuring stable and efficient vehicle operation. Solution Advantages High Efficiency & Energy Saving: Features variable-speed compressor, smart fan control, and motor waste heat recovery to minimize energy consumption. Reliable and Safe: Equipped with multiple layers of protection for pressure, temperature, current, and voltage to ensure system safety. Intelligent Control: Supports CAN bus vehicle communication, human-machine interface (HMI), and real-time display of temperature and airflow conditions. Highly Integrated Design: Combines heating and cooling modules into a single compact unit, with shared use of PTC heaters, fans, and other components to reduce footprint and simplify vehicle layout. Discover our BTMS Solutions here: https://brogenevsolution.com/battery-thermal-management-system-btms/ 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 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 electric motor for trucks electric truck motor with AMT for electric dump trucks

EV Industry, Heavy Transport

Integrated ePowertrain Solution for Electric Dump Trucks: Motor + 2-Speed AMT

Integrated ePowertrain Solution for Electric Dump Trucks:Motor + 2-Speed AMT This integrated ePowertrain solution is ideal for Class 7 electric heavy-duty trucks around 12 tons, such as electric dump trucks. It combines a high-performance motor with a 2-speed AMT to optimize system efficiency and extend the lifespan of key components, even under heavy-duty operating conditions. Lower energy consumption Higher torque performance Long-term durability Safety and environmental friendliness Enhanced driving comfort Email: contact@brogenevsolution.com Get Custom Quote Optimized ePowertrain for Heavy-Duty, Low-Speed Operations Background In today’s electric heavy-duty truck market, many OEMs adopt a direct-drive architecture – using a single PMSM to drive the shaft – mainly to reduce cost. While simple and cost-effective, this design struggles to deliver efficient motor performance across both low-speed high-torque and high-speed low-torque working conditions. This challenge becomes even more critical for electric dump trucks operating in urban construction and transport scenarios, where vehicles often run under heavy-load and low-speed conditions such as uphill driving or stop-and-go operation. Our Solution: PMSM + 2-Speed AMT ePowertrain To overcome the limitations of traditional direct-drive systems in electric dump trucks, we provide a dedicated ePowertrain solution that pairs a high-performance PMSM with a 2-speed AMT. This configuration is specifically engineered to enhance energy efficiency and extend system durability under heavy-duty, low-speed operating conditions. This combination enables the motor to operate more efficiently in low-speed, high-torque scenarios – such as hill climbing or fully loaded starts, where energy losses are typically high. By optimizing motor load and shifting gears as needed, this system helps reduce overall power consumption and prolong motor life, even during continuous high-load operation. In addition, the inclusion of a 2-speed AMT provides greater flexibility for PTO integration, which is essential for construction and utility vehicles that require hydraulic lifting or other auxiliary power applications. System Parameters Model Drive motor Transmission System PTO Rated/peak power Rated/peak torque Maximum speed Number of gears Speed ratio Maximum output torque System weight Maximum output torque Speed ratio OETED3010 80/160 kW 500/1100 N.m 4500 rpm 2 1st – 2.7412nd – 1 3015 N.m 174 kg 1.175 300 N.m OETED3380 120/185 kW 650/1300 N.m 3500 rpm 2 1st – 2.7412nd – 1 3380 N.m 210 kg 1.175 300 N.m Solution Advantages – High Reliability & Proven Performance Our 2-speed AMT gearbox is rigorously tested to meet the highest reliability standards: Waterproof, dustproof, high/low temperature, salt spray, and vibration resistance Over 3x rated torque in static torsion tests 1 million gear shifts in durability per gear 200,000 km bench durability simulation 50,000+ km road testing Consistency testing across 50 units Targeted service life: 1 million kilometers Over 30,000 units of the motor+AMT ePowertrain have been deployed Application Example This electric dump truck is equipped with a motor and a 2-speed AMT e-powertrain. The motor delivers a peak power of 160 kW, significantly improving efficiency during low-speed, high-torque operating conditions. Discover more of our electric truck motor solutions here: https://brogenevsolution.com/electric-motors-for-truck/ Business inquiry: contact@BrogenEVSolution.com We usually reply within 2 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

EV Industry, Heavy Transport

Electric Truck Axle Guide: How to Choose the Right E-Axle for Heavy-Duty Trucks?

Electric Truck Axle Guide: How to Choose the Right E-Axle for Heavy-Duty Trucks? 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, using

EV Industry, Heavy Transport

Development Trends in Battery Electric Heavy Duty Trucks (e-HDTs)

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

electric heavy truck with brogen electric truck axles

Heavy Transport

Brogen Electric Truck Axles Drive Our Partner’s First Batch of Heavy-Duty Electric Trucks

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

Heavy Transport, Industry Insight, Specialty Equipment

Case Study: Electric Street Sweeper for Urban Cleaning

Electric Street Sweeper: Leading the Way in Urban Sanitation Electrification Introduction: Electrification Is Reshaping Urban Sanitation As cities around the world prioritize sustainability, the transition to electric vehicles (EVs) has become increasingly significant. One key player in this movement is the electric street sweeper, a revolutionary piece of sanitation equipment that combines powerful performance with environmental responsibility. This electric road sweeper represents a game-changing step forward in municipal cleaning technology, offering a cleaner, quieter, and more efficient alternative to traditional diesel-powered models. This case study highlights a production electric street sweeper model, demonstrating how electrification is transforming the industry — and how we can support street sweeper manufacturers with tailored electrification solutions, including high-performance motors, battery systems, and charging technologies. A Benchmark in Electric Street Sweeper Design The electric sweeper featured here represents a new generation of urban cleaning equipment: Dimensions: 9270 × 2490 × 3150 mm Curb weight: 8.05 tons Gross vehicle weight: 18 tons Sweeping width: Standard 4.1 meters; Deep-cleaning mode 2.4 meters Tank capacity: 8.5 m³ freshwater, 7.5 m³ wastewater Functions: Full sweeping and washing, one-sided sweeping, deep cleaning, winter water-blow, high-pressure tank self-cleaning This electric sweeper is engineered for high performance in city streets, municipal squares, industrial sites, and more, delivering superior cleaning efficiency while reducing environmental impact. Core Electrification Technologies 1. High-Efficiency Electric Motor The electric street sweeper is powered by a permanent magnet synchronous motor, which offers 350 kW peak power (about 476 horsepower), ensuring strong and reliable performance under various urban conditions. The motor operates with a high efficiency rate of 98%, converting electrical energy into mechanical power with minimal loss. Key benefits of this electric motor include: Mud and condensation resistance: Ensures the motor stays protected even in challenging working environments. 8-year maintenance-free bearings: Reduces maintenance costs and extends the lifespan of the vehicle. IP68 & IP6K9K protection levels: The motor is protected against water, dust, and debris, allowing it to perform reliably even under extreme weather conditions, including heavy rain and floods. 2. Multi-In-One Controller for Optimized Energy Efficiency This electric street sweeper is equipped with a carbon-silicon (SiC) multi-in-one controller. This state-of-the-art controller is designed for high efficiency and low energy consumption, and it offers a host of advantages: Energy savings: The system boosts overall energy efficiency by 8%, allowing the vehicle to run longer on a single charge. Reduced failure rates: The failure rate is reduced by 25%, ensuring more reliable performance. Weight reduction: The controller weighs 50% less than traditional models, helping to improve the vehicle’s overall energy efficiency and performance. Together, these elements combine to make the electric road sweeper a highly reliable and efficient vehicle for urban sanitation needs. 3. Powerful and Efficient EV Battery Design At the heart of this electric sweeper is a high-capacity EV battery system that ensures both longevity and performance. The electric street sweeper’s battery is housed behind the driver’s cabin and is designed for long-lasting power: Rated voltage: 589.26V Rated capacity: 456Ah Total energy capacity: 268.7 kWh This system provides excellent energy density, achieving 175Wh/kg, which allows for longer operational times between charges. Moreover, the battery has been engineered for durability with an IP68+IP6K9K protection level, allowing it to withstand extreme conditions — including up to 72 hours submerged under 2 meters of water. 4. Fast Charging Capabilities The electric street sweeper incorporates fast-charging technology that dramatically reduces downtime: Single gun fast charge: 300A Dual gun fast charge: 600A This unique charging system increases the charging speed by 20%, ensuring the sweeper is ready to return to work quickly, minimizing the interruptions to city cleaning operations. With the combination of fast charging and long-lasting battery capacity, this sweeper is built to tackle large-scale urban cleaning projects without requiring extensive downtime. Environmental and Economic Impact Sustainability Benefits The electric street sweeper is a key part of the ongoing effort to electrify municipal vehicles and reduce urban pollution. Unlike traditional fuel-powered sweepers, which emit harmful pollutants and contribute to greenhouse gases, this electric sweeper has: 10% of the energy consumption compared to a diesel-powered model. A significant reduction in carbon emissions, supporting cities in their sustainability efforts. Cost-Effectiveness Additionally, the operating costs are significantly lower than those of diesel vehicles: Lower fuel costs due to the use of electricity instead of diesel. Reduced maintenance costs thanks to the maintenance-free bearings and robust motor design. The vehicle’s overall economic performance and long-term cost savings make it a highly attractive option for municipalities looking to upgrade their sanitation fleets without sacrificing performance. Partner with Us: Your Expert in Electric Street Sweeper Solutions With over 14 years of experience in the EV industry, we’ve helped more than 300 EV builders worldwide successfully deploy their projects — from electric trucks and buses to sanitation vehicles like electric sweepers. Our electrification solutions for street sweepers or other municipal vehicles include: Electric Powertrain Solution Electric Drive Motor The motor achieves a maximum efficiency of over 97%, with the system efficiency exceeding 90% in 90% of the operational range. 2m 72h extreme water-proof, sediment-proof structure, anti-condensation structure, long-life bearing and oil seal. Noise at full speed section of motor ≤72dB(A), linearity≤2dB(A). Lightweight design X-in-1 Integrated Controller Maximum efficiency>99% EMC reaches class 5 under no-load Functional safety level ASIL C Motor controller+steering controller+air compressor controller+DC/DC+high voltage power distribution Tailored EV Battery System Full system integration of battery Pack+BMS+BTMS+PDU Premium battery cells from top battery cell suppliers Excellent thermal management strategy for enhanced reliability Lightweight design with alumium alloy composites for battery box DC Fast Charging Solution Tailored solutions from project consulting, product delivery to after-sales support. Professional training for installation, operation, and maintenance. Free technical support throughout the product lifecycle for safe and efficiency operation 60 kW to 420 kW integrated DC fast chargers with CCS2 standard 80 kW to 400 kW integrated DC fast chargers with GB/T standard Power distribution system Charging operation management system, flexible user-friendly payment and charging options Security & monitoring system Fire safety system Other Solutions Onboard Charger Auxiliary Inverter Electric Power Steering Air Brake

Heavy Transport, Industry Insight

What Will Be the Mainstream Battery Capacity of Electric Heavy Trucks in 2025?

What Will Be the Mainstream Battery Capacity of Electric Heavy Trucks in 2025? In 2024, the electric heavy truck market has seen unprecedented changes. Fierce industry competition, exploration of long-haul transportation, significant price drops, the rise of large-battery electric heavy trucks, and the resurgence of fast-charging trucks have all shaped the current landscape. Among these changes, the sharp decline in vehicle prices has left the deepest impact. More importantly, it has accelerated the large-scale adoption of electric heavy trucks with higher battery capacities — a trend that is fundamentally reshaping fleet operations. The substantial reduction in purchase costs has opened the door for the widespread deployment of electric heavy trucks equipped with large-capacity battery packs. While electric heavy trucks with smaller battery capacities have seen a relative decline in market share, their sales continue to grow steadily. They remain an essential part of the market and are far from being phased out. According to the Research, the battery capacity of electric heavy trucks currently available on the market varies significantly — ranging from 282 kWh to 729 kWh. This diversity provides operators with more choices, but also raises an important question: How should fleet operators choose the right electric heavy truck configuration for their specific application scenarios? (Note: This article refers to electric heavy trucks used for legally compliant, standard-load transportation.) Operational Scenarios Define Battery Capacity Requirements After several years of development, electric heavy trucks have been primarily applied in short-distance transport scenarios, such as port drayage, mining logistics, and regional distribution. However, the industry is actively testing electric heavy trucks in long-haul and trunk line transportation, leading to increasingly diverse and complex operational demands. One of the most widely discussed topics remains driving range — a factor directly linked to battery capacity. While a higher battery capacity provides a longer range, it also increases vehicle weight, reducing payload capacity and potentially affecting profitability. For instance, a 300 kWh battery pack typically weighs around 1,875 kg. Including the battery frame and auxiliary structures, the total battery system weight easily exceeds 2 tons. (This calculation assumes an energy density of 160 Wh/kg, meaning approximately 6.25 kg per kWh.) Under legal load restrictions, the heavier the battery, the lower the cargo capacity — posing a challenge for operators to balance battery size and transport efficiency. Example 1: Short-Haul Urban Logistics — Prioritizing Light Weight and Flexibility In urban logistics scenarios, where electric heavy trucks operate within a city radius of 100-150 km, smaller battery capacities are often more practical. For example, a 350 kWh battery pack provides sufficient range for daily operations while minimizing additional vehicle weight. A logistics company operating within a port area in Shanghai chose electric heavy trucks equipped with 350 kWh batteries. These trucks focus on high-frequency, short-distance transport tasks, benefiting from fast-charging stations deployed within the port zone. The lighter battery system allows the trucks to maximize payload capacity while maintaining operational flexibility. Example 2: Long-Haul Trunk Line Transportation — Embracing Large-Capacity Batteries For long-haul transport scenarios, where electric heavy trucks must travel 300-400 km or more between charging opportunities, larger battery capacities become essential. In northern China, a coal transport fleet has adopted electric heavy trucks equipped with 729 kWh battery packs. These vehicles operate on a dedicated trunk line of approximately 350 km between two mining sites and a port terminal. The large-capacity batteries ensure sufficient range under heavy-load conditions and allow for fewer charging interruptions, improving overall transport efficiency. Conclusion: Choosing the Right Battery Capacity for Electric Heavy Trucks Ultimately, the choice of battery capacity for electric heavy trucks depends on the specific operational scenario. Operators must carefully evaluate transport distance, charging infrastructure availability, cargo load requirements, and total cost of ownership. Looking ahead to 2025, it is expected that electric heavy trucks with battery capacities ranging from 350 kWh to 600 kWh will become the mainstream choice for most standard logistics applications. Meanwhile, ultra-large battery systems above 700 kWh will continue to serve specialized long-haul and heavy-load transport needs. With the ongoing advancement of battery technology and the expansion of fast-charging networks, the future of electric heavy trucks looks promising, offering operators more efficient, sustainable, and cost-effective transport solutions. Looking for a customized EV solution for your electric heavy truck project?Discover here or 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

Heavy Transport, Industry Insight

Tips for Choosing the Right Electric Truck

Tips for Choosing the Right Electric Truck As the adoption of electric trucks continues to rise, their economic and environmental advantages are becoming increasingly evident across various use cases. More and more logistics companies are now considering a transition from traditional diesel-powered trucks to electric alternatives. However, shifting to electric trucks is not merely a matter of replacing diesel engines with electric motors. It requires a holistic transformation that includes considerations around battery range, charging infrastructure, operational strategies, and business model adjustments. According to industry research, many fleet operators are still in the exploratory phase of their electrification journey. The most common questions they face are:How do we select the right electric truck?What battery capacity is appropriate for our operations?This article provides a brief analysis of these two critical questions. 1. Understanding Two Key Energy Consumption Metrics: Technical vs. Economic Energy efficiency is a key factor for logistics companies when choosing a truck. In the diesel era, manufacturers emphasized fuel economy. In the electric era, the focus has naturally shifted to electricity consumption. However, the energy consumption figures provided by electric truck manufacturers are often based on short-term, controlled testing conditions—what can be called “laboratory data”—and may differ significantly from real-world usage. Before purchasing an electric truck, it’s essential to distinguish between two types of energy consumption metrics: ● Technical Metric (kWh/km) This refers to the energy used per kilometer to drive the vehicle and is the most commonly advertised figure by OEMs. Under standard test conditions—such as on level roads with balanced loading—many electric heavy-duty trucks achieve an average of 1.5 kWh per kilometer.However, this figure typically excludes the energy consumed by auxiliary systems such as thermal management, air conditioning, battery heating or cooling systems, and more. In real-world scenarios, especially during northern winters, the actual range of electric trucks can drop to only 60% of what is achievable in summer, meaning energy consumption increases significantly. Therefore, the technical metric is more of an idealized efficiency indicator that reflects the performance of the motor and drivetrain under optimal conditions, without accounting for real-life variables. ● Economic Metric (kWh per Ton) This is a more realistic metric for fleet operations. Rather than measuring energy per kilometer, it calculates energy use based on the amount of cargo transported—specifically, the total electricity consumed divided by the total tonnage hauled. This “ton-kWh” metric includes both driving energy and the power consumed by auxiliary systems. For logistics companies, focusing on this economic metric allows for a more accurate assessment of a vehicle’s real-world energy efficiency and operating cost, making it a more valuable reference for decision-making. It’s also important to remember that energy consumption can vary significantly depending on operational context, driving habits, road conditions, and climate. All of these should be considered when selecting a vehicle. 2. Is Bigger Battery Capacity Always Better? Once energy consumption is well understood, the next key question for logistics companies is: How much battery capacity do we really need?Battery capacity directly determines the driving range and operational efficiency of an electric heavy-duty truck. Selecting the right battery specification for specific transport scenarios is critical for fleet operators. With technological advancements and declining raw material costs, battery options on the market have become increasingly diverse. Capacities have grown from 282 kWh just a few years ago to 350 kWh, 423 kWh, and even 500–800 kWh packs are now available. But does bigger always mean better when it comes to batteries? ● The Trade-offs of Larger Battery Packs Admittedly, a larger battery pack can significantly extend a truck’s driving range and reduce the frequency of charging, improving operational flexibility. This naturally appeals to many logistics operators looking to maximize efficiency. However, when choosing battery capacity, companies must carefully balance several factors — including actual operational needs, cost budgets, and compatibility with available charging infrastructure. ● Key Considerations: If local charging facilities cannot support fast charging for large-capacity batteries, it may hinder the vehicle’s turnaround efficiency — offsetting the benefits of a larger battery. Heavier batteries increase the truck’s curb weight, reducing its payload capacity and, in turn, affecting the profitability of the fleet. For example, current battery technology adds approximately 5 to 6 kg of weight per additional kilowatt-hour. Comparing a 282 kWh battery to a 423 kWh battery, the weight difference exceeds 700 kg. If a truck operates two trips per day, this weight penalty translates to a reduction of 1.5 tons of cargo capacity daily. Over the course of a year (assuming 300 working days), the lost payload could amount to 450 tons — a significant profit loss that logistics companies cannot ignore. Moreover, larger battery packs drive up the initial vehicle purchase cost, placing additional financial pressure on logistics operators in the early stages of electrification. Final Thoughts Whether evaluating the true energy consumption of an electric truck or selecting the appropriate battery capacity, logistics companies must consider these decisions within the context of their specific transport scenarios and operational requirements. By taking a comprehensive approach — weighing energy efficiency, operational demands, infrastructure readiness, and cost-effectiveness — companies can strike the optimal balance between economic benefit and operational efficiency, paving the way for sustainable fleet development in the electric era. 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,