Heavy Transport

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

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

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