Heavy Transport | Page 2 of 3 | Brogen EV Solution | Shanghai OE Industrial Co., Ltd.

Heavy Transport, Industry Insight, Technologies

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

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

Heavy Transport, Industry Insight

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

18-Ton Heavy Duty Electric Truck: E-Powertrain Configuration As electric vehicles continue to rise in popularity, pure electric light trucks and tractors are gaining traction due to their efficiency and cost-effectiveness. However, heavy trucks can also benefit from electrification. This 18-ton heavy duty electric truck features a powerful 322 kWh battery, providing an estimated range of approximately 460 kilometers under consistent driving conditions. This makes it an excellent choice for urban logistics and intercity transportation across various regions. 322 kWh EV Battery System This vehicle is equipped with a liquid-cooled battery systems boasting an impressive capacity of 322 kWh. The battery pack is securely integrated within the chassis frame, offering excellent protection and leaving ample space on both sides for additional installations, such as toolboxes. 160 kW Electric Drive Axle This vehicle is equipped with a two-speed electric drive axle, featuring a drive motor with a peak power of 160 kW and a maximum output torque of 27,600 N·m. The integration of the electric drive axle eliminates the need for components like the driveshaft and universal joints, enhancing overall efficiency and performance. Compact and Lightweight Design For cargo trucks, curb weight has always been a major concern, as it directly affects the vehicle’s loading capacity and consequently, the profitability of each trip. Even though this vehicle is equipped with a large 322 kWh battery system, its curb weight control is still quite impressive. The chassis has an unladen weight of only 7800 kg, with a gross vehicle weight of 18,000 kg. Conclusion Given the current competitive landscape in the logistics industry, businesses and individuals are continually striving to reduce costs and improve operational efficiency. With their outstanding economic performance and efficient transportation capabilities, pure heavy duty electric trucks have become a new choice for urban distribution and intercity transportation. Our Solution for Heavy Duty Electric Trucks At Brogen, our customizable EV systems accelerate heavy-duty electric truck development by reducing R&D costs and time, boosting efficiency, and providing a competitive advantage for EV manufacturers in the rapidly expanding market. Electric Axle 165 kW – 360 kW Explore Traction Battery Customizable Explore Auxiliary Inverter DC/DC, DC/AC, PDU Explore Contact Us Get in touch with us by sending us an email, using the Whatsapp number below, or filling in the form below. We usually reply within 2 business days. Whatsapp: +8619352173376 Email: contact@brogenevsolution.com ContactFill in the form and we will get in touch with you within 2 business days.Please enable JavaScript in your browser to complete this form.Please enable JavaScript in your browser to complete this form. Name * FirstLast Work Email *Company Name *Your EV Project Type *– Please select –BusLight-duty truckHeavy-duty truckConstruction machineryVesselOthers (please write it in the note)Your Interested Solutions *– Please select –MotorBatteryChassise-AxleAuxiliary inverterOBC / DCDC / PDUAir compressorEPS / EHPSBTMSOthers (please write it in the note)Do you have other contact info? (Whatsapp, Wechat, Skype, etc.)Please introduce your EV project and your request here. * Checkbox * I consent to receive updates on products and events from Brogen, and give consent based on Brogen’s Privacy Policy. Submit

Heavy Transport, Technologies

160 kW / 360 kW Electric Axle for Trucks

160 kW / 360 kW High-Voltage Electric Axle for Trucks System Introduction This electric axle for trucks boasts a rated power of 160 kW and a peak power of 360 kW. Utilizing a distributed drive system, it integrates two PMSM electric motors within the e-axle. The advanced gear-shifting control strategy ensures uninterrupted power delivery during gear changes, enhancing driving safety. Additionally, in the event of a single motor failure, the remaining motor continues to provide power, offering an extra layer of safety redundancy to the eAxle system. Benefits of Our Electric Axle for Trucks – Safe Core Strategy Controlled by the distributed drive electronic differential system; equipped with EASR, IESS safety configurations. Benefits Reduce the vehicle energy consumption, and increase vehicle safety and stability in harsh environments; the electronic differential lock can effectively get out of trouble on the road. Lower Gravity Center The gravity center of the battery system is lowered by 1620 mm. Benefits Provide ample space for the bottom placement of the battery and increase the stability of the whole vehicle. Dual Motor Design Integrating the dual motor structure and advanced gear-shifting control strategy to ensure uninterrupted power delivery during gear changes. Beneifts It’s safer and more comfortable to drive the vehicle. Benefits of Our Electric Axle for Trucks – Economical 0 % The transmission system features a simple structure with a concise transmission chain, enhancing overall system efficiency by up to 4% 0 % Enhanced Energy Regeneration by 100%: The gear’s forward and reverse torques are balanced, significantly improving energy regeneration efficiency and extending the driving range. Benefits of Our Electric Axle for Trucks – Powerful & Lightweight 0 N.m The maximum output torque for a single axle can reach 51480 N.m. The maximum motor generation torque can also reach 51480 N.m, reducing brake heat fade on long downhill stretches and eliminating the need for additional water cooling for the brakes. 0 kg The single e-axle weight is about 920 kg. For 4×2 tractor-trailers, the distributed drive system reduces weight by 462 kg compared to direct drive systems and by 300 kg compared to central drive electric axle systems, increasing payload capacity. Product Parameters Motor type: PMSM Motor power (rated/peak): 2×80 kW / 2×180 kW Motor speed (max.): 9500 rpm Motor torque (rated/peak): 2×260 N.m / 2×520 N.m Rated voltage: 540 VDC IP rating: IP68 E-axle weight: 950 kg Rated axle load: 13000 kg Wheel speed (max.): 620 rpm Gear ratio: 49.4/15.3 Rim size: 22.5 inch Tire size: 12R22.5 Brake: Air disc brake Contact Us Get in touch with us by sending us an email, using the Whatsapp number below, or filling in the form below. We usually reply within 2 business days. Whatsapp: +8619352173376 Email: contact@brogenevsolution.com ContactFill in the form and we will get in touch with you within 2 business days.Please enable JavaScript in your browser to complete this form.Please enable JavaScript in your browser to complete this form. Name * FirstLast Work Email *Company Name *Your EV Project Type *– Please select –BusLight-duty truckHeavy-duty truckConstruction machineryVesselOthers (please write it in the note)Your Interested Solutions *– Please select –MotorBatteryChassise-AxleAuxiliary inverterOBC / DCDC / PDUAir compressorEPS / EHPSBTMSOthers (please write it in the note)Do you have other contact info? (Whatsapp, Wechat, Skype, etc.)Please introduce your EV project and your request here. * Checkbox * I consent to receive updates on products and events from Brogen, and give consent based on Brogen’s Privacy Policy. Submit

Electric municipal vehicle water truck with our electric truck axle

Heavy Transport, Specialty Equipment, Technologies

18-ton Battery Electric Water Truck With Our Electric Truck Axle

Introduction This case highlights our collaboration with an EV manufacturer to deliver a highly efficient, 100% electric water truck. Specializing in municipal and specialty vehicles, the EV manufacturer serves an environmental resources company as their end customer. This innovative vehicle incorporates our advanced electric truck axle technology. Application of Our Electric Truck Axle Our electric truck axle utilizes the latest e-axle technology, featuring a distributed approach that offers numerous benefits including low noise, extended cruising range, intelligent control, energy efficiency, and high performance. For instance, the 18-ton water truck in this project is equipped with a 231 kWh EV battery system. Thanks to the energy-saving and efficiency-boosting design, it achieves a cruising range comparable to a similar vehicle with a 280 kWh battery system. This allows up to 8 hours of operation on a single charge, significantly reducing costs for fleet operators. More features about this water truck: Versatility and Safety of Our Electric Truck Axle Our electric drive axle is also suitable for heavy-duty trucks, tractors, and trailers. The distributed approach enhances safety redundancy, ensuring that even if one motor fails, the other can continue to operate normally. Advanced software technology further ensures vehicles’ safety and reliability. Learn more about our innovative e-axle solutions here. Benefits of Upfit Electrification We also provide electric motors for the upfit of specialty and hybrid vehicles, such as street sweepers, water trucks, and concrete mixers, etc. Upfit electrification separates the power source for retrofitting from the vehicle’s drive systems. This enables specialty vehicles like hybrid concrete mixers to shut off their engines during loading and unloading while maintaining retrofit operations. Drivers can also benefit from air conditioning in hot weather. For fleet operators, this significantly reduces annual fuel costs. Learn more about our electric motor solutions here. EV Battery Systems At Brogen, we offer standard LFP EV battery packs for electric trucks, as well as fast-charging LMO battery packs for PHEVs, FCEVs, HEVs used in applications such as mining trucks, dump trucks, forklifts, and AGVs. Learn more about our EV battery systems here. Contact Us for Comprehensive Electrification Solutions We offer a wide range of customizable electrification solutions for EV manufacturers. Our product lineup includes electric motors, electric axles, EV batteries, on-board chargers, and more. If you are seeking an EV solution for your project, please contact us by filling out the form below or by emailing us at contact@brogenevsolution.com. We typically respond within two business days.

Heavy Transport, Industry Insight, Light Commercial Vehicles

EV Truck Drive Systems: Direct Drive Motor vs. E-Axle

When it comes to the pure EV truck, understanding the differences between traditional electric motor structures and modern e-axle systems is crucial. Let’s use an electric dump truck as an example to explore these differences. Traditional Drivetrain Structure – Direct Drive Motor The traditional drivetrain in electric trucks closely resembles the layout found in conventional vehicles. The drive motor, equivalent to a diesel engine, is the heart of this system. Directly behind the motor is a reducer, functioning similarly to a traditional gearbox. The reducer’s job is to increase torque by reducing the motor’s speed, effectively amplifying power. This amplified power is then transmitted through a driveshaft to the rear axle. The rear axle, with a gear ratio of approximately 5.857, is comparable to that of traditional dump trucks. How It Works A notable feature of this system is the two-speed function of the reducer, which allows the vehicle to switch between different gear ratios based on the load, similar to shifting gears in a traditional transmission. This functionality provides both speed and power as needed. E-Axle System Now, let’s delve into the e-axle system. An e-axle integrates the electric motor with the rear axle, combining four major functions: the motor, rear axle, transmission, and differential. This integration brings several significant advantages: However, the e-axle system does present challenges. Integrating the motor with the rear axle reduces space for torque amplification mechanisms, potentially limiting the power output compared to traditional setups with a gearbox. Achieving high power levels with an e-axle requires advanced design and engineering capabilities. Brogen’s Solutions At Brogen, we supply traditional drive motor and e-axle systems for electric vehicle builders. Our e-axle for heavy-duty trucks can deliver a maximum output torque of 50,000 Nm, providing ample power for these vehicles. Our electric motors offer power options ranging from 165 kW to nearly 800 kW, catering to various commercial vehicles, including light trucks, tractors, concrete mixers, and more. Explore our cutting-edge electric axle solutions and see how Brogen can help you achieve success in the rapidly expanding e-mobility sector. Contact

blade battery for battery electric truck

Heavy Transport, Industry Insight, Light Commercial Vehicles, Technologies

How Blade Battery Packs Benefit the Electric Truck?

Electric Trucks Equipped With Blade Batteries: Higher Energy, Lower Consumption The latest all-electric truck from BYD features blade battery packs. Introduced by BYD four years ago, these LFP blade battery packs eliminate the module design, reducing many structural components. The close connection between the upper and lower casings and the battery cells significantly increases volumetric energy density, reaching levels comparable to high-energy-density ternary lithium batteries. This battery electric vehicle model boasts a battery capacity of 94.3 kWh, providing a pure electric range of over 275 kilometers, surpassing the typical 100~200 kilometer range of industry-standard electric light trucks. In addition to the impressive energy density, blade battery technology offers higher thermal stability, lower thermal runaway temperature, smaller thermal runaway reactions, and a reduced likelihood of thermal runaway compared to ternary lithium and standard LFP batteries. This makes the light-duty truck, which operates over longer distances annually, safer. The blade battery’s exceptional thermal management extends battery life, improves charging and discharging efficiency, and shortens charging time. This all-electric truck can achieve over 100 kilometers of range with just half an hour of charging, further enhancing operational efficiency. Electric Truck Chassis Optimization: Better Layout, Higher Load Capacity Unlike traditional electric light trucks that position the standard battery boxes on the sides of the chassis or hang them in the middle, this electric truck’s blade battery is semi-embedded within the chassis frame. This structure integrates the battery into the chassis, making it part of the vehicle’s framework, providing both an energy source and structural rigidity. This design completely revolutionizes traditional electric light truck chassis layouts. Additionally, the semi-embedded design increases the chassis’ ground clearance, improving overall vehicle possibility. The flat-laying design of the chassis battery allows the truck to use a direct-drive system with an integrated electric drive axle. This system features a flat-wire motor and reducer within a shared casing, improving slot fill rate and efficiency. The lightweight aluminum alloy casing enhances transmission efficiency and reduces energy loss compared to traditional direct-drive systems. In terms of the suspension design, the vehicle uses a 3/5+6 leaf spring, with significantly more leaves in the rear axle springs, directly boosting the vehicle’s load capacity. Cabin Design: More Space, Lower Wind Resistance Building on the previous generation electric light truck, which positioned the integrated controller and battery systems on the sides of the chassis under the body, this EV truck continues this design, thanks to the more compact blade battery pack. This allows for a more spacious cabin layout. The cabin details have been optimized, upgrading the traditional mechanical handbrake to an electronic handbrake for increased comfort during driver rest periods while charging. Additionally, the vehicle’s battery system is split into two sets: one located on the side of the chassis under the body, and the other under the tilting cab, powering the low-voltage system of the cabin. This separated design enhances the stability and safety of the cabin’s power supply system. Summary In summary, the new electric light-duty truck, equipped with a 94.3 kWh blade battery, not only significantly improves vehicle range but also addresses user-identified issues through comprehensive upgrades to the chassis structure and cabin design. By leveraging blade battery technology, the vehicle reduces costs and increases efficiency for users. With competitive blade battery prices and enhanced electric truck battery capacity, BYD’s approach to batteries for electric vehicles sets a new standard in the industry. Looking for an EV Battery System for Your Project? Here at Brogen, we provide customized EV battery solutions, including standard LFP battery packs and advanced LFP blade battery systems for trucks, buses, vans, and other construction equipment or specialty vehicles. Contact us through the form below and we’ll get back to you shortly to discuss how we can empower your EV project!

Heavy Transport, Specialty Equipment

Pure Electric Mining Truck Project

This collaborative project enabled our client, a leading construction equipment manufacturer, to replace diesel mining trucks with its own line of purpose-built, all-electric mining truck models designed specifically for rugged, mountainous terrain. These innovative electric mining trucks offer many advantages, including ample battery capacity, reliable performance, and adaptability in a variety of working environments. This strategic shift has not only resulted in fuel cost savings but has also made a significant dent in carbon emissions. As a result, it represents a win-win scenario that offers both economic benefits and environmental stewardship – an offer that has been enthusiastically embraced by our client’s customer base. Project Overview Project timeline: 2021 Offered products: E-powertrain system (dual motor power uninterrupted solution) Application: 120-ton to 180-ton mining truck Provided services: Pre-sales consultation; solution planning; technical coordination; product testing; shipping; post-sales technical support; onsite debugging Challenge Our client, a seasoned manufacturer of construction equipment, places a strong emphasis on thorough, scientifically supported research prior to making any significant decisions. They recognize that establishing trust is the pivotal first step in our partnership. They also highlight that relying solely on branded core components does not guarantee consistent equipment quality, especially with the introduction of novel electric technologies requiring heightened caution. In addition, design integrity is fundamental. How effectively we address challenges has a significant impact on our customers’ perceptions. Our commitment extends beyond product delivery; we’re entrusted with ensuring the smooth flow of their vehicle production operations. Our Approach To meet the demanding power requirements of steep-grade applications, we introduce our dual-motor electric powertrain system. Designed to excel under continuous heavy loads, it delivers an impressive power output of up to 540 kW at rated capacity and 800 kW at maximum, equivalent to over 1000 horsepower. Even on a daunting 30% grade, it rises to the challenge, effortlessly pulling heavy loads while maintaining rapid movement, significantly improving transportation efficiency. Beyond design, our customer appreciates our proactive approach to problem-solving. In particular, they praise our “delivery is the beginning of service, not the end of sales” ethos. We don’t just provide products; we provide comprehensive green transportation solutions. Our commitment extends beyond the mere delivery of equipment; we ensure seamless production operations for our users. Providing dedicated field service personnel is just the beginning. When faced with complex challenges, we mobilize our R&D and quality teams and go the extra mile to support our customers’ production needs. Solutions We’ve Provided Motor 1 & Motor 2 Parameters Gearbox Parameters Gear 1 3 5 2 4 6 Speed ratio 9.16 3.02 1.22 5.27 2.17 1 System Parameters Contact If you’re seeking an EV solution for your project, feel free to fill out the following form. You can also write to us at contact@brogenevsolution.com Our experts will promptly respond within 2 business days, crafting a tailored EV system to empower your projects.

Heavy Transport

40-ton Electric Heavy Truck Project in Portugal

40-ton Electric Heavy Truck Project in Portugal Introduction This project marks a significant milestone as we partnered with a new energy company in Portugal to successfully deliver their first all-electric heavy-duty truck, signaling a decisive step towards zero carbon emissions. It embodies our mission and underscores our commitment to accelerating the transition to green renewable energy, advancing humanity’s journey to carbon neutrality, and driving societal progress. Project Overview Project timeline: 2021 Offered solutions: e-powertrain system, power steering system, braking system, 3-in-1 auxiliary converter Application model: 40-ton pure electric heavy duty truck Provided services: pre-sales consultation, solution planning, technical coordination, product testing, post-sales technical support, remote debugging Challenge Collaborating with this company on their first electric heavy-duty truck project presents both exciting prospects and challenges for both parties involved. For them, embarking on their first electric heavy truck endeavor poses a learning curve. Given their parent company’s background in construction and energy storage, their newly established new energy department may lack the technical expertise needed for designing and developing comprehensive EV solutions. Additionally, the R&D costs could be substantial, potentially leading to longer project timelines and delayed vehicle launches. For us, our foremost task is to establish clear lines of communication and grasp a thorough understanding of their requirements, preferences, and expectations for the heavy truck project. From there, we must devise tailored EV solutions to precisely meet their needs. Effective collaboration with their team is paramount to address any technical hurdles, tackle challenges head-on, and ensure seamless project execution. Our Approach In assisting this company in its EV truck project, our approach has been anchored in robust communication from inception to completion, ensuring a thorough understanding of our client’s needs. We’ve tailored the EV solution precisely to their specifications, guiding them through any technical challenges encountered along the way. Furthermore, we extend ongoing remote technical support and engage in cooperative discussions with their team to address any lingering technical concerns. Solutions We Have Provided 1. E-Powertrain (Electric Motor + Gearbox) We’ve equipped the truck with our 350 kW 2-in-1 integrated e-powertrain system, seamlessly combining the EV motor and gearbox alongside an independent MCU. The electric motor used in this project System Parameters Rated / peak power: 220 / 350 kW Rated voltage: 618 V Rated / peak speed: 1400 / 3000 rpm Rated / peak torque: 1500 / 2500 N.m Rated / peak current: 340 / 610 A Protection level: IP67/H Cooling method: liquid cooling Applicable models: heavy truck System Features The electric powertrain system with the gearbox Integrated motor: a streamlined design for convenient vehicle layout, eliminating phase harness EMC radiation while minimizing energy loss. Real-time weight measurement: ensures precision within 10%, while dynamic slope measurement boasts an accuracy of ±0.2° and static accuracy of ±0.1°. Adaptive shift timing: responds to factors like vehicle weight, slope, and driver input, including throttle system, pedal depth, and acceleration, adjusting shift points dynamically. Shift time clocks in at under 0.7s. Digital intelligent shifting: employs an electronically controlled shifting system for precise gear changes, enhancing overall performance. The electric powertrain system efficiency map 2. Power Steering System (Electric Hydraulic Power Steering) We have supplied the 4 kW electric hydraulic power steering system (EHPS) on the truck. The integrated design combines a motor, steering pump, ECU, DC power processing, and oil tank into a single unit, which maximizes space utilization, simplifies system integration, and offers compact size and light weight. The EHPS for this project System Parameters Rated power: 4 kW Rated voltage: AC 380 V Rated current: 7.4 A Rated torque: 34.2 N.m Rated speed: 1200 rpm Peak power: 10.75 kW Back EMF (rated speed): 140 V/krpm Peak current: 19.2 A Peak torque: 85.6 N.m Peak speed: 1281 rpm Controlled flow: 18±2 L/min Insulation class: H Rated efficiency: 92% Line resistance (20°C): 1.88Ω Phase resistance (20°C): 0.9Ω Working frequency: 80 Hz Protection class: IP67 Pole pairs: 4 Q-axis inductance: 9.3 mH D-axis inductance: 12.5 mH 3. Braking System (Air Brake Compressor) We have supplied the 4 kW oil-free air brake compressor for the electric heavy truck. With the latest technology, our air compressor delivers air that’s entirely oil and water-free, eliminating concerns of oil emulsification, leaks, and fire hazards. Its innovative structural design minimizes energy waste during compression, optimizing efficiency. The air brake compressor used in this project System Parameters Rated exhaust: 380 L/min Rated exhaust pressure: 1 Mpa Exhaust pressure: 1.2 Mpa Dimensions: 560*335*370 mm Motor power: 4 kW Weight: 65 kg Operating temperature: -40°C ~ + 60°C Protection class: IP67 4. Auxiliary Inverter We have used the 3-in-1 auxiliary inverter for the project, which consists of a DC/DC converter, a DC/AC oil pump, and a DC/AC air compressor. This integrated and lightweight design significantly reduces system weight and size. It not only offers a lightweight solution but also delivers substantial space, wiring, and cost savings for electric commercial vehicles. Result The e-powertrain system installed on the truck Our systems performed exceptionally well on the client’s 40-ton electric heavy trucks, earning high satisfaction from the client. As a result, they promptly initiated another project involving a 26-ton logistics truck (AGV) for port operations, utilizing our systems to efficiently transport goods between sites. Our Customizable Solution for Heavy-Duty Trucks For heavy commercial vehicles, we offer an extensive range of EV systems, including e-powertrains, batteries, chassis, braking systems, steering systems, and more. Our comprehensive solutions are designed to enhance fleet operational efficiency and elevate safety standards in heavy-duty transportation. Discover HCV solutions 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

E-axles that integrates motors, MCU , transmission system electric drive axle

Heavy Transport, Technologies

Introduction of the Electric Drive Axle for Heavy Duty Trucks

Introduction of the Electric Drive Axle for Heavy Duty Trucks Sales of electric trucks have continued to rise in 2023 compared to 2022, driven by strong and ambitious government policies. For heavy-duty vehicle manufacturers, adopting a reliable and powerful electric powertrain system is crucial to staying competitive in this rapidly expanding market. As demand for sustainable transportation grows, integrating advanced electric systems will be key to their long-term success. The Evolution of the Electric Drive Axle for Heavy Duty Trucks The evolution of heavy-duty trucks has gone through three distinct phases, with a vision of the future of electric mobility shaping the landscape. First, traditional fuel-powered trucks dominated the roads, with cabs that were flat and high drag coefficient. These trucks relied on engine-based power systems located at the bottom of the cab. The next phase saw the emergence of gas-electric heavy-duty trucks, which retained the central drive model but swapped the engine for electric motors. However, these vehicles retained conventional propulsion systems that were bulky, inefficient, and compromised cargo space due to rear-mounted battery boxes. Today, all-electric heavy-duty trucks typically use the electric axle as the e-powertrain system. EV solutions with electric drive axles provide increased transmission efficiency and space flexibility. At the same time, cabin structures are redesigned to lower the center of gravity and improve aerodynamics. Why The Electric Drive Axle is a Better Choice for Battery-Electric Trucks Building on the advanced design of the electric axle drive system, the structural design of the chassis for pure electric heavy-duty trucks can be further optimized, resulting in more efficient use of space. For example, all-electric heavy-duty trucks using our e-axle solution can eliminate traditional driveshafts, allowing the chassis structure to be redesigned to accommodate the battery spread flat across the chassis. This layout has many advantages: Placing the battery flat at the bottom allows for a larger battery capacity, extending the range while minimizing intrusion into the cargo area. By using a box-shaped beam frame structure, the battery pack is placed within the box frame structure, ensuring both battery safety and full utilization of the chassis load capacity. Lowering the vehicle’s overall center of gravity reduces the risk of rollover during cornering and improves driving stability and maneuverability. The overall appearance of the vehicle is improved. Analysis of Different Electric Powertrain Systems for Heavy Trucks At present, the primary e-powertrain configurations for electric heavy trucks encompass several distinct forms: Different configurations of electric powertrains for heavy-duty trucks Analysis of configuration characteristics of different electric drive axles Comparison of dual-motor central drive and dual-motor distribute drive systems An Example of Our Electric Drive Axle for Heavy Duty Trucks Let’s take our 360 kW eAxle as an example, which is suitable for 6×4 and 4×2 tractors and heavy-duty trucks. Compared to similar eAxle products on the market, our eAxle integrates two motors, providing higher system power and torque with a smaller footprint, and has 100% regenerative braking capability, eliminating mechanical differentials. This results in lower space requirements, weight, and cost. Our electric drive axle installed on the heavy-duty truck Additional Safety Redundancy In addition, our distributed drive system minimizes layout losses, reduces weight, and incorporates fault and safety strategies. The two drive systems are completely independent, consisting of a motor + 2-speed AMT and wheel-side reducer, using electronic differential technology and independently controlling the left and right drive systems. In the event of a single motor failure, the other motor can continue to operate normally, ensuring system safety. 23% System Weight Reduction Weight of different electric powertrain solutions for heavy trucks In contrast to the central drive system, our distributed drive system has achieved a weight reduction of 23.6%. Similarly, compared to the motor gearbox integration system, our distributed drive system has managed to reduce weight by 23.9%. Good Passability The distributed drive system boasts a 7.3% increase in ground clearance compared to the central drive system. Moreover, it achieves an even greater elevation of 11.7% when compared to the motor gearbox integration system. Higher Transmission Efficiency Compared to the central drive system, our distributed drive system demonstrates a 6% enhancement in overall transmission efficiency. High Security Currently, heavy-duty trucks are only equipped with ABS and lack ASR, ESC, and EDL. With our EV motor’s electronic differential system strategy control, heavy trucks can be equipped with ASR/ESC safety configurations, improving vehicle traction, stability, and safety. Technical Parameters for Brogen Electric Drive Axle for Heavy Duty Vehicles Our e-axle for heavy trucks showcased at Automechanika Shanghai 2023 Motor power (peak/rated): 2×180 kW / 2×80 kW Motor speed (max.): 9500 rpm Motor torque (peak/rated): 2×520 N.m / 2×260 N.m Maximum output torque: 50000 N.m Rated voltage: 540 VDC Axle weight: 950 kg Rated axle load: 13000 kg Wheel speed (max.): 620 rpm Gear ratio: 49.4/15.3 Solution Advantages The dual motor structure ensures uninterrupted power during gear shifts. Reduces vehicle weight by 300 kg, boosting loading capacity. A compact design saves chassis space and lowers the center of gravity for better stability. Maximum output torque of 50,000 N.m, ideal for 4×2 tractors. Passed 1 million load-bearing tests with 2.5 times load capacity, ensuring reliability. Equipped with ASR function for enhanced grip on slippery surfaces, ensuring safer driving. Relevant Solution All Posts EV Industry EV Products EV Projects Electric Axle for Heavy-duty Truck Read More 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,

Heavy Transport, Specialty Equipment

Concrete Mixer’s Mixing Drum Electrification Project

Client: A concrete company Demand: An EV solution for their 22 concrete mixer trucks to save fuel costs Introduction: In 2022, a concrete company approached us and wanted an EV solution for their concrete mixer trucks to reduce the fuel costs. Challenges Faced by the Concrete Company: In the concrete mixer industry, as long as the mixing tank is turning, the engine cannot be turned off. This has been a persistant challenge, leading to high fuel consumption. Between 36% and 70% of the operating conditions for concrete mixers involve idling. Although they operate for 12 to 14 hours a day, only half of that time is spent in actual motion. Prolonged idling not only significantly increases fuel consumption but also necessitates frequent engine maintenance, reducing the lifespan of the vehicles. The Axial Flux Motor Solution for Concrete Mixer: Starting in 2022, they implemented our EV system using axial flux motors. The system replaced the traditional hydraulic transmission of concrete mixers with an electrically powered attachement, achieving a separation of engine power and mixing drum power. During loading, unloading, or normail driving, the system’s onboard power battery provides the rotating power for the mixing drum autonomously, eliminating the reliance on engine power. Consequently, during vehicle idling, engine shutdown no longer affects the drum’s rotation, allowing the air conditioning system to function normally and resulting in a significant reduction in fuel consumption. Morever, the system incorporates an energy-efficient loop mechanism that automatically collects surplus power from the engine during vehicle operation to recharge the battery. As a result, the system minimally draws on the engine’s power, further enhancing fuel efficiency. Result: After almost a year of practical application, the results speak volumes: some trucks have achieved monthly fuel cost savings of up to $1000. Despite the inital investment required for the system, the company anticipates a swift return on investment, with costs recovered within a few months. Contact us We provide EV solutions for commercial vehicles, including buses, vans, light-duty trucks, heavy-duty trucks, mining trucks, vessels, and other construction machinery. If you’re looking for an EV solution for your fleet, you can contact us at contact@brogenevsolution.com. We usually respond within 2 business days.