Heavy Transport

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

Introduction of the Electric Drive Axle for Heavy Duty Trucks

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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,

axial flux motor on mixing tank
Heavy Transport, Specialty Equipment

Concrete Mixer’s Mixing Drum Electrification Project

Heavy Transport, Specialty Equipment /

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.

Axial Flux Motor on Concrete Mixer Truck
Heavy Transport, Specialty Equipment

All Electric Concrete Mixer Truck Project

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Client:  A concrete mixer truck manufacturer Demand:  An electric axle solution for 31-ton heavy-duty all-electric concrete mixer trucks Introduction:  The electrification trend in commercial vehicles extends to concrete transportation, driven by a dual desire for environmental sustainability and cost savings. Facing the challenge of high fuel costs, concrete mixer truck manufacturers seek innovation solutions to optimize efficiency and reduce operational costs. Description:  In 2023, a leading concrete mixer truck manufacturer approached us for an EV solution for their fleet’s 31-ton heavy-duty requirements. Understanding the industry’s need for cost-effective electrification, our experienced experts recommended the e-axle solution with axial flux motors for heavy-duty trucks to meet their demands. The 460 kW E-Axle Solution for the Electric Concrete Mixer:  Our integrated e-axle system features two axial flux motors, each with 230 kW power. With the maximum power of 460 kW, the drivetrain system achieves a wheel end transmission efficiency exceeding 96%, and the maximum gradeability reaches 50%. This also helps effectively increase the cruising range. Benefits of the E-Axle Solution With Axial Flux Motors:  1. Enhanced transmission efficiency and range: since the weight and size of the axial flux motor is 50% that of the traditional radial flux motor, this e-axle system uses the three-speedautomatic transmission. The first, second, and third gears each have a two-stage transmission. While significantly improving transmission efficiency, the system operates in the high-efficiency range at almost any vehicle speed. 2. Dual-mode shifting: the dual-mode shifting mode can achieve differential shifting between the front and rear axles as well as power compensation. There’s no interruption of power to the vehicle during the shifting process, with a shift response time of less than 0.6 seconds. 3. Optimized vehicle layout: thanks to the use of the axial flux motors, this solution offers a more spacious vehicle layout, allowing the entire vehicle traction battery pack to be positioned under the vehicle’s main beams. As a result, the electric concrete mixer truck’s center of gravity is lowered by more than 100 mm compared to conventional gasoline-powered vehicles. And it’s 130 mm lower compared to similar all-electric concrete mixer trucks from other brands. Thus this fully electric concrete mixer truck has better roll stability, ensuring safer driving. Results:  The application of the lightweight and more efficient axial flux motor system has enabled this 31-ton new energy concrete mixer truck to achieve a range of 260 km (according to steady-speed method), with an actual operational range of up to 180 km, significantly outperforming similar products on the market. A drive of this all-electric concrete mixer truck remarked, “This electric truck has strong power and is comfortable to drive, just like driving a car. Plus, charging it once at night is basically enough for a day’s use, and charging speed is also very fast, almost done in an hour.” 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.

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