Light Commercial Vehicles

E-Powertrain Solutions for Light Trucks, Vans, Pickups: Overiview The transition to electric powertrains is revolutionizing the light commercial vehicle (LCV) market, driven by increasing demand for sustainability, regulatory compliance, and operational efficiency. OEMs face critical decisions in selecting the right e-powertrain architecture to balance performance, cost, and integration complexity. This article explores the three primary e-powertrain solutions for LCVs: Central Drive, Centralized Electric Drive Axle, and Distributed Electric Drive, highlighting their advantages, challenges, and applications. 1. Central Drive: The Most Established Conversion Approach The central drive system remains a widely adopted method for converting conventional internal combustion engine (ICE) vehicles to electric power. This architecture retains key drivetrain components, such as the driveshaft, rear axle, and suspension, making it a cost-effective transition option. There are two main configurations: Direct Drive: The electric motor directly transmits power to the rear axle via the driveshaft. This solution is widely adopted due to its simplicity and ease of integration. Motor + Transmission/Reducer: The motor’s power is first adjusted by a transmission or reducer before reaching the rear axle, optimizing torque and efficiency. Central Direct Drive Configuration Brogen Direct Drive Motor Solution Integrated Motor+Reducer Configuration Brogen Motor+Reducer+MCU Solution Integrated Motor+Transmission Configuration Brogen Motor+2-Speed AMT Solution While the central direct drive system offers a straightforward path to electrification, it presents certain limitations in terms of efficiency, weight, and cost. Key challenges include: Efficiency Constraints: Although modern electric motors achieve efficiency levels of up to 95%, the mechanical complexity of the central direct drive system introduces additional losses. Weight Considerations: Direct drive configurations require high-torque motors, which are typically larger and heavier, resulting in increased energy consumption. Cost Implications: The need for high-torque motors leads to higher production costs, making it challenging to achieve significant cost reductions. An alternative approach involves integrating the motor with a reducer or multi-speed transmission. This configuration enhances torque multiplication and motor efficiency while reducing overall system weight and cost. Multi-speed transmissions are particularly beneficial for larger commercial vehicles that require a broader torque range. 2. Centralized Electric Drive Axle: An Integrated Powertrain Solution The centralized electric drive axle incorporates the motor directly into the axle assembly, eliminating the driveshaft and enabling improved packaging for the battery system. This architecture is available in three configurations: Parallel-Axis Electric Drive Axle: Utilizes a high-speed cylindrical gear transmission to enhance power density and efficiency while maintaining the structural integrity of conventional axles. Coaxial Electric Drive Axle: Aligns the motor and drive axle to simplify installation and reduce weight, making it an optimal solution for LCVs with a gross vehicle weight of up to 4.5 tons. Independent Suspension Electric Drive Axle: Integrates the motor and reducer within the vehicle frame, optimizing space utilization and improving ride comfort. However, this configuration is typically limited to LCVs under 4.5 tons due to cost and engineering constraints. Parallel-Axis eAxle Configuration Brogen Parallel-Axis eAxle Co-Axial eAxle Configuration Brogen Co-Axial eAxle Independent Suspension eAxle Configuration Brogen Independent Suspension eAxle The centralized electric drive axle offers several advantages, including: Enhanced Efficiency: The elimination of a driveshaft reduces energy losses and increases overall powertrain efficiency. Optimized Chassis Space: The available space allows for a centrally mounted battery pack, improving vehicle weight distribution and safety. Improved Handling: Reduced unsprung mass contributes to better ride comfort and vehicle stability. 3. Distributed Drive: A Next-Generation Powertrain Architecture Distributed drive technology encompasses wheel-end electric drive axles and in-hub motor drive axles, offering greater flexibility in vehicle design and operational efficiency. Wheel-End Electric Drive Axle: Integrates the motor, reducer, and axle into a single unit, eliminating differentials and reducing drivetrain length. This configuration improves efficiency and creates additional underfloor space for battery placement. In-Hub Motor Drive: Embeds the motor directly within the wheel hub, eliminating traditional drivetrain components and maximizing efficiency. However, current technological constraints restrict its application to specific vehicle types such as large buses and low-speed commercial vehicles. Wheel-Side eAxle Configuration In-Hub Motor Configuration Although distributed drive systems offer numerous benefits, they require advanced electronic differential control to ensure precise torque distribution between wheels. When effectively implemented, these systems enhance vehicle performance in high-speed and high-load conditions. Key Trends Influencing the Future of LCV E-Powertrain Development Several industry trends are shaping the advancement of next-generation e-powertrain solutions for LCVs: Greater Adoption of Multi-Speed Transmissions: Improving energy efficiency and torque adaptability across various driving conditions. Increased System Integration: Combining motors, transmissions, and controllers into compact, high-efficiency units to reduce weight and manufacturing costs. Dedicated Electric Chassis Platforms: Purpose-built vehicle architectures designed exclusively for electrification. Lightweight Design Innovations: Implementing advanced materials and structural optimizations to reduce vehicle weight and extend driving range. Brogen specializes in advanced e-powertrain solutions tailored to the evolving requirements of commercial electric vehicle manufacturers. Our integrated three-in-one system, which combines a motor, gearbox, and controller, enhances efficiency while reducing system complexity. Additionally, our centralized and distributed electric axle solutions provide OEMs with optimized powertrain architectures that enhance vehicle performance and reliability. For OEMs navigating the rapidly evolving commercial EV market, selecting the appropriate e-powertrain solution is critical. Brogen’s expertise and cutting-edge technologies empower manufacturers to achieve superior efficiency, durability, and cost-effectiveness in their electrification initiatives. Discover our LCV electrification solutions here: https://brogenevsolution.com/light-commercial-vehicle-electrification-solutions/ EV Motors for LCVs: https://brogenevsolution.com/electric-motors-for-lcvs/ eAxle for LCVs: https://brogenevsolution.com/electric-axle-for-light-truck/ EV Battery Solutions for LCVs: https://brogenevsolution.com/ev-battery-solutions-for-lcv/ Business inquiry: 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. 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Electric Light Truck Technology Trends to Watch in 2025 In today’s rapidly evolving market, electric light trucks have transitioned from relying on government policies to being driven by market demand. As consumer expectations rise, challenges such as limited range, slow charging, and insufficient application scenarios have emerged, limiting the industry’s growth. Overcoming these challenges requires continuous technological innovation. Electric light trucks, crucial for urban “last-mile” delivery, help businesses reduce costs, improve efficiency, and contribute to the transformation of the transport sector. By advancing technology, electric light trucks will play a key role in reducing logistics costs, achieving the industry’s carbon emission reduction goals, and supporting sustainable development. In 2024, significant technological trends in electric light trucks have emerged, bringing new opportunities and shaping the future of the industry. 1. Semi-Solid-State Batteries On December 21, 2024, Foton became the first to apply semi-solid-state batteries in electric light trucks, featuring liquid cooling and heating technology that supports 2.2C fast charging. In recent years, to address the range anxiety of electric light commercial vehicles, battery capacities have been steadily increasing, particularly in the electric light truck sector, where battery capacities have exceeded 160 kWh. However, this has also led to higher vehicle costs and longer charging times. Solid-state batteries, with their high safety, high energy density, fast charging capabilities, and excellent cycle performance, are emerging as an ideal solution to these challenges. Currently, solid-state batteries are primarily used in electric passenger cars, often in semi-solid-state form, and are still in the prototype or small-batch demonstration phase. Foton’s application of semi-solid-state batteries in light trucks sets an industry precedent, encouraging more companies to ramp up R&D efforts, accelerate battery development, and drive the widespread adoption of solid-state batteries in the electric commercial vehicle sector. 2. Battery Energy Density Boost: Significant Improvement in Range To effectively address the range anxiety of electric light trucks, battery manufacturers and automotive manufacturers have been increasing R&D investment, focusing on enhancing battery energy density. This enables vehicles to travel longer distances on a single charge, meeting the diverse needs of various transport scenarios. On July 4, 2024, CATL unveiled CATL TIANXING, its first EV battery brand for commercial applications, along with two products for light commercial vehicles, namely CATL TIANXING-L superfast charging edition and CATL TIANXING-L long range edition. The latter boasts an industry-leading energy density of 200 Wh/kg, offering a range of up to 500 km. These technological breakthroughs provide strong support for long-distance transportation with electric light trucks, improving largely their operational efficiency. 3. Advanced Driver Assistance Systems: From Optional to Standard In 2024, Advanced Driver Assistance Systems (ADAS) have been widely adopted in the electric light truck sector. Looking ahead, these systems are expected to become standard features in electric light trucks. Functions such as adaptive cruise control, lane departure warning, forward collision warning, and blind spot monitoring will help drivers better navigate complex and dynamic road conditions, reducing traffic accidents, lowering risk exposure, and ultimately reducing insurance costs. At the same time, the application of autonomous driving technology in electric light trucks will continue to evolve. From the current partial automation, the shift towards fully autonomous driving will take place. Vehicles will be able to perform complex tasks such as automatic cruising, adaptive following, lane changing, and obstacle avoidance, greatly enhancing both transportation efficiency and safety. 4. Connected Vehicles and Information Technology: Building a New Smart Logistics Ecosystem With the continuous advancement of vehicle connectivity and information technology, the software systems in electric light trucks now support remote upgrades. Automotive manufacturers can push software updates and feature upgrades to vehicles remotely. This ensures that customers can access the latest features and services in real-time. For logistics companies, vehicle connectivity technology enables real-time monitoring of vehicle location, speed, and status, facilitating more precise vehicle management and scheduling. By leveraging big data analytics and AI algorithms, companies can optimize transport routes, predict vehicle faults, and plan maintenance efficiently. This not only improves operational efficiency and service quality but also reduce costs. 5. Lightweight and High Energy Efficiency Technologies To reduce energy consumption and increase range, lightweight materials and technologies are being increasingly applied in the manufacturing of light trucks. Material such as carbon fiber composites, aluminum alloys, and high-strength steel effectively reduce vehicle weight while maintaining strength and safety. This improves energy utilization efficiency and transport capacity. Conclusion The technological trends observed in the electric light trucks sector in 2024 lay a solid foundation for the industry’s growth in 2025 and beyond. As technology continues to advance, electric light trucks will see comprehensive improvements in performance, intelligence, and safety, offering more opportunities and transformations for the logistics industry. These developments will drive the sector toward greater efficiency, sustainability, and innovation. At Brogen, our mission is to help automotive manufacturers stay at the forefront of industry trends by providing advanced EV solutions. Focused on the latest technologies, we specialize in lightweight design, high efficiency, and intelligent systems, all while maintaining a core commitment to safety and reliability. Our offerings include LFP battery packs, electric axles, motors & controllers, 3-in-1 e-powertrain assembly, EPS, and more. These solutions are tailored to support OEMs in their electrification journey, enhancing innovation, performance, and operational efficiency across the automotive sector. Business inquiry: contact@brogenevsolution.com Relevant Solutions All Posts Heavy Transport Industry Insight Light Commercial Vehicles Marine Electrification Public Transportation Specialty Equipment Technologies Electric Axle for LCV Electric Power Steering Solutions LCV Battery Solutions All Posts Heavy Transport Industry Insight Light Commercial Vehicles Marine Electrification Public Transportation Specialty Equipment Technologies 60kW / 100kW Electric Motor for Pickup Truck, Light Truck, Van 60 kW / 115 kW Electric Axle For Truck 30kW / 60kW Electric Motor for Light Commercial Vehicles 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

Optimizing Electric Pickup Truck Development: E-Axle Benefits The Unique Requirements of Electric Pickup Trucks Pickup trucks, primarily commercial vehicles, have a chassis design more aligned with light commercial vehicles than with passenger cars or SUVs. Directly using passenger car electric powertrains in electric pickup trucks can increase costs and fail to meet the specific demands of pickup truck usage. A truck-style rear axle design is an economical and effective solution that meets the essential requirements of electric pickup trucks, such as traction, payload capacity, durability, and off-road capability. Additionally, it ensures superior towing performance. Electric Drive Axle Technology for Electric Pickup Trucks The axle is a critical element in the strength and durability of pickups and light trucks. The electric drive axle technology integrates the electric motor directly with the axle, allowing seamless integration with existing truck structures without the need for specialized suspension, chassis, or braking systems. This setup enables electric pickup trucks to retain the towing capacity of traditional fuel-powered vehicles while also accommodating higher payloads. The highly concentrated power system of the electric drive axle simplifies vehicle battery placement and features an integrated structure that adapts to the unique operating conditions of fully electric vehicles. Flexibility in E-Powertrain Configurations In addition to rear-wheel drive, pickup manufacturers can integrate a standard electric drive system into the front axle of their electric pickup trucks, achieving an electric four-wheel drive configuration. For the ultimate solution, a three-motor setup, including a front axle motor, offers the highest level of performance for electric pickup trucks. However, manufacturers can opt for a simpler rear-drive system or a lower power output axle, such as a 115 kW rear axle motor, which is generally suited for fully electric vehicles with a GVWR of 4.5 to 6 tons. The 150 kW electric drive axle is suitable for larger fully electric commercial vehicles. Benefits for OEMs This approach allows electric pickup trucks and light commercial vehicles to maintain their performance without compromising payload or towing capacity, all without requiring a complete redesign of the existing truck platform. These advantages make it easier for OEMs to transition to electrification. Additionally, the reduced number of moving parts in the powertrain translates to lower maintenance and servicing needs. High-Power Electric Drive Axles for Pickup Trucks Our high-power output electric drive axles feature the PMSM motor, offering peak power options ranging from 90 kW to 165 kW, with a top speed of up to 110 km/h. This makes it ideal for pickup trucks and light commercial vehicles. The use of finely ground gears results in lower noise levels and a more comfortable driving experience. With an IP68 protection rating, the system includes features like active gear speed monitoring, real-time brake disc temperature control, and friction pad wear alerts, ensuring enhanced safety. Explore E-Axles for LCV