Light Commercial Vehicles | Brogen EV Solution | Shanghai OE Industrial Co., Ltd.

Coaxial eAxle for Light Trucks: Technology Overview and Performance Analysis

Light Commercial Vehicles, Technologies / November 1, 2024

Coaxial eAxle for Light Trucks: Technology Overview and Performance Analysis Traditional fuel-powered trucks reply on a complex drivetrain consisting of an engine, clutch, transmission, driveshaft, and axle. This setup is not only heavy but also has low transmission efficiency. Early electric trucks often adopted a “retrofit” approach, replacing the engine and transmission with a motor and reducer. However, this direct-drive solution was both costly and inefficient. With the growing understanding of electric truck design and the need to lower costs, reduce energy consumption, and lighten vehicle weight, the industry is shifting toward integrated electric drivetrains. Today, many small and light-duty electric trucks are equipped with a coaxial eAxle. A coaxial eAxle integrates the motor, planetary reducer, differential, and axle housing into a single, compact unit, significantly shortening the drivetrain, reducing parts, and simplifying structure. This system offers traction, braking, and efficient energy conversion while ensuring higher transmission efficiency than direct-drive systems. It also features automatic transmission and regenerative braking, which help extend driving range by recovering energy. Advantages of Brogen Coaxial Drive eAxle Over Central Motor Direct-Drive At Brogen, we provide coaxial drive eAxles, suitable for electric light duty trucks. They have the following advantages: Structural Efficiency:The coaxial drive eAxle combines the motor, planetary reducer, differential, and axle housing in one integrated unit, creating a short drivetrain with fewer parts and a simpler structure. In contrast, the direct-drive approach requires separate motor, reducer, driveshaft, and axle assemblies, resulting in a longer, more complex drivetrain. Space Efficiency: The coaxial design is highly integrated, freeing up valuable chassis space and simplifying the assembly process. Direct-drive systems, on the other hand, require space for multiple components, complicating the overall vehicle layout. Energy Efficiency: With a direct-drive and planetary reduction transmission, the coaxial eAxle achieves an overall transmission efficiency of ≥94%, while traditional direct-drive systems fall below 90% due to a longer drivetrain and additional components. Transmission Process: In the coaxial system, power from the battery drives the motor shaft, which in turn powers the differential and planetary reducer to move the wheels. Direct-drive systems use the motor torque to drive a longer sequence of parts, resulting in lower efficiency. Weight Advantage: Coaxial drive axles are 10-25% lighter than direct-drive systems, reducing energy consumption, increasing motor speed capacity, and offering a higher power density, which extends range. Direct-drive systems are bulkier and lower in power density. Technical Superiority: Coaxial eAxles support a high level of regenerative braking and align with future trends in drivetrain integration. Direct-drive systems, by contrast, offer lower levels of integration and energy recovery. Maintenance Benefits: Coaxial drive eAxles have fewer components, which simplifies maintenance and reduces lifecycle costs. Direct-drive systems, with more parts, tend to have more complex maintenance requirements. In sum, the coaxial electric drive axle offers a highly integrated, efficient, and cost-effective solution for electric light trucks, aligning well with the industry’s movement towards compact, high-performance e-powertrains that maximize both range and durability. Discover our e-axle solutions here: https://brogenevsolution.com/electric-axle-system/ 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

hybrid suv project with brogen onboard charger

Light Commercial Vehicles

Hybrid SUV Project in Europe With Our 800V OBC & DC/DC Combo

Leave a Comment / Light Commercial Vehicles / September 11, 2024

Hybrid SUV Project in Europe With Our 800V OBC & DC/DC Converter Combo Project Overview As the automotive industry continues to evolve, the demand for innovative charging solutions is on the rise. In 2022, a European automotive company approached us for an 800V high-voltage onboard charger (OBC) to power their hybrid SUV project. They were in search of a reliable solution that could meet the unique requirements of their vehicle platform. Similar models of hybrid SUVs, as the newly developed vehicle remains confidential The Shift to 800V EV Cars With electric vehicle (EV) adoption expected to grow rapidly in the coming years, the next generation of EVs needs to offer longer range, faster charging, and higher power output to fully replace traditional gasoline-powered cars. To achieve these goals, EV battery systems require higher voltage configurations. This is why the shift from 400V to 800V platforms in the EV market has become inevitable. There are currently two main approaches to implementing an 800V platform for hybrid cars: Partial 800V Platform: This method retains some 400V components, such as air conditioning and DC/DC converters, while upgrading only specific high-voltage parts to 800V. Full 800V High-Voltage System: All high-voltage components, from the battery to the drivetrain (including the inverter, onboard power control unit, air conditioning compressor, and thermal management system), are designed with an 800V architecture. This approach significantly improves charging efficiency, speed, and overall system energy performance. 800V high-voltage platform architectures However, for automotive manufacturers, finding suitable EV systems that support the 800V high-voltage platform with high product quality and reliable performance is challenging. As a result, sourcing the right solutions becomes crucial and can require additional time and costs. How We Worked Despite extensive market research, the client had difficulty finding a reliable solution that matched the 800V high-voltage requirements for their hybrid SUV. When they reached out to us, we were able to offer them the solution from out range of EV onboard chargers and converters, which span from 3.3 kW to 40 kW, with high-voltage and V2X options. After reviewing their specifications, we proposed an OBC and DC/DC converter system designed for 800V EV cars that perfectly matched their needs. They quickly ordered samples for testing, and the results exceeded their expectations. Our system’s compact, lightweight design and high performance amazed the client. Brogen team preparing the shipment of samples Result The client was so impressed with the results that they placed an additional order for 25 more units and signed a contract with us to begin preparing for mass production of their hybrid SUVs within 2 years. In total, they have ordered 30 units for the initial testing, with plans to order over 500 units for the first phase of production. These hybrid SUVs are set to lead the market with the latest automotive high-voltage system technology. System in This Project 10 kW Onboard Charger & DC/DC Converter Combo Appearance Dimension: 310*219*111 mm (connectors excluded) Weight: 9.2 kg Charging Mode Input voltage range: 90-264 VAC@1φ; 185-456 VAC@3φ Rated input voltage: 230 VAC@1φ; 380 VAC@3φ Input frequency range: 45-65 Hz Input current: 32 A max.@1φ; 16 A max.@3φ High Voltage Output Output voltage range: 350-800 VDC Max. output current: 13.8 A@1φ; 20.3A@3φ Output power: 6.6 kW max. @1φ; 9.6 kW max.@3φ Efficiency: ≥94@rated load; ≥95@half load Inverter Mode Input voltage range: 350-800 VDC Input current: 11 A max. Output voltage: 220 VAC (±5%)@1φ Output voltage frequency: 50 Hz (±1%) Rated output power: 3.3 kVA Output efficiency: 93% DCDC Mode Input voltage range: 350-800 VDC Output voltage range: 11-16 VDC Rated output voltage: 14 VDC Output current: 215 A continuous Output power: 3 kW continuous Explore Onboard Chargers Contact Info 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

Light Commercial Vehicles

Electric Light Truck Project in South Korea With Our EV Systems

Leave a Comment / Light Commercial Vehicles / September 3, 2024

Electric Light Truck Project in South Korea With Our EV Systems Project Overview In 2021, an electric truck manufacturer in South Korea approached us for EV systems to support their electric light truck project. After a thorough analysis of their vehicle requirements and specifications, we recommended a range of EV systems including air conditioning compressors, water pumps, DC/DC converters, and EHPS. We then customized these systems to perfectly align with their vehicle platform. By 2023, the prototype had successfully entered mass production, and we continued to supply additional systems to meet their growing needs. Challenges Faced During the project, the client considered changing their voltage platform, which would have required adjustments to our products. However, after careful evaluation by engineers from both sides, it was concluded that maintaining the original voltage platform would be more beneficial. The client ultimately accepted this recommendation and kept the original platform unchanged. Another challenge was the client’s requirement for the CAN protocol to be based entirely on their standard frame, whereas some of our systems used extended frames. To ensure the project’s success, our engineers customized the CAN protocol, adjusting both the content and communication speed to meet the client’s standards. Preparing the shipment to the client How We Worked To ensure our systems work well on the client’s electric light truck, we modified the water pump bracket to fit the electric light truck chassis. During vehicle installation testing, our engineers provided remote technical support, assisting the client in modifying the software protocol and completing the full vehicle testing. Systems in This Project DC/DC Converter Dimension: 300x185x73 mm Weight: ≤ 5 kg Efficiency: 94% Input voltage range: 450 – 750 VDC Rated input voltage: 640 VDC Rated output voltage: 14 VDC Output current range: 0 – 214 A Explore more DC/DC converters Air Conditioning Compressor Refrigerating capacity (max.): 2.9 kW, 9900 BTU/hr Input power: 1.5 kW Current: 4.8 A Displacement: 18.0 cc/rev Oil charge: 100 cc Speed range: 1500 – 6000 rpm Relief pressure: 4.0 MPa (G) Inquiry Now EHPS Controller voltage range: 10 – 15 VDC Rated voltage: 12 VDC Rated speed: 3000 rpm Rated power: 0.5 kW Peak power: 1.5 kW Protection level: IP67 Discover Electric Power Steering Solutions Result In the end, our systems successfully operated on the client’s prototype vehicle and passed all tests. In 2023, the client placed bulk orders for our EV systems and is expected to continue with further mass production plans in 2024. Contact Info 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

Industry Insight, Light Commercial Vehicles

Optimizing Electric Pickup Truck Development: E-Axles Benefits

Leave a Comment / Industry Insight, Light Commercial Vehicles / August 23, 2024

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

Brogen epowertrain-motor 100 kW Electric Motor

Light Commercial Vehicles, Technologies

60 kW / 100 kW Electric Motor for Pickup Truck, Light Truck, Van

Leave a Comment / Light Commercial Vehicles, Technologies / August 22, 2024

60 kW / 100 kW Electric Motor for Pickup Truck, Light Truck, Van This 60 kW / 100 kW electric motor is integrated with a motor controller and reducer, forming a 3-in-1 e-powertrain system. It is ideal for light commercial vehicles such as electric pickup trucks, vans, and light-duty trucks. This system has already been successfully implemented in our client’s electric light truck projects in South Korea. The compact design of this 100 kW e-powertrain system offers a smaller size and lighter weight, providing an efficient solution for EV manufacturers. Its integration improves vehicle layout, allowing for more space for batteries, which in turn enhances the cruising range. 60 kW / 100 kW Electric Powertrain Parameters Motor Parameters Rated voltage: 380 V Rated power: 60 kW Peak power: 100 kW Rated torque: 120 N.m Peak torque: 280 N.m @min Peak speed: 12000 rpm Protection level: IP67 Weight:52 kg Motor Controller Short-time working current: 420 A Continuous working current: 190 A Operating voltage range: 250 V – 450 V Weight:8 kg Reducer Speed ratio: 3.04 E-Powertrain Efficiency Map Contact Us Please note: these products are only available for OEMs (automotive manufacturers) and are not sold to retail/end customers.More options upon request. We usually respond within 2 business days. Inquiry: contact@brogenevsolution.com Whatsapp: +8619352173376 Discover Other EV Motor Solutions All Posts EV Industry EV Products EV Projects Electric Motors for Commercial Vehicles Electric Motors for Commercial Vehicles Our electric motors for commercial vehicles are ideal for buses, trucks, municipal vehicles, construction equipment,… 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. 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

3-ton electric pickup truck proejct with our e-powertrain in Thailand

Light Commercial Vehicles

3-ton Electric Pickup Truck in Thailand With Our E-Powertrain

Leave a Comment / Light Commercial Vehicles / August 22, 2024

3-ton Electric Pickup Truck in Thailand With Our E-Powertrain System Project Overview: Our client, a technology company specializing in electric vehicle conversion in Thailand, approached us in 2022 with a specific requirement for their electric pickup truck project. They needed an e-powertrain system featuring an electric motor with a rated power of 60 kW. After a detailed assessment of their project specifications and vehicle requirements, we proposed two optimized e-powertrain systems to them. The client ultimately selected the system that best met the demands of their electric pickup truck project. Client testing the pickup truck on the road Solution and Implementation Once our e-powertrain system was integrated into the client’s electric pickup truck, they conducted rigorous testing, including water wading, high-speed performance, and other essential assessments. Our system successfully passed all tests, resulting in the client being highly satisfied with the performance of their upgraded electric pickup truck. Expansion of Partnership Due to the successful outcome of the electric pickup truck project, the client expanded their collaboration with us, requesting e-powertrain solutions for additional vehicles, including their 6-ton medium-duty trucks and 25-ton heavy-duty trucks. Throughout this collaboration, we also supplied key systems such as onboard chargers and battery thermal management systems. Ongoing Collaboration This partnership has now flourished over the past two years, with our solutions continuously meeting the client’s high standards of their electric vehicle conversions. The strong relationship between our companies continues to grow as we support their efforts to electrify a wider range of vehicles. E-Powertrain System Used in This Project Motor Parameters Rated power: 60 kW Peak power: 115 kW Rated torque: 143 N.m Peak torque: 325 N.m Rated speed: 4000 rpm Peak speed: 12000 rpm Reducer Parameter Speed ratio: single – 3.037 Controller Parameter Voltage range: 200 – 450 V Rated voltage: 336 VDC Current module:384 A Rated current: 174 A At Brogen, 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 project, you can 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. 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

Industry Insight, Light Commercial Vehicles

Electric Pickup Truck Axle: Understanding the Difference Between Flexible and Rigid Axles

Leave a Comment / Industry Insight, Light Commercial Vehicles / August 21, 2024

Electric Pickup Truck Axle: Understanding the Difference Between Rigid and Flexible Axles Recently, BYD launched its first hybrid pickup truck: BYD SHARK in Mexico, showcasing its latest advancements in hybrid technology on a global stage. This vehicle, built on the DMO platform, features an off-road specific longitudinal EHS hybrid system in the front and a globally pioneering rear-drive electric powertrain at the rear. What sets this pickup apart is its “flexible axle” rear design, a significant departure from traditional pickups. As we enter the era of electric and hybrid pickups, could traditional “rigid axles” become a thing of the past? What Are “Rigid Axles” and “Flexible Axles”? To understand this concept, it’s essential to know what an axle is. An axle, also known as a drive axle, connects the suspension to the vehicle’s frame or chassis, with wheels mounted at either end. It transmits power and supports the vehicle’s weight. Axles can be classified into two types based on their suspension structure: solid and independent. A solid axle, commonly known as a “rigid axle,” features a rigid beam that connects the wheels, ensuring they move in unison. On the other hand, a “flexible axle” uses an independent suspension system where the wheels can move independently, providing more flexibility and better ride comfort. The Shift to Flexible Axles in Electric Pickup Trucks In traditional pickup trucks, especially those with rear-wheel drive, the rear axle is typically a rigid axle because it needs to be rigid to handle the load. However, as pickups evolve into more passenger-friendly and electric-powered vehicles, many are transitioning to flexible axles. This allows the half-shafts between the differential and wheels to flex, offering better ride comfort and versatility. The BYD SHARK, mentioned earlier, is a prime example of this shift. Other electric pickup trucks, like the Radar RD6, Horizon, and various American models, also use flexible axles. The Tesla Cybertruck, Hummer EV, Ford F-150 Lightning, and Rivian R1T are all examples of electric trucks that have adopted this design. Even Toyota’s recently announced electric Hilux is expected to feature a flexible axle. Are Rigid Electric Pickup Truck Axles Becoming Obsolete? While many new electric pickup trucks are adopting flexible axles, some still use rigid axles, especially those designed for heavy-duty or off-road use. For instance, the Jiangling Daoda EV features a world-first high-performance oil-cooled coaxial electric drive axle, which is essentially a rigid axle integrated with an electric motor. This design offers superior load capacity, making it ideal for heavy-duty applications. Similarly, the Changan Hunter EV uses a hard axle structure for its electric drive axle. The single-motor rear-wheel-drive version delivers a maximum power of 110 kW and a torque of 300 Nm, retaining the characteristics of traditional solid axles while incorporating electric drive technology. Pros and Cons of Flexible and Rigid Electric Pickup Truck Axles Each type of axle has its advantages and disadvantages. Flexible axles, with their independent suspension, offer better ride comfort and are well-suited for light-duty, household, and light off-road use. However, they may compromise ground clearance, which can be a drawback on rough terrain. Additionally, the complex structure of flexible axles can limit customization options and increase the risk of damage when subjected to extreme conditions. Rigid axles, on the other hand, provide consistent ground clearance, making them more suitable for off-road and heavy-duty applications. They offer greater load capacity and are better suited for modifications. However, the added weight of a rigid axle, especially when integrated with an electric motor, can affect handling and reduce ride comfort. The Future of Electric Pickup Truck Axles While flexible axles are becoming more common, rigid electric drive axles remain essential for heavy-duty and off-road electric trucks. These axles provide consistent ground clearance, superior load capacity, and enhanced durability, making them ideal for demanding applications. Our rigid electric drive axles are designed to integrate seamlessly with electric powertrains, offering the strength and reliability needed for tough environments. As the market for electric trucks grows, hard axles will continue to be crucial for those who prioritize performance and durability. Learn more about our electric drive axle systems here.

electric axle system electric truck axle electric axle for lcv

Light Commercial Vehicles, Technologies

60 kW / 115 kW Electric Axle For Truck

Leave a Comment / Light Commercial Vehicles, Technologies / August 16, 2024

60 kW / 115 kW Electric Axle for Truck This 60/115 kW electric axle for truck is specifically designed and developed for light commercial vehicles. It features a lightweight design, high efficiency, intelligence, low noise, and integration. Compared to traditional direct-drive systems, this electric truck axle assembly reduces overall weight by more than 100 kg and decreases energy consumption by over 5%. It is suitable for light commercial vehicles such as pickup trucks, light trucks, vans, buses, etc. Whatsapp: +8619352173376 Email: contact@brogenevsolution.com Download Brochure Get Custom Quote We Offer Best Features Lightweight The highly integrated drive system optimizes the chassis layout. The electric motor features a high rotation speed and compact size, resulting in a lightweight assembly that reduces the e-powertrain system by over 100 kg. Energy-Efficient This electric truck axle features a short drive chain, offering a 2% increase in transmission efficiency and 5% decrease in energy consumption compared to traditional direct drives. Lower Maintenance Costs The oil change interval for the main reducer extends to 100,000 km, resulting in higher uptime and lower maintenance costs – maximizing savings for fleet operators and drivers. System Advantages 100 kg reduce in weight compared to direct drive systems. 5% reduce in power consumption compared to direct drive systems. 350 N.m maximum torque for robust power during climbing. 100% counter torque for increased cruising range. Lower than 70 dB noise for a more pleasant driving experience. Technical Parameters Model 5PE A5PE (steering drive) Rated Axle Load 3500 kg 3500 kg 2700 kg Maximum Torque 5400 N.m 5800 N.m 5400 N.m Gear Ratio 15.58/16.60 16.60 15.58 Motor Voltage 360 V / 540 V 360 V / 540 V 360 V / 540 V Motor Rated / Peak Power 60 kW / 115 kW 60 kW / 115 kW 60 kW / 115 kW Motor Rated / Peak Torque 135 N.m / 325 N.m 135 N.m / 350 N.m 135 N.m / 350 N.m Motor Rated / Peak Speed 4244 rpm / 12000 rpm 4244 rpm / 12000 rpm 4244 rpm / 12000 rpm Explore More E-Axle Solutions Applications 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

Light Commercial Vehicles

2-ton Electric Pickup Trucks in South Korea With Our E-Axles

Leave a Comment / Light Commercial Vehicles / July 29, 2024

2-Ton Electric Pickup Trucks in South Korea With Our Electric Axles Project Overview In 2021, a leading vehicle manufacturer in South Korea sought our expertise to develop an electric powertrain system for their new 2-ton electric pickup trucks. The client’s primary requirement was an electric axle capable of delivering a maximum power output of 60 kW. Our team swiftly proposed a comprehensive solution tailored to meet their specific needs. Systems We Provided for the Electric Pickup Trucks Electric Axle Rated axle load: 2000 kg Maximum output torque: 2266 N.m Maximum output power: 60 kW Wheel speed: 870 rpm Speed ratio: 10.5 Axle weight: 105 kg Protection class: IP 67 Rated voltage: 336 VDC Explore more e-axle solutions Motor Controller Applicable motor type: three-phase AC synchronous motor Applicable voltage range: 250 – 420 VDC Rated voltage: 336 VDC Conversion & Distribution Unit (OBC+DC/DC+PDU) For the On-Board Charger Input voltage: 85 – 264 VAC Maximum input current: 32 A Maximum output power: 6.6 kW Output voltage range: 200 – 420 VDC Maximum output current: 20 A Module efficiency: 95% For the DC/DC Converter Input voltage: 200 – 450 VDC Maximum input current: 11 A Maximum output power: 1.5 kW peak Output voltage range: 13.8±0.3 V Maximum output current: 145 A Module efficiency: 94% Explore more onboard charger systems Project Execution and Collaboration To facilitate efficient communication and problem-solving, we established a dedicated WeChat group, bringing together engineering teams from both companies. This platform allowed for real-time discussion and on-site debugging, ensuring a smooth development process. Our software engineers customized the control software to align with the client’s specific vehicle requirements, and regular video meetings were held to address any challenges encountered during testing. Results and Achievements Our factory preparing the shipment of the electric axles. Our factory preparing the shipment of the electric axles. In 2022, the client successfully completed vehicle verification for their electric pickup trucks and proceeded to the SOP phase. They introduced eight different models based on the same electric axle system and held a local press conference to showcase their new lineup. The client expressed gratitude for our technical support and responsiveness throughout the project. By the end of 2022, the client commenced mass production and placed an order for 1,000 sets of our electric powertrain systems for their pickup trucks. This collaboration not only highlighted our capability to deliver high-quality, customized solutions but also solidified our partnership with the client for future projects. 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

Light Commercial Vehicles, Technologies

Electric Power Steering for Light Trucks

Leave a Comment / Light Commercial Vehicles, Technologies / July 18, 2024

Electric Power Steering for Light Trucks System Introduction Rack-assist Electric Power steering (R-EPS) positions the motor directly on the steering rack, making it ideal for medium to large vehicles that require significant power assistance. Typically, a ball screw and belt mechanism is used to transit motor assistance to the rack. This electric power steering for light trucks is of the rack-assist type. Features of Our Electric Power Steering for Light Trucks Testing our electric power steering for light trucks at the labortary Compact design: optimized for space efficiency in vehicle layout. High rack force: the integration of belt and ball screw structures enables a rack force of up to 18 kN Proven reliability: utilizes a mature hardware and software platform, with established production processes, to ensure stability and reliability. Enhanced steering feel: provides a smooth and refined steering experience. Upgraded functionalities, including end-point control, return-to-center, and drift compensation, position this system at the forefront of steering technology. Superior NVH performance: incorporates advanced motor active noise reduction algorithms and production line calibration algorithms to deliver a quiet and serene vehicle environment. Product Parameters Applications: RH/Light truck Type: Rack-assist type Rated current: 80A@DC12V; 60A@DC24V Operating voltage: DC 12 V / 24 V Rack stroke & ratio: ±80 mm & 50.27 mm/rev Maximum pull-push force: 16kN@12V; 18kN@24V Applicable vehicle information: Front axle load 3000 kg (reference) Sensor type: TAS Protection level: IP67 Frequently Asked Questions How’s your R&D strength? We have 52 R&D team members for the EPS systems, with a core specialist who has designed and developed steering and suspension systems for world-class vehicle manufacturers such as Toyota, Mitsubishi, Lexus, Honda, etc. What’s your typical annual production volume for EPS systems? Our annual manufacturing capacity for EPS is about 1,100,000 sets. Do you offer custom EPS solutions in addition to standard products? Sure, as we have a professional R&D team, we provide OEM / ODM service and can customize a system for your project. Do you have other EPS products for cars, or trucks? Yes, you can visit here to learn more about our electric power steering systems: https://brogenevsolution.com/electric-power-steering-solutions/ What are the steps of working with you? You may fill in the form below to get in touch with us first. Remember to describe your project info and product requirements as detailed as possible. Then we will arrange an expert to get back to you shortly and provide a customized solution for you. If necessary, our engineering team will discuss with your engineering team to check if our system can work well on your platform and if we need further modification, etc. Then we will provide the quotation to you. Discover Our Power Steering Solutions All Posts EV Industry EV Products EV Projects Electric Power Steering Solutions Electric Power Steering Our power steering solutions primarily feature Electric-Hydraulic Power Steering Systems (EHPS) and Electric Power Steering Systems (EPS),… 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. 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