Technologies | Brogen EV Solution | Shanghai OE Industrial Co., Ltd.

electric air brake compressor for truck, bus

Oil-Free Air Brake Compressors For Commercial EVs

Oil-Free Air Brake Compressor for Commercial EVs: The Next Step in Clean Mobility With the rapid growth of electric vehicles worldwide, the electrification of commercial vehicles has entered a stage of fast expansion. Among their key subsystems, the electric air brake compressor plays a critical role in the pneumatic braking system, air suspension, and other auxiliary air systems. It’s a core component that directly impacts vehicle safety, reliability, and efficiency – and is now entering a rapid phase of technological evolution. This article explores the current market landscape and development trends of EV air brake compressors, particularly for commercial vehicles. 1. What is An Electric Air Brake Compressor in Commercial Vehicles In traditional commercial vehicles, the air compressor is typically driven by the engine. However, in electric vehicles, which no longer rely on internal combustion, an electric air compressor replaces this function. It provides compressed air for the vehicle’s brake system, air suspension, and auxiliary actuators, making it an essential element of EV safety and performance. With strong government policies promoting EVs globally, the market demand for electric air brake compressors has grown significantly. Traditional air compressor Electric air brake compressor 2. Current Status of Electric Air Brake Compressor Technology The shift toward electrification in commercial vehicles has given rise to multiple types of electric air brake compressors, such as screw, vane, and scroll compressors. However, over nearly a decade of market validation, these designs have shown limitations such as oil-gas emulsification, low discharge pressure, and poor reliability – leading to their gradual replacement. Today, piston-type air compressors have become the mainstream solution for electric commercial vehicles, offering better efficiency, reliability, and adaptability to high-pressure systems. Screw compressor Vane compressor Scroll compressor Piston compressor Item Oil-lubricated piston type Screw type Vane type Scroll type Lubricating oil type Traditional diesel engine oil Special screw compressor oil Special vane compressor oil – Driving safety Safe If maintenance is not timely, it will contaminate the air system, causing rubber parts to expand and age, easily leading to brake system failure – Lubricant consumption Small Large Large – Lubricant emulsification and deterioration None Easy Easy – Environmental adaptability (air contact) Less contact with external air Easily affected by external air contamination – Oil-gas separator Not required Required Required – Oil separator filter element lifespan – Short Short – Lubricant temperature control Not required Required Required – Impact of ambient humidity Small Large Large – Discharge pressure Can withstand short-term overload General General Low Special maintenance experience requirements None High High Very high Environmental adaptability Good Poor Poor Poor Service life Good Poor Poor Poor 3. The Rise of Oil-Free Piston Electric Air Brake Compressor Most piston-type electric air compressors in use today are still oil-lubricated, which requires regular oil changes and maintenance. Problems such as oil leakage or contamination can lead to secondary pollution and increased maintenance costs. In constrast, oil-free air brake compressors eliminate the need for lubrication oil, reduce system complexity, and ensure clean, oil-free compressed air – protecting pneumatic components and improving environmental sustainability. Based on years of market application and customer feedback, the trend is clear: oil-free piston compressors are becoming the future direction of EV air brake compressor technology. Oil electric air brake compressor Oil-free electric air brake compressor 4. Oil-Free Air Brake Compressor Technology Overview Among current oil-free air compressor designs, scroll compressors have seen early adoption in electric vehicles. They offer compact structure, smooth operation, and high efficiency. However, due to their tight sealing gaps, scroll compressors require extremely clean intake air, making them vulnerable to dust and humidity, especially since compressors in commercial EVs are often mounted on the chassis. Additionally, scroll compressors tend to have high discharge temperatures and struggle to meet the >1 MPa high-pressure requirements of commercial brake systems. Maintenance is also costly, as damaged scroll plates must be replaced entirely. As a result, oil-free piston compressors have emerged as the mainstream solution due to their superior pressure performance, environmental adaptability, and long service life. Comparison of Oil-Free Air Compressor Types Item Oil-free piston air compressor Oil-free scroll air compressor Discharge pressure Strong high-pressure capability; easily meets the standard requirement of ≥ 1 Mpa. Limited by the scroll sealing structure, poor high-pressure sealing performance leads to low discharge pressure. High-pressure performance decays significantly over time, making it difficult to maintain 1 MPa for long periods. Structural sealing Use a direct-drive motor design with a simple and reliable transmission structure; minimal high-pressure attenuation. Requires a precise clearance between moving components to achieve sealing, resulting in high requirements for sealing materials. The complex sealing structure is prone to thermal deformation and leakage. Environmental adaptability Excellent adaptability; IP67 or higher protection level allows operation in harsh environments (high temperature, low temperature, high altitude). Both the orbiting and fixed scroll plates feature curved surfaces requiring high machining accuracy. The strict sealing demands on upper and lower end faces make it sensitive to environmental conditions. Cooling performance The compressor head uses air or water cooling with an additional cooler, providing excellent heat dissipation. The internal working chamber cannot be externally cooled, making heat removal difficult. Localized overheating occurs easily, resulting in high discharge temperatures. Maintenance Requires no special maintenance – only periodic air filter cleaning. High sealing precision requirements lead to faster seal wear. Maintenance involves disassembling the entire unit to replace seals, making servicing difficult and costly. If scroll plates are damaged, the entire assembly must be replaced. Service life High reliability and long service life. Due to its unique sealing structure, service life is highly dependent on working conditions. Components operate under high temperature, humidity, and pressure, significantly shortening lifespan and overall reliability. 5. Advantages of the Two-Stage Oil-Free Piston Air Brake Compressor In response to the GB 7258 national standard requiring brake air pressure above 1 MPa, and OEMs demanding even higher efficiency and emission reduction, two-stage oil-free piston compressors have become the latest evolution trend. They are designed for high discharge pressure, low exhaust temperature, high efficiency, and long service life. Single-stage oil-free

Heavy Transport, Technologies

Mining Electrification Solutions: Electric Dump Truck System Design

Mining Electrification Solutions: Electric Dump Truck System Design 1. Introduction The electric dump truck is a specialized off-highway vehicle designed for short-haul material transport in industries such as mining, metallurgy, cement, water conservancy, and construction. Its working conditions are characterized by steep slopes, short routes, large load variations, fixed transport lines, and complex operating environments. Traditional diesel-powered dump trucks face several challenges in these conditions: high fuel consumption, elevated maintenance costs, and shorter service life. By contrast, electric dump trucks replace diesel engines and manual transmissions with battery packs and electric drive motors. When traveling on flat roads or downhill, the motor operates in regenerative braking mode, converting braking energy into electricity to recharge the battery. This not only reduces wear on the mechanical brake system – improving safety and extending component life – but also increases vehicle range. With fewer maintenance needs, high protection levels, and superior adaptability to harsh mining environments, electric dump trucks are becoming the preferred choice for heavy-duty operations. 2. High-Voltage System Architecture of Electric Dump Truck High-voltage system architecture for the electric dump truck (for reference) Electric dump trucks replace the conventional powertrain with a high-voltage system. The main high-voltage components include: traction battery, PDU, DC fast charging port, integrated controller, thermal management system, and other auxiliary high-voltage systems. ● Traction Battery It’s the energy supply unit in an electric dump truck, providing electric power to all vehicle systems. When the battery is depleted, it also requires recharging. Therefore, the energy flow of the battery is bidirectional. ● High-Voltage Power Distribution Unit (PDU) The PDU is a distribution hub for high-voltage power, supplying electricity to all components within the high-voltage system. For example, battery heating, charging circuits, and power distribution to the integrated controller. Inside the PDU are fuses, relays, and a pre-charge circuit for each controllable high-voltage loop. Between the traction battery and the PDU, a Manual Service Disconnect (MSD) is installed. The MSD is a mandatory safety device that allows physical disconnection of the high-voltage circuit during battery servicing or vehicle maintenance. It ensures safe isolation of the high-voltage system and often incorporates fuse protection to enhance electrical safety and reliability. ● Thermal Management System The thermal management system integrates both heating and cooling functions, maintaining the traction battery within its optimal operating temperature range to ensure safety, efficiency, and extended service life. Brogen traction batteries for electric trucks Brogen PDU for electric trucks Brogen BTMS for electric trucks ● Motor Controller and Drive Motor The motor controller converts high-voltage DC from the integrated controller into three-phase AC to power the drive motor. It regulates motor torque and rotational direction, enabling smooth vehicle start, stop, forward, and reverse operations. Additionally, during braking or deceleration, the drive motor recovers kinetic energy, converts it into electrical energy, and feeds it back to the traction battery for extended range and efficiency. Brogen e-powertrain (motor+AMT) for heavy-duty trucks System schematic for Brogen’s electric motor + AMT e-powertrain ● DC Fast-Charging Port The DC fast-charging port delivers high-voltage direct current, which can be routed through the PDU directly to the power battery for rapid charging without additional processing. ● Integrated Controller The integrated controller receives commands from the VCU and coordinates both the main drive system and auxiliary subsystems. Key auxiliary loads include the cab air-conditioning compressor, PTC heater, electro-hydraulic power steering pump, air compressor, and DC/DC converter. The DC/DC converter steps down high-voltage DC from the traction battery to low-voltage DC to charge the auxiliary lead-acid battery. Compared with traditional distributed controllers, the integrated controller offers reduced size and footprint, optimizing vehicle layout. Minimizing high-voltage external wiring between discrete controllers reduces potential failure points, lowers costs, and enhances overall system reliability and safety. Brogen 4-in-1 integrated auxiliary inverter System schematic for Brogen’s integrated auxiliary inverter ● Auxiliary High-Voltage Systems The electric A/C compressor and PTC heater serve as the core components of the HVAC system, delivering cooling and heating functions. The electric air compressor supplies high-pressure compressed air for the braking system. The electro-hydraulic power steering pump provides hydraulic assistance to the steering system. 3. Traction Battery Selection and Design At present, mainstream electric vehicles generally adopt ternary lithium batteries or lithium iron phosphate (LFP) batteries. LFP batteries use lithium iron phosphate as the cathode material and graphite as the anode material. Compared with ternary batteries, LFP batteries offer the following advantages: High safety performance: The decomposition temperature of LFP is about 600°C. Even under high temperature or overcharge conditions, it does not undergo structural collapse, generate excessive heat, or form highly oxidative substances as ternary batteries do. In the event of a collision or short circuit, LFP batteries are also highly resistant to explosion. Long cycle life: The cell cycle life can reach up to 4,000 cycles, and around 3,000 cycles at the PACK level. Excellent high-temperature performance: Wide operating temperature range with strong thermal stability. Environmental friendliness: LFP batteries contain no heavy metals or rare metals, making them non-toxic and pollution-free. These features make LFP batteries particularly well-suited for mining applications, where operating conditions are harsh, ambient temperatures vary widely, and safety requirements are stringent. Battery packs for electric dump trucks Brogen traction battery factory Brogen traction battery pack details 4. High-Voltage Power Distribution Unit (PDU) Design The High-Voltage Power Distribution Unit (PDU) is responsible for distributing electrical power throughout the vehicle’s high-voltage system. Its function is similar to a fuse box in a low-voltage electrical system, primarily managing power distribution and providing overload and short-circuit protection for high-voltage circuits. High-voltage distribution schematic Brogen PDU system, typically integrated with the battery system The PDU distributes the energy supplied by the power battery to the integrated controller, as well as to the battery heating and cooling systems. During DC fast charging, the charging current also flows through the PDU to charge the power battery. Additionally, the Battery Management System (BMS) is integrated into the PDU. The BMS performs the following key functions: Monitoring the total battery voltage and charge/discharge current. Monitoring battery status, including individual cell

semi trailer ev solution electrified trailers

Heavy Transport, Technologies

Electrified Trailers: Driving the Next Evolution of Semi-Trailer Trucks

Electrified Trailers: Driving the Next Evolution of Semi-Trailer Trucks 1. The Strategic Role of Semi Trailers in Commercial Vehicles In the commercial vehicle sector, semi-trucks and semi-trailers are typically manufactured by two separate companies. While semi-truck sales often attract more attention, semi-trailers represent an equally important and sizeable market segment. The performance of a tractor-trailer combination largely depends on how well the two units are coordinated and matched. Electrifying semi-trailers brings new opportunities. By integrating batteries into trailers, the overall driving range can be extended. In more advanced scenarios, an electrified trailer could even supply supplementary power to the semi-truck, reducing operating costs. This multi-mode adaptability – whether paired with internal combustion engine (ICE) semi-trucks, hybrid semi-trucks, or fully electric semi-trucks – creates flexibility in today’s mixed market where ICE trucks still dominate. For fleet operators, return on investment must be visible in the short term. This is why leasing models for intelligent or electrified trailers are emerging: the upfront cost of advanced perception and drive systems is high, but a leasing approach allows broader adoption. Traditional semi-trailers are already widely leased in the logistics sector, making this model a natural fit. 2. Technical Trends: Architecture of Electrified Trailers Despite trailers’ relatively simple structures, electrification presents unique engineering challenges. Semi-trailers require integration of electric drive components, with the most efficient solution being the use of an electric drive axle (e-axle) (Discover our e-axle solution for electrified trailers here). With the mature e-axle technology, trailers can become independent driving units, capable of moving under their own power while still requiring support from the semi-truck. This allows for better performance when combined with semi-trucks, as integrated control systems can optimize the overall semi-trailer truck dynamics beyond what conventional, loosely coupled combinations can achieve. Advantages of Semi-Trailer Truck Integrated Control With Electrified Trailers Energy Efficiency: Up to 20%-30% reduction in fuel consumption and CO₂ emissions through optimized power coordination; More than 50% of braking energy can be recovered; Supply power to refrigeration units or other auxiliary equipment. Performance: Improved traction on slippery surfaces (up to +80%); Enhanced acceleration (time reduced by 50%); Stronger climbing ability; Safer lane-change and overtaking capability. Cost Benefits: Lower lifecycle operating costs; Better synergy with smart vehicle technologies; Moderate weight increase offset by efficiency gains. Safety: Improved stability; Reduced risk of jackknifing or trailer swing; Integration with braking systems enables advanced dual electric braking control. Electrified trailer with Brogen e-axle solutions Electrified trailer with Brogen e-axle solutions 3. Engineering Challenges in Electrified Trailers Adapting semi-truck e-drive technology to trailers is technically feasible. The primary challenges lie in: Integrated Control: Developing precise tractor-trailer coordination strategies. Electronic Architecture: Reconfiguring trailer E/E systems to support additional electric drive and control functions. Lightweight Design: Since gross vehicle weight limits are fixed, adding e-axles and batteries reduces payload. This necessitates advanced materials and optimized structural design to preserve carrying capacity. 4. Industry Outlook and the Future of Electrified Trailer The commercial vehicle industry faces a paradox of limited market size but high R&D demands, as system complexity in trucks far exceeds that of passenger cars. This tension requires innovative approaches to balance performance, cost, and adoption. Under the dual trends of electrification and intelligent vehicle systems, technologies such as smart chassis, electrified trailers, and tractor-trailer integrated control are becoming core areas of research and competition. Electrified trailers, with their potential to boost efficiency, safety, and versatility, are set to become a vital part of the commercial transport market. 5. Toward Our Electrified Trailer Solution While challenges remain, the trajectory is clear: electrified trailers will reshape the performance of semi-trailer trucks. Our electrified trailer solution builds upon these insights – delivering integrated power, control, and efficiency to unlock new value for logistics operators. We deliver an integrated electrified trailer solution, covering electric axle, controller, and battery system. Hardware + software co-developed for seamless performance, simplified integration, and faster time-to-market. Discover our electrified trailer solution here: https://brogenevsolution.com/electrified-trailer-solution/ 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. 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

Heavy Transport, Technologies

Electric Truck Powertrain Solutions: Single-Motor + AMT Configuration

Electric Truck Powertrain Solutions: Single-Motor + AMT Configuration As the global demand for electric heavy trucks continues to grow, manufacturers are exploring efficient and cost-effective solutions for electrification. One of the most widely adopted configurations in the electric truck powertrain is the single motor + AMT (Automated Manual Transmission) solution, which combines a high-power PMSM with a multi-speed AMT while retaining the traditional driveshaft layout. This article will explore how this solution works, its advantages and challenges, and why it is becoming a mainstream technology for electric truck powertrain in various heavy-duty applications. 1. What is the Single Motor + AMT Solution for Electric Trucks? The single motor + AMT architecture is designed to provide strong power output and optimized efficiency across a wide speed range. By pairing a high-torque electric motor for trucks with a multi-speed AMT transmission, the system delivers excellent climbing capability, high-speed cruising, and smooth shifting performance. 1.1 Advantages of Single Motor + AMT Electric Truck Powertrain Simple Structure and Lower Cost: The single-motor + AMT architecture adopts a straightforward design, minimizing the number of components compared to multi-motor systems. This simplicity not only reduces manufacturing complexity but also lowers the overall system cost, making it an economical choice for OEMs and fleet operators. Easy Integration with Existing Chassis Platforms: One of the key benefits of this electric truck powertrain configuration is its compatibility with traditional heavy-duty truck chassis. OEMs can easily adopt this e-powertrain to their current platforms without major structural modifications, significantly reducing development time and cost. High Reliability for Demanding Applications: The system is designed for rigorous operating conditions such as long-haul transportation, construction vehicles, and high-load scenarios. With fewer components subject to wear, it provides excellent durability and reliability, ensuring stable performance over extended service life. Brogen Single Motor + AMT System for 6×4 Electric Semi Trucks 1.2 Challenges to Consider Mechanical Losses in the Transmission: Although the AMT provides efficient torque transmission across different speed ranges, mechanical losses can slightly reduce overall system efficiency compared to direct-drive configurations. Heat Management Under Continuous Climbing: In extended uphill operations, the motor operates under high load for prolonged periods, which can trigger overheating protection. This highlights the need for optimized thermal management and cooling strategies. Despite these challenges, the single motor + AMT e-powertrain offers strong performance, high durability, and low energy consumption, making it the mainstream solution for electric heavy-duty trucks. 2. Key Application Scenarios for the Single Motor + AMT Electric Truck Powertrain This electric truck powertrain configuration is widely applied in heavy-duty EV segments such as electric concrete mixer trucks, electric dump trucks, electric semi-trucks, and other specialized vehicles. Here are the major use cases: 2.1 Closed-Loop Transport Operations Ports & Terminals: Ideal for container handling and short-haul transfers with fixed routes and frequent stop-and-go conditions. The electric truck motor delivers high low-speed torque combined with regenerative braking for improved loading efficiency. Mining Operations: Handles rough terrain and heavy loads with optimized multi-gear power output, preventing power interruptions. Steel & Power Plants: Short-haul transfers with strict emission regulations benefit from zero-emission electric truck powertrain solutions. 2.2 Short-Haul Urban Logistics Electric Concrete Trucks & Municipal Vehicles: Frequent acceleration and hill climbing require efficient torque distribution, reducing energy consumption. Intermodal Coal Transport: Fixed routes, but long endurance requirements, making electric truck motors paired with AMT a practical choice. 2.3 Line-Haul Logistics While battery-swap heavy-duty trucks currently dominate, the single motor + AMT solution is advancing with higher-density batteries and fast-charging technologies to penetrate this segment. 2.4 Special Operating Conditions Mounting Roads & Complex Terrain: Requires continuous high torque and power stability. Low-Temperature & High-Altitude Regions: Multi-gear adjustment optimizes motor operating range, ensuring reliable performance in harsh conditions. 2.5 Hybrid Transition Scenarios For fuel-cost-sensitive markets, the single motor + AMT solution can work in hybrid configurations with internal combustion engines, bridging the gap toward full electrification. Brogen Single Motor + AMT Solution for Electric Heavy Trucks At Brogen, we deliver proven electric truck powertrain solutions tailored for heavy-duty commercial vehicles. Our single-motor + 4-speed AMT system has been successfully deployed in more than 20,000 vehicles worldwide, providing strong market validation and trusted performance. For EV builders, this solution provides: Faster Time-to-Market with a validated platform Lower Risk through proven mass-production reliability Optimized Cost & Energy Efficiency with a scalable powertrain Compliance & Sustainability for zero-emission transportation Discover this solution here: https://brogenevsolution.com/250-kw-400-kw-electric-motor-for-heavy-duty-truck/ Discover our other electric truck motors here: https://brogenevsolution.com/electric-motors-for-truck/ About Brogen At Brogen, we provide advanced EV solutions for global commercial vehicle manufacturers, enabling them to streamline research and development while capitalizing on cutting-edge technology. Our offerings ensure superior efficiency, extended range, and seamless system integration with proven reliability—empowering our partners to lead in the rapidly evolving green mobility landscape. Currently, our EV solutions for battery electric vehicles have been adopted by vehicle manufacturers in countries and regions such as Canada, Türkiye, Brazil, the Philippines, Indonesia, the Middle East, and more. Discover our HCV electrification solution here: https://brogenevsolution.com/heavy-duty-vehicle-electrification-solutions/ Looking for an EV solution for your project? Reach out to us at contact@brogenevsolution.com Contact Us Get in touch with us by sending us an email, using the Whatsapp number below, or filling in the form below. We usually reply within 2 business days. Email: contact@brogenevsolution.com Respond within 1 business day Whatsapp: +8619352173376 Business hours: 9 am to 6 pm, GMT+8, Mon. to Fri. LinkedIn channel Follow us for regular updates > YouTube channel Ev systems introduction & industry insights > ContactFill in the form and we will get in touch with you within 2 business days.Please enable JavaScript in your browser to complete this form.Please enable JavaScript in your browser to complete this form. Name * FirstLast Work Email *Company Name *Your Project Type *– Please select –Car, SUV, MPVBus, coach, trainLCV (pickup 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

Technologies

High-Voltage Connectors: An Overview

High-Voltage Connectors: An Overview In electric vehicle systems, high-voltage connectors serve as the “bridge” for power transmission and are a critical components in ensuring electrical safety. Although small in size, these connectors integrate multiple precision structures and safety features. Let’s break down their key components and see how they ensure safe and reliable performance in high-voltage, high-current environments. 1. Components of High-Voltage Connectors High-voltage connectors are generally composed of the following structures: housing (male and female ends), terminals (male and female terminals), shielding shell, seals (rear, half-end, wire-end, and contact seals), rear protective cover, high-voltage interlock system, and CPA (Connector Position Assurance device). 1.1 Housing The housing acts as the “armor” of the connector, providing both mechanical protection and structural support. It consists of male and female shells that fit together seamlessly. Material strength: Typically made of PA66+GF (glass fiber-reinforced nylon) or PBT, designed to withstand ≥ 125°C (up to 150°C in some applications) and certified to UL94 V-0 for flame resistance. Anti-static surface treatments prevent arcing in high-voltage environments. Thoughtful design: Male and female housings lock together via snap-fit mechanisms, with mating forces carefully controlled between 80-150 N to ensure both secure connection and ease of operation. 1.2 Therminals If the housing is the armor, the terminals are the heart, responsible for current transmission. Materials: High-purity T2 copper or CuCrZr (copper-chrominum-zirconium alloy) with silver or nickel plating, ensuring contact resistance below 5 mΩ。 Design: Male terminals are typically pin-type, while female terminals use spring or crown structures that apply ≥20 N contact pressure. Even after 500+ mating cycles, resistance variation remains under 10%, ensuring durability. 1.3 Shielding High-voltage transmission can generate EMI (electromagnetic interference) that disrupts vehicle electronics. The shielding enclosure acts as an “invisble barrier”. Performance indicators: Made of copper alloy or aluminum alloy, the shielding efficiency reaches ≥60 dB within the 100 MHz-1 GHz frequency range, equivalent to putting electromagnetic signals into “silent mode”. At the same time, it works with the housing and terminals to form a complete grounding loop, with grounding resistance ≤50 mΩ, effectively eliminating interference risks. Installation details: Fixed to the housing by clips or welding, it achieves a fully enclosed shielding structure, leacing no “escape gap” for electromagnetic signals. 1.4 Sealing System EV batteries are often exposed to harsh environments such as rain and dust. The sealing system acts as a “waterproof shield” for the connectors, building multiple layers of protection: Rear seal: Silicone rubber sealing rings wrap around the cables, achieving IP67 (no water ingress after 30 minutes of immersion at 1m depth) or IP6K9K (resistant to high-pressure water spray). Even when the vehicle drives through water, safety is ensured. Half-end/Wire-end Seal: At the connector interface and cable entry point, O-rings or lip structures fit into housing grooves to form dual protection – like adding a “double safeguard” to every gap. 1.5 Rear Protective Cover The cable interface at the rear of the connector is relatively fragile and prone to damage. The rear protective cover functions like a “safety helmet,” secured to the rear end by threads or clips. It can withstand an axial tensile force of ≥50 N, preventing cable loosening due to pulling, while also enhancing the sealing performance. Some models are further equipped with integrated harness clamps, ensuring a more organized cable layout. 1.6 High-Voltage Interlock System (HVIL) This is an intelligent system that continuously monitors the connection status – serving as the “safety guardian” of the connector. Working principle: A 5V closed-loop circuit is established via micro-switches or Hall sensors. If the connector loosens or disconnects, the circuit is immediately interrupted. The BMS triggers power cut-off protection within 100 ms, cutting the high-voltage supply like an “emergency brake,” fundamentally eliminating the risk of electric shock. 1.7 CPA To prevent issues such as poor contact or overheating caused by incompletely inserted connectors, the CPA (Connector Position Assurance device) was developed. Design details: It typically uses mechanical structures such as plastic clips. When the male and female terminals are fully mated, the CPA provides a clear confirmation – either an audible “click” or a visual color indicator, allowing operators to easily verify the connection status and eliminate the risk of “false mating”. 1.8 Auxiliary Structures In addition to the core components, these auxiliary designs are equally essential: Mis-insertion prevention: The male and female housings feature asymmetric keys, grooves, or other positioning structures – like uniquely shaped keys – preventing connectors of different specifications from being mismated. Thermal management structure: For high-power platforms such as 800 V systems, the connector may include built-in heat sinks or thermally conductive silicone. This controls the temperature rise during high-current transmission to within 50 K, preventing overheating and ensuring stable performance. 2. Key Considerations in High-Voltage Connectors Selection When selecting a high-voltage connector, critical parameters include: Operating temperature: -40°C to 125°C (or higher depending on vehicle requirements). Current capacity: Rated and peak current must meet system requirements. Voltage capacity: Must exceed the maximum battery system voltage. Locking system: Secondary locking (hook+latch) to prevent loosening under vibration. Waterproofing: IP67 / Ip6K9K compliance. Insertion/withdrawal force: Controlled within specified ranges. HVIL support: Determined by system requirements. Conclusion From the housing and terminals to the sealing and interlock systems, every aspect of a high-voltage connector is engineered with safety and reliability in mind. It is this advanced, compact technology that ensures EV batteries can transmit energy efficiently and stably under high-voltage conditions, safeguarding the safe operation of electric vehicles. About Brogen At Brogen, we provide advanced EV solutions for global commercial vehicle manufacturers, enabling them to streamline research and development while capitalizing on cutting-edge technology. Our offerings ensure superior efficiency, extended range, and seamless system integration with proven reliability—empowering our partners to lead in the rapidly evolving green mobility landscape. Currently, our EV solutions for battery electric vehicles have been adopted by vehicle manufacturers in countries and regions such as Canada, Türkiye, Brazil, the Philippines, Indonesia, the Middle East, and more. Discover our HCV electrification solution here: https://brogenevsolution.com/heavy-duty-vehicle-electrification-solutions/ Looking for an EV solution for your project? Reach

BTMS project - 1 EV thermal management system for electric mining truck

Heavy Transport, Technologies

EV Thermal Management System for Battery Electric Mining Trucks

EV Thermal Management System for Battery Electric Mining Trucks For battery electric mining trucks, it’s critical to maintain the traction battery within an optimal temperature range to ensure both performance and safety. Given the high charge and discharge currents typical of mining operations, the EV thermal management system adopts a liquid cooling technology with superior heat dissipation efficiency. How Does the EV Thermal Management System for Battery Electric Mining Trucks Work? The EV thermal management system for battery electric mining trucks works by actively heating or cooling the coolant to keep the battery operating between 25°C and 35°C, which is considered the ideal thermal range for lithium battery performance. The system is also capable of maintaining the temperature difference between individual cells within 5°C, ensuring consistent operation and extending overall battery lifespan. Operating Principle The heat exchanger inside the EV thermal management system features two flow channels: one channel circulates coolant, the other circulates refrigerant. These channels are alternately arranged:odd-numbered layers carry coolant, while even-numbered layers carry refrigerant. Heat is exchanged between the two media, reducing the temperature of the coolant before it is circulated into the battery pack to absorb and dissipate heat from the cells. In cold environments, a PTC heater is activated to warm the coolant, which in turn heats the battery, ensuring safe operation and charging efficiency at low ambient temperatures. A simplified schematic of the EV thermal management system Our Integrated EV Thermal Management System for Battery Electric Mining Trucks Our integrated EV thermal management system for battery electric mining trucks is designed to address the following key challenges: Cabin climate control Maintain a comfortable temperature and airflow for the driver. Defrost and defog the windshield for clear visibility. Control cabin humidity and air outlet temperature to ensure a clear driving view. Battery temperature regulation Prevent extreme temperatures from affecting charging/discharging rates and battery lifespan. Motor cooling Maintain optimal coolant temperature for efficient motor operation. Limited space constraints Electric commercial vehicles require additional battery cooling, but lack waste heat from an engine. Complex vehicle layout with multiple components. Solution Introduction The integrated EV thermal management solution is engineered to manage both cabin and e-powertrain temperature needs. By sharing core components such as the condensers module and compressor module, the system supports both air conditioning and equipment cooling/heating, ensuring stable and efficient vehicle operation. Solution Advantages High Efficiency & Energy Saving: Features variable-speed compressor, smart fan control, and motor waste heat recovery to minimize energy consumption. Reliable and Safe: Equipped with multiple layers of protection for pressure, temperature, current, and voltage to ensure system safety. Intelligent Control: Supports CAN bus vehicle communication, human-machine interface (HMI), and real-time display of temperature and airflow conditions. Highly Integrated Design: Combines heating and cooling modules into a single compact unit, with shared use of PTC heaters, fans, and other components to reduce footprint and simplify vehicle layout. Discover our BTMS Solutions here: https://brogenevsolution.com/battery-thermal-management-system-btms/ About Brogen At Brogen, we provide advanced EV solutions for global commercial vehicle manufacturers, enabling them to streamline research and development while capitalizing on cutting-edge technology. Our offerings ensure superior efficiency, extended range, and seamless system integration with proven reliability—empowering our partners to lead in the rapidly evolving green mobility landscape. Currently, our EV solutions for battery electric heavy trucks have been adopted by vehicle manufacturers in countries and regions such as Canada, Türkiye, Brazil, the Philippines, Indonesia, the Middle East, and more. Discover our HCV electrification solution here: https://brogenevsolution.com/heavy-duty-vehicle-electrification-solutions/ Looking for an EV solution for your project? Reach out to us at contact@brogenevsolution.com Contact Us Get in touch with us by sending us an email, using the Whatsapp number below, or filling in the form below. We usually reply within 2 business days. Email: contact@brogenevsolution.com Respond within 1 business day Whatsapp: +8619352173376 Business hours: 9 am to 6 pm, GMT+8, Mon. to Fri. LinkedIn channel Follow us for regular updates > YouTube channel Ev systems introduction & industry insights > ContactFill in the form and we will get in touch with you within 2 business days.Please enable JavaScript in your browser to complete this form.Please enable JavaScript in your browser to complete this form. Name * FirstLast Work Email *Company Name *Your Project Type *– Please select –Car, SUV, MPVBus, coach, trainLCV (pickup 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

EV Industry, Technologies

How the VCU Manages Power-Up and Power-Down in Electric Vehicles

How the VCU Manages Power-Up and Power-Down in Electric Vehicles: Comprehensive Control Logic Overview 1. Understanding Vehicle Power-Up/ Power-Down Logic Before delving into the vehicle’s power-up and power-down sequences and understand the control strategy via VCU, it’s essential to clarify two fundamental concepts: (1) Why must the VCU control the wake-up of high-voltage component controllers (e.g., BMS, MCU, DCDC, OBC, AC)? Unified vehicle wake-up logic: The vehicle can be awakened via several sources – key ignition, slow charging, fast charging, or remote control. The VCU receives these wake-up signals and subsequently controls the wake-up of other controllers, enabling centralized monitoring and management of the vehicle status while simplifying low-voltage wiring design. Enhanced functionality: By controlling the wake-up of high-voltage components, the VCU facilitates key features such as charging while the vehicle is OFF, remote preconditioning, scheduled charging, and safe sequencing of high-voltage system operations. (2) Key considerations for high-voltage circuits before power-on/off Before power-on: Prevent inrush current: Motor controllers contain large internal capacitors, which allow AC to pass but block DC. At the moment the high-voltage circuit is closed, the capacitors cause the circuit to behave like an AC circuit. If no resistance is present in the circuit (I=U/R), a large inrush current will be generated, potentially damaging high-voltage components. Ensure system safety: Prior to high-voltage activation, safety checks must be performed – verifying proper interlock connections, insulation resistance to prevent electric shock risks, and ensuring there are no high-voltage-related faults. Before power-off: Relay protection: If the system carries a high current during shutdown, opening the relay under load may damage it or cause welding, leading to failure in disconnecting the high voltage. Component protection: Motors can generate back-EMF when rotating. Disconnecting power at high speed can cause voltage spikes (several kV), risking damage to power devices like IGBTs and electric compressors. (3) Diagrams VCU Low-Voltage Schematic Example: Shows typical low-voltage pins used in the VCU; though simplified, it aligns with the overall power control sequence. Vehicle High-Voltage Circuit Example: While layouts vary by manufacturer, the core principles are similar and correspond with the logic described above. 2. Full Vehicle Power-Up and Power-Down Sequence The vehicle’s power-up and power-down process is not a simple on/off switch but a precise system-level operation. When the driver turns the key or presses the start button, the Vehicle Control Unit (VCU) – the vehicle’s central brain – coordinates the initialization of key systems like the MCU, PDU, TCU, and TMS. It manages their low-voltage power-up and sends wake-up signals, ensuring safe and synchronized startup of high-voltage components. Power-Up Sequence: Key On (KL15), VCU wakes up and completes initialization. Wake up high-voltage controllers such as MCU, BMS, DCDC, DCAC, TCU, and TMS. VCU checks the vehicle’s low-voltage system status. If all high-voltage controllers are initialized and there are no HV-related faults, and a high-voltage activation request is present, proceed to step 4; otherwise, stay in step 3. VCU sends a command to close the negative relay. If feedback confirms the relay closed within time t0, proceed to step 5; if not, switch to negative relay disconnection. VCU sends a command to close the positive relay, which is preceded by pre-charge relay activation. After pre-charging, the system confirms that the MCU DC voltage reaches ≥95% of the nominal battery voltage within time t1. If confirmed, proceed to step 6; otherwise, disconnect the positive relay. VCU performs a high-voltage status check. Enables DCDC/DCAC and verifies their operational status. If confirmed, proceed to step 7; otherwise, enter zero torque state. Drive-ready state: VCU enables the MCU and turns on the READY indicator. If the driver shifts into gear, VCU sends torque or speed control commands for driving. If a shutdown request is received, proceed to step 8. Shutdown request received: VCU sends the zero torque command to the MCU to decelerate. Once motor speed<N, torque<T, bus current<A, and vehicle speed<V or timeout t2 is reached, proceed to step 9. VCU disables DCDC/AC/PTC/DCAC. DCAC, which powers steering/braking assist, is disabled only when the vehicle is stationary to maintain safety. After confirming the shutdown status and that the A/C compressor speed<Nac, or timeout>t3, proceed to step 10. VCU sends command to disconnect the positive relay. Once MCU DC voltage≤ 60V (safe threshold) or timeout>t4, proceed to step 11. VCU sends command to disconnect the negative relay. After confirmation or timeout>t5, proceed to step 12. High-voltage components are powered down. If key=off, VCU proceeds to data storage and sleep; otherwise, return to VCU wake-up. 3. Charging Process and Notes on Power-Up/Down (1) Differences in Charging Process: Wake-up source shifts from ignition to charging signal; If both ignition and charging signals are present, the charging process takes precedence. If the charging cable is connected during READY state, the system performs a shutdown process first, then begins charging. MCU and DCAC are not enabled during charging; driving is not permitted. (2) Key Reminders: During vehicle power-up, low voltage is activated before high voltage. During power-down, high voltage is disconnected before low voltage. For HV activation, negative relay closes before the positive replay. For HV shutdown, positive relay opens before the negative relay. About Brogen At Brogen, we provide advanced EV solutions for global commercial vehicle manufacturers, enabling them to streamline research and development while capitalizing on cutting-edge technology. Our offerings ensure superior efficiency, extended range, and seamless system integration with proven reliability—empowering our partners to lead in the rapidly evolving green mobility landscape. Currently, our EV solutions for battery electric buses and trucks have been adopted by vehicle manufacturers in countries and regions such as Australia, Türkiye, Brazil, the Philippines, Indonesia, the Middle East, and more. Looking for an EV solution for your project? Reach out to us at contact@brogenevsolution.com Contact Us Get in touch with us by sending us an email, using the Whatsapp number below, or filling in the form below. We usually reply within 2 business days. Email: contact@brogenevsolution.com Respond within 1 business day Whatsapp: +8619352173376 Business hours: 9 am to 6 pm, GMT+8, Mon. to Fri. LinkedIn channel Follow

Public Transportation, Technologies

Battery Electric Bus Body: Structural Design and Strength Optimization for Lightweight and Safety

Battery Electric Bus Body: Structural Design and Strength Optimization To advance the adoption of electric vehicles and fully capitalize on the energy-saving and emission-reduction benefits of battery electric buses (BEBs), a lightweight electric bus body design is essential. This article presents an overview of topology optimization theory and explores key material options for electric bus body construction, including high-strength steel, aluminum alloys, and carbon fiber composites. It highlights the advantages of advanced materials in improving structural performance and outlines methodologies for analyzing structural loads, optimizing topology, and ensuring strength and reliability. These insights provide valuable guidance for the development, design, and manufacturing of next-generation electric buses, supporting both performance and sustainability goals. Introduction The electric vehicle (EV) sector is undergoing rapid development, particularly in the public transportation segment, where battery electric buses offer significant advantages such as zero emissions, reduced operating costs, and simpler maintenance. However, one of the primary challenges hindering wider adoption is limited driving range. Reducing curb weight – while maintaining safety and structural integrity – is a proven strategy to extend range and improve overall vehicle efficiency. Since the body structure contributes more than one-third of a bus’s total weight, lightweighting the body is a critical focus. By leveraging topology optimization theory and finite element analysis (FEA), engineers can minimize material use while maintaining required levels of stiffness and strength. This approach not only enhances vehicle range but also contributes to long-term energy efficiency and emission reduction goals. 1. Topology Optimization Principles When applying topology optimization to electric bus body design, shape optimization techniques are used to find the most efficient material layout under one or more loading conditions. This approach targets minimum structural stiffness. It starts with developing a digital base model of the bus body, then uses optimization algorithms to remove unnecessary components while retaining critical structural elements. This improves the structural layout’s rationality and reliability. Basic mathematical model of battery electric bus In practice, topology optimization is performed with the following considerations: Analysis Type: Static analysis Element Types: First-order and second-order tetrahedral elements Material Behavior: Liner elastic, elastoplastic, hyperelastic Loading Conditions: Concentrated force, pressure, torque, gravity Boundary Conditions: Displacement constraints Contact Conditions: Bonded and surface contact Connection Types: Rigid and beam connections Objective Function: Maximize stiffness Design Variables: Topology variables Constraints: Volume fraction If the total number of elements is denoted as a, then each element can be represented as y(i = 1, 2, 3, …, a). During the structural optimization process, if the h-th element is determined to be non-essential, it will be assigned a value of yₕ = 0; if it is essential and should be retained, it will be assigned yₕ = 1. The structural optimization design of a pure electric bus body can be carried out using finite element analysis (FEA) combined with variable design methods. 2. Main Types of Electric Bus Materials The evolution of bus body materials reflects a broader shift toward lightweight and high-performance materials. Initially dominated by steel (over 90% of body structure), the industry has gradually shifted toward aluminum alloys and carbon fiber composites. This shift is driven by the demand for lightweight, energy-efficient, and low-emission vehicles. High-Strength Steel (HSS): Created by adding trace elements to low-carbon steel and undergoing specialized rolling processes. It offers tensile strength up to 420 N/mm² and excellent deep-drawing properties, making it a strong candidate for lightweight structural components. Aluminum Alloys: Compared to steel, aluminum alloys have a lower density (2.7 g/cm³), higher specific strength, good corrosion resistance, thermal stability, and recyclability. These advantages make aluminum alloys widely used for lightweight applications. Carbon Fiber Composites: Composed of carbon fiber bundles and resin, these materials offer exceptional high tensile strength (often over 3500 MPa), high stability, and resistance to deformation during impact. Carbon fiber composites can significantly enhance passive safety and are more than twice as durable as steel. With increasing demand for extended range, pure electric buses have transitioned from using high-strength steel to aluminum alloy bodies, which reduce body weight by 25%-35%. Modern aluminum alloy components are often assembled using rivets and bolts rather than traditional welding, and stamped aluminum parts have replaced conventional steel panels. Aluminum alloys also offer high recyclability, with recovery rates exceeding 85% when vehicles are retired. Skeleton layout of 10.5 m battery electric bus aluminum alloy roof Skeleton layout of 10.5 m pure electric bus aluminum alloy bone around on the left side Skeleton layout of 10.5 m pure electric bus aluminum alloy bone around on the right side 3. Performance and Cost of Advanced Automotive Materials Advanced materials and manufacturing processes are key drivers of automotive innovation. High-Strength Steel: Offers 15%-25% higher strength than standard steel, with better balance and 20% improved corrosion resistance. However, it requires additional anti-corrosion treatments to meet durability requirements. Aluminum Alloys: In a 10-meter bus, switching from steel to aluminum components can reduce body weight by over 450 kg. Aluminum also provides superior thermal insulation and vibration damping compared to steel. Manufacturing methods such as hot forming, die casting, and precision machining enhance part performance and structural integrity. Carbon Fiber Composites: Carbon fiber’s strength and stiffness per unit weight surpass all other commonly used materials. It absorbs 4-5 times more impact energy than steel and can reduce body weight by over 40%, while enhancing safety and aesthetic appeal. However, its high cost restricts its applications to high-end or specialized vehicles. Relative Costs: Steel: Lowest cost Aluminum Alloys: Moderate cost Carbon Fiber Composites: Highest cost 4. Structural Load Analysis and Topology Optimization of Battery Electric Bus Body The structural design of a battery electric bus must comply with the requirements outlined in relevant national standards and the specific design brief. This includes determining the vehicle’s primary exterior dimensions – such as length, width, height, wheelbase, front overhang, and rear overhang – while ensuring a balanced and harmonious overall appearance. Effective spatial arrangement of the driver’s cabin and passenger area is essential for optimal internal layout. The number, position, and minimum dimensions of passenger doors and emergency

Technologies

A Comprehensive Guide to CCS Integrated Busbars for EV Battery Packs

A Comprehensive Guide to CCS Integrated Busbars for EV Battery Packs What is CCS on a Battery? CCS, short for Cells Contact System, refers to an integrated busbar system that combines conductive busbars, control circuits (such as voltage and temperature sensors), and other components into a single modular unit. It plays a critical role in the internal electrical architecture of battery modules. By consolidating multiple functions into one system, CCS enhances the integration, reliability, and safety of battery systems. It also helps reduce assembly complexity, save space, lower production costs, and simplify maintenance. In essence, CCS is an electrical connection structure within the battery module. It integrates data acquisition components, plastic structural parts, copper/aluminum busbars, and more into a single module. This allows it to perform high-voltage series-parallel connections, temperature sensing, voltage sampling, and overcurrent protection, serving as a key component of the Battery Management System (BMS). CCS technology is widely used in electric vehicles (EVs), energy storage systems, and other high-voltage battery applications. Advantages of CCS Busbar for EV Battery Packs High Integration: Multiple functions are integrated into one module, reducing the number of components and wiring complexity. Enhanced Reliability: The integrated design improves system stability and reduces failure rates. Lightweight Design: With compact architecture and lightweight materials, CCS helps lower overall vehicle weight and improve energy efficiency. Improved Production Efficiency: Simplified assembly processes and high automation levels reduce labor costs and improve manufacturing throughput. Ease of Maintenance: Modular design allows for easier maintenance and component replacement, reducing downtime and service costs. CCS Structure and Classifications CCS systems vary based on the type of signal acquisition component used, and include several solutions such as wire harnesses, PCB, FPC, FFC, FDC, and FCC. Various integration techniques are employed, including injection-molded brackets, vacuum-formed plates, hot pressing, and die-cut PET films. The industry currently sees multiple technical paths coexisting and evolving. Common Materials Used in CCS Include: Hot-pressed insulation film Aluminum busbars Vacuum-formed trays Injection-molded structural brackets PCB/FPC/FFC signal acquisition components Type Signal Acquisition Component Common Integration Techniques Wire Harness Traditional Wiring Harness Injection-molded bracket; Thermal riveting process with vacuum-formed tray (blister riveting process) PCB Printed Circuit Board Hot pressing process; Thermal riveting process with vacuum-formed tray (blister riveting process) FPC Flexible Printed Circuit FFC Flexible Flat Cable FDC Flexible Die-cut Circuit FCC FFC connected with FPC or FDC Overview of CCS Variants for EV Batteries Each CCS implementation offers unique benefits depending on the application scenario: 1. Wire Harness Solution Structure: Wire harness + acquisition terminals + NTC sensors + aluminum busbar + injection/vacuum-formed bracket Features: Cost-effective and stable signal transmission, but with lower automation potential. 2. PCB Solution Structure: PCB + nickel strips + aluminum busbar + hot pressing with PET film or vacuum thermal riveting Features: Lightweight, high automation, and excellent signal integrity. 3. FPC Solution Structure: FPC + nickel strips + aluminum busbar + hot pressing with PET film or vacuum-formed plate Features: Ultra-lightweight with high automation and stable signal transmission, though with higher costs. 4. FFC Solution Structure: FFC + nickel strips + aluminum busbar + PET film hot pressing or vacuum thermal riveting Features: Lightweight, low cost, high automation—ideal for long-format battery modules. 5. FDC Solution Structure: Die-cut flexible circuits using rotary die technology Features: Fewer processing steps, low cost, and suitable for mass production. 6. FCC Solution Structure: FFC as the main body with soldered FPC or FDC branches through window openings Features: An emerging cost-effective solution still under evaluation and testing. Key Considerations for CCS Design and Manufacturing 1. Material Selection & Integration Process The choice of conductive (copper, aluminum) and insulating materials, as well as integration techniques like hot pressing and riveting, greatly impacts performance, safety, and durability. 2. Automation & Manufacturing Efficiency High levels of automation are essential for scale and cost control. However, due to differing requirements across battery and vehicle manufacturers, semi-automated processes may offer better return on investment at lower volumes. 3. Signal Transmission Reliability Ensuring stable and accurate transmission of voltage and temperature data is crucial. PCB and FPC solutions perform well in this regard but come at a higher cost. 4. Lightweight Design & Cost Control As electrification continues to grow, CCS must balance performance, weight reduction, and affordability. FFC and FDC solutions offer promising trade-offs, but continuous optimization is necessary. 5. Safety & Protection Features CCS must provide overcurrent protection, corrosion resistance, and thermal stability. Design considerations must include cell-level protection to ensure safe operation under extreme conditions. 6. Thermal Management Proper heat dissipation and thermal balance within the battery pack are vital. CCS design must support efficient thermal management through material selection and structural layout. 7. Quality Control & Testing Rigorous quality assurance is key to reliable CCS performance. This includes testing electrical performance, mechanical durability, and environmental adaptability to ensure consistent results across operating conditions. 8. Market Competition & Innovation With growing competition, CCS manufacturers must innovate in process technologies, improve product quality, and reduce costs to stay competitive. Our CCS Technology for EV Battery Packs Our intelligent integrated CCS technology, featuring a fully integrated design that replaces the traditional complex approach of “wiring harness + BMS + temperature sensors.” By integrating multiple cell state detection components directly into the system, we achieve a streamlined, intelligent solution. Starting from the battery cell level, our CCS system establishes a multidimensional safety architecture—combining active and passive protection mechanisms and system-level thermal runaway risk management. Centered on real user needs, our solution delivers smarter, safer, and more reliable battery management—putting safety at the core. Cost-Effective Standardized integrated systems enhance quality and production efficiency, significantly improving PACK assembly speed while reducing overall costs. The use of standardized components greatly simplifies the assembly process. Ultimate Safety Superior insulation and high-voltage withstand capability reduce the risk of accidents. The design minimizes common issues associated with traditional sampling harnesses, such as insulation failure, aging, breakage, and short circuits. Highly Integrated Combines sampling harnesses, aluminum busbars, temperature sensors, as well as internal PACK components like air pressure sensors, explosion-proof valves, electrolyte

Public Transportation, Technologies

Integrated Electric Bus Powertrain Axle Assembly Design

Integrated Electric Bus Powertrain Axle Assembly Design Introduction to Electric Bus Powertrain Development Electric buses have increasingly been recognized worldwide as a leading direction in EV development. As the consumption of non-renewable resources accelerates, the automotive industry’s shift toward electrification is becoming even more pronounced. However, due to current limitations in energy storage technology, electric vehicles continue to lag behind traditional vehicles in areas such as driving range, battery lifespan, and charging convenience. Consequently, pure battery electric buses (BEBs) tailored to specific routes and operating conditions are at the forefront of pilot programs. In recent years, the electrification of public transportation fleets in major cities around the world has gained significant momentum. With substantial investments flowing into the pure electric bus sector, it is critical to harness emerging technologies to strengthen product competitiveness. Among these advancements, the integration of electric motor and drive axle design has notably enhanced the performance of electric buses and has become a key focus in EV safety development. Overview of Integrated Electric Bus Powertrain Axle Assembly Traditional bus powertrains consist of an engine, transmission, driveshaft, and axle assemblies. As the electric bus powertrain industry continues to evolve, many manufacturers initially adopted transitional solutions — replacing the internal combustion engine with an electric motor while largely retaining the traditional mechanical layout, as illustrated in Figure 1. However, this approach introduces several challenges: Low transmission efficiency: Overall system efficiency remains below 80%. Poor system integration: The design conflicts with the industry’s ongoing lightweighting initiatives. Limited regenerative braking performance: Due to the inherent limitations of traditional bevel gear axles, brake energy recovery rates are typically below 30%. The new generation electric bus powertrain layout proposed in this paper effectively overcomes these shortcomings (Figure 2). In this new design, the electric motor is fully integrated into the drive axle assembly, eliminating the need for separately mounted motors, suspension components, and driveshafts within the vehicle frame. This integrated configuration simplifies vehicle layout and installation. The suspension system mounts directly to the axle housing, and the battery packaging is optimized, significantly improving internal space utilization. Nevertheless, engineering challenges remain. Precisely determining the torque axis is complex due to factors such as vehicle and drivetrain layout, packaging constraints, and the mechanical characteristics of rubber isolators, all of which affect the compression-to-shear stiffness ratio and complicate accurate positioning of the fore-aft mounting centers along the torque shaft. System Design of the Integrated Electric Bus Powertrain Axle Assembly Taking an 8.5-meter pure electric bus as a design example: Current mainstream design: Uses a low-speed, permanent magnet synchronous, water-cooled electric motor. Max power: 300 kW Max torque: 2070 Nm Speed: 4000 rpm Axle load: 8 tons Gear ratio: 5.857 Motor weight: 550 kg Driveshaft weight: 40 kg Maximum wheel driving torque: 2070 × 5.857 = 12100 Nm The suspension system’s natural frequency is below 30 Hz. New high-speed design: Introduces a high-speed permanent magnet synchronous, water-cooled motor: Power: 205 kW Torque: 500 Nm Max speed: 12,000 rpm Motor weight: 102 kg Axle weight: 580 kg (with no driveshaft required) Gear ratio: 24.8 Maximum wheel driving torque: 500 × 24.8 = 12400 Nm In traditional axles, the engine layout perpendicular to the driving direction necessitates the use of bevel gears to redirect power. Bevel gear manufacturing limitations mean that convex and concave gear sides have different accuracies. During regenerative braking, if over 30% of braking energy is recovered, the concave gear side’s insufficient precision can cause gear surface damage or even failure. To address this, the new solution arranges the motor parallel to the vehicle’s driving direction, eliminating the need for bevel gears. All gears are cylindrical gears, which are easier to design and manufacture with high precision, improving durability and supporting more efficient brake energy recovery. Weight Comparison Category Weight (kg) Traditional pure electric design 300 + 550 + 40 = 890 kg Integrated axle motor design 102 + 580 = 682 kg Weight saving 890 – 682 = 208 kg Application of Integrated Electric Bus Powertrain Axle Assembly By integrating the motor and axle into a unified powertrain system, there is no longer a need to reserve separate space for the motor. This design reduces the rear suspension space requirements, as shown below, and significantly improves passenger cabin space by increasing the distance between the front and rear doors. Performance Comparison Between Integrated and Traditional Electric Bus Powertrains The integrated electric bus powertrain offers the following advantages over traditional designs: Higher system integration:The axle self-assembles with the powertrain, simplifying vehicle layout and improving transmission efficiency. Enhanced regenerative braking:Brake energy recovery capacity can reach up to 100%. Significant weight reduction:Lightweighting of approximately 208 kg for an 8.5-meter electric bus. Improved vibration isolation and vehicle stability:Experimental tests confirm enhanced ride quality and comfort. Conclusion This study explores an innovative electric bus powertrain layout that significantly improves electric vehicle performance. Through ultra-short rear suspension designs and system lightweighting, the proposed integrated axle motor assembly enhances vehicle energy efficiency (EKG indicators) and extends the continuous driving range. The results demonstrate higher transmission efficiency, superior regenerative braking capabilities, and reveal the future electrification trends for heavy-duty vehicles. Discover our integrated electric bus powertrain (electric bus axle) here: https://brogenevsolution.com/electric-axle-for-bus/ Business inquiry: contact@BrogenEVSolution.com Or you can complete the table below to get in touch with us. 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