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

120 kW / 185 kW Electric Motor + 2-Speed AMT E-Powertrain | Bus & Truck

120 kW / 185 kW Electric Motor + 2-Speed AMT E-Powertrain for Bus & Truck This 120 kW / 185 kW electric motor with a 2-speed AMT offers a cost-effective and versatile e-powertrain solution for city buses from 12 meters to 13 meters, highway coaches from 10 meters to 12 meters, and electric trucks from 12 tons to 18 tons. The system features a lightweight design, weighing about 30-40% less than comparable direct-drive products. This weight reduction not only enhances vehicle efficiency but also supports higher payload capacity. The motor and transmission are designed as an integrated unit, which helps reduce both motor and controller costs. The system also eliminates the need for costly transmission matching, further lowering the overall drivetrain cost. Email: contact@brogenevsolution.com Get Custom Quote 120 kW / 185 kW E-Powertrain: Solution Details 1. System Architecture Diagram 2. Technical Parameters *Parameters may differ depending on the configuration and vehicle model. Certain specifications can be customized. For more information, please contact us at contact@BrogenEVSolution.com Model OETED3380 System Maximum Output Torque 3380 N.m Total Weight 210 kg Dimension 636x516x549 mm Motor Parameters Rated/Peak Power 120 kW / 185 kW Rated/Peak Torque 650 N.m / 1300 N.m Peak Speed 3500 rpm Transmission Parameters Gear 2 Speed Ratio 2.741, 1 PTO Parameters Speed Ratio 1.175 Maximum Output Torque 300 N.m 3. Solution Features The e-powertrain assembly features the AMT rated for over 2 million gear shifts and a design lifespan exceeding 8 years or 1 million kilometers. The AMT is precisely calibrated with the motor in an integrated configuration and features a PTO. This design ensures short shift intervals and smoother, more consistent power delivery. Lightweight aluminum-alloy design: Approximately 30-40% lighter than comparable direct-drive systems, enhancing vehicle efficiency and performance. 2-speed pure electric system: Optimizes the motor’s operating point through gear shifting, improving overall efficiency and reducing energy consumption by 3-5% compared to similar products under combined operating conditions. High torque & strong gradeability: Delivers up to 3380 N.m of peak output torque, enabling powerful performance for heavy-duty applications. Achieves a maximum gradeability of over 25% under full load, ensuring strong climbing capability and reliable operation on steep terrains. 4. How Do We Ensure the Reliability of the AMT? To maximize transmission reliability, our 2-speed AMT, specifically designed for pure electric vehicles, undergoes a comprehensive series of environmental and durability tests. Through these interative tests and optimizations, our pure electric AMT achieves a service life exceeding 1 million kilometers, delivering reliability comparable to direct-drive systems. Environmental testing: waterproof, dustproof, high/low temperature, salt spray, and vibration tests. Torque endurance: static torque tests exceeding 3x the rated torque. Durability testing: rigorous comprehensive endurance tests, including over 1 million shift cycles per gear. Bench simulation: over 200,000 km of chassis dynamometer testing simulating real vehicle operation. Real-world road testing: more than 50,000 km of on-road trials. Consistency verification: full-vehicle consistency tests across 50 assembled units. 5. Real-World Applications Discover our other electric truck motors here: https://brogenevsolution.com/electric-motors-for-truck/ Discover our HCV electrification solution here: https://brogenevsolution.com/heavy-duty-vehicle-electrification-solutions/ 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

Heavy Transport, Technologies

250 kW / 400 kW Electric Motor for Heavy-Duty Truck

250 kW / 400 kW Electric Motor for Heavy-Duty Trucks This 250 kW / 400 kW electric motor paired with a 4-speed AMT is a highly mature and proven e-powertrain solution for heavy-duty commercial vehicles such as electric dump trucks, electric semi-trucks, and other construction machinery weighing between 31 and 55 tons. The system employs a single high-power motor integrated with a 4-speed AMT, leveraging the gear ratio variation and torque multiplication capabilities of the transmission. This approach enables the use of a smaller, high-efficiency motor while still achieving the high-torque output required for heavy-duty operations. Key technical advantages include optimized torque delivery, smooth gear shifts, high reliability, and a wide operational range. Email: contact@brogenevsolution.com Get Custom Quote 250 kW / 400 kW Electric Motor for Heavy-Duty Trucks: Solution Details 1. System Architecture Diagram 2. Technical Parameters *Parameters may differ depending on the configuration and vehicle model. Certain specifications can be customized. For more information, please contact us at contact@BrogenEVSolution.com System Parameters Model OEHTED16000 OEHTED20000L2 OEHTED22000 Applications Electric concrete mixer truck, heavy truck, semi truck System Maximum Output Torque 16360 N.m 20136 N.m 21814 N.m Total Weight 400 kg 425 kg 445 kg Dimension 1145x612x615 mm Motor Parameters Rated/Peak Power 200 kW / 300 kW 250 kW / 400 kW 280 kW / 420 kW Rated/Peak Torque 850 N.m / 1950 N.m 1200 N.m / 2400 N.m 1500 N.m / 2600 N.m Peak Speed 3500 rpm 3500 rpm 3500 rpm Transmission Parameters Gear Numbers 4 Maximum Input Torque 2600 N.m Speed Ratio 8.39, 3.54, 1.74, 1 PTO Parameters Total Speed Ratio 1.643 Peak Output Torque 700 N.m 3. Solution Features Proven AMT Architecture: Utilizes a 4-speed Automated Manual Transmission (AMT), the industry-standard solution for heavy-duty commercial EVs. This transmission delivers excellent low-gear gradeability, high-speed capability, and optimized efficiency across the entire operating range, ensuring performance in diverse operating conditions. Single Motor + AMT ePowertrain Design: The system adopts a PMSM integrated with an AMT in a clutchless coaxial layout, enabling smooth and synchronized shifting through motor speed control. This design eliminates the need for a mechanical clutch, improving reliability and reducing complexity. High Power Density & Torque Multiplication: Rated at 250 kW (continuous) / 400 kW (peak) and delivering 1200 N.m (continuous) / 2400 N.m (peak) torque, the solution leverages AMT’s gear ratio flexibility to provide high torque for heavy-load starts and steep gradients while maintaining high efficiency at cruising speeds. Operational Efficiency & Energy Savings: Compared with direct-drive systems, this solution offers lighter weight for the same torque capability and superior efficiency at high speeds, reducing energy consumption and enhancing vehicle range. Enhanced Driving Comfort & Reliability: Features smooth gear shifts, robust system reliability, and a quiet powertrain operation, improving driving comfort and reducing NVH levels during operations. Full-Scope Application Adaptability: Designed for heavy-duty applications such as construction material transport, resource hauling, and urban infrastructure projects, delivering high transport efficiency, strong performance, and optimized total cost of ownership (TCO). Proven in the Market: With over 20,000 units in operation, this solution platform has demonstrated stable performance and long-term durability in real-world conditions. It is widely deployed in dump trucks, concrete mixers, semi-trucks, and even electric cranes. 4. Benefits for EV Builders Accelerated Time-to-Market: The mature solution minimizes development cycles, helping OEMs achieve faster commercialization. Proven Reliability: With large-scale deployment and robust performance, we reduce technical and operational risks for new projects. Customization Support: We provide platform adaptability and engineering support to meet specific operational needs and vehicle designs. Sustainability Advantage: Our system supports green mobility, helping OEMs meet regulatory and ESG goals. 5. Real-World Applications The 250 kW / 400 kW electric motor + 4-speed AMT solution has already entered mass production and represents a mature and proven solution. The platform’s products have been deployed in over 20,000 vehicles, demonstrating strong market validation. It’s ideally suited for sectors such as construction waste removal, concrete transport, building materials delivery, and resource logistics. Vehicles equipped with this e-powertrain deliver high transport efficiency, excellent cost-effectiveness, and reduced noise, creating a much quieter and cleaner working environment at depots and job sites. 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

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

504kW_620kW electric truck axle brogen electric truck axle

Heavy Transport, Technologies

Heavy-Duty Electric Truck Axles (504 kW / 620 kW)

Heavy-Duty Electric Truck Axles (504 kW / 620 kW) These heavy-duty electric truck axles feature a dual-motor integrated design and are engineered for high-performance applications. With a rated axle load of 13 tons and a maximum system power output of 504 kW or 620 kW, they are capable of meeting the demanding requirements of various heavy-duty commercial vehicles, including 4×2, 6×4, and 8×4 configurations such as municipal vehicles, semi-trucks, and dump trucks. By delivering strong performance and efficiency under heavy-load conditions, these e-axles help significantly reduce both carbon emissions and overall energy consumption. Email: contact@brogenevsolution.com Get Custom Quote Heavy-Duty Electric Truck Axles: Solution Details 1. Solution Features of Our Heavy-Duty Electric Truck Axles Dual Motor + 4-speed AMT Configuration: Adaptable to multiple use cases, from high-capacity long-haul electric semi-trucks to high-torque construction trucks operating under frequent load shifts. Modular Design for Easier Maintenance: High integration of motors and gearbox enables a compact layout and simplifies service and maintenance processes. Transverse Layout Without Hypoid Gear Set: Eliminates the hypoid gear set to reduce mechanical losses, enhancing transmission and regenerative braking efficiency. One-piece Axle Housing with Aluminum Alloy Casing: Integrated cast axle housing offers higher structural strength and sealing performance; aluminum casing helps reduce overall system weight. 2. Technical Parameters Model OESTEA45000Z-1 OESTEA45000Z-2 E-Powertrain Rated Axle Load 13 T (16 T Under Development) Wheel-End Output Torque 45000 N.m 45000 N.m Assembly Weight 985 kg 990 kg Reference Leaf Spring Distance 1018-1050 mm (Adjustable) Wheel Mounting Distance 1837 mm Compatible Suspension Leaf Spring / Air Suspension Motor Parameters Motor Rated/Peak Power 150/252 kW*2 190/310 kW*2 Motor Rated/Peak Torque 285/550 N.m 280/590 N.m Motor Maximum Speed 9000 rpm Transmission Parameters Speed Ratio 4-speed 1st: main transmission 71.0+auxiliary transmission 46.8 2nd: main transmission 36.3+auxiliary transmission 46.8 3rd: main transmission 20.0+auxiliary transmission 13.2 4th: main transmission 10.2+auxiliary transmission 13.2 Brake Brake Specifications Drum brake φ410*220; disc brake 22.5″ Brake Torque 2*18000 N.m (drum brake); 2*22000 N.m (disc brake) Air Brake Chamber Specifications 30/24 (recommended) Other Options Differential Lock Optional PTO Optional PTO for retrofit 3. Advanced AMT Technology – Built for Smarter, Smoother Electric Trucks This electric truck axle platform features a 4-speed AMT. It enables active speed synchronization between the motor and the transmission input shaft, allowing for rapid and smooth gear shifts. By combining gear profile modification with in-depth analysis of casing and shaft tooth deformation, the system achieves optimal meshing conditions, minimizing transmission error and reducing efficiency loss. Faster gear shifting: Reduced shift time improves drivability, especially under frequent stop-and-go scenarios. Higher drivetrain efficiency: Enhances energy use and supports longer driving range. Lower NVH: Quiet and smooth gear transitions improve driving comfort. Lower maintenance cost: Long-life gear oil with no initial oil chaange required; supports extended intervals of 50,000-200,000 km. 4. Key Performance Data Weight reduction vs. direct drive (dual axle): 22% per set Range improvement vs. direct drive: Up to 20% Energy use: 10% less per 100 km at 49t full load vs. industry average Axial space saving: 40% Deployed units (to date): ~13,000 Projected annual production capacity (2025): Over 10,000 units How We Ensure the Reliability of Our Electric Truck Axles Our electric truck axles undergo a rigorous multi-level validation process to guarantee long-term performance, safety, and durability under real-world operating conditions. Component-Level Testing Over 50 tests are conducted on individual components to verify structural integrity, strength, and consistency. These include: Vibration Salt spray Tensile Torsion Hardness Full-dimension inspections Subsystem-Level Testing More than 90 tests are performed across all core subsystems – including the shifting mechanism, gearbox, motor, high/low voltage controllers, wiring harnesses, and software. These tests fall into six major categories: Module validation Functional testing Performance testing Durability testing Reliability testing Environmental resistance System-Level Testing Over 50 tests are carried out at the system level using specialized test benches and real-vehicle road trials, including: High and low temperature cycling Thermal shock testing Salt spray and corrosion resistance Waterproof and dustproof validation Vibration and noise testing System integration and special-condition simulation R&D and Manufacturing Excellence Comprehensive and Integrated R&D Capabilities The R&D team is built on a robust, cross-functional framework encompassing structural engineering, electronic hardware, system architecture, software development, testing, and manufacturing processes. We maintain a full-spectrum development capability that spans from concept design to real-world validation. With in-house expertise in mechanical design, control unit development, computer-aided simulation, bench testing, and complete vehicle road testing, we are equipped to support rapid iteration and innovation across the entire product lifecycle. Hybrid and pure electric powertrains Transmission systems and controllers Electric motors and motor controllers Shift and clutch actuators Vehicle control units (VCUs) Quality Management & Full Lifecycle Traceability The factory strictly adheres to IATF 16949, ISO 14001, and other international standards, ensuring precise control over every production process and uncompromising quality in every product. The digital management system enables a full lifecycle traceability and control, ensuring that every component is trackable and accountable from production to delivery. In 2025, the e-axle for trucks production capacity is expected to exceed 10,000 units, further demonstrating our ability to scale with quality and consistency. 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

Heavy Transport, Technologies

250kW / 290kW E-Axle for Trucks, Heavy-Duty Truck E-Powertrain

250 kW / 290 kW E-Axle for Trucks Our 250 kW / 290 kW e-axle for trucks integrates a high-efficiency PMSM, transmission, and axle into a compact unit. By leveraging the gear ratio of the integrated transmission, the system delivers high torque output even with a relatively smaller motor. The wheel-end output torque can reach up to 40,000 N.m, making it ideal for 6×4 and 4×2 truck tractors, semi-trailers, water tankers, garbage trucks, dump trucks, and other heavy-duty transport or municipal vehicles. This e-axle system is already in mass production and has been deployed in batch applications on electric semi-trailers. Email: contact@brogenevsolution.com Get Custom Quote E-Axle for Trucks: Solution Details Item Technical Parameters Model OESTEA40000Z-1.5 OESTEA40000Z-1.6 E-Powertrain Axle Load 13 T Wheel-End Output Torque 40000 N.m Assembly Weight 1030 kg Motor Parameters Motor Rated / Peak Power 121 kW / 250 kW 136 kW / 290 kW Motor Rated / Peak Torque 320 N.m / 850 N.m 326 N.m / 860 N.m Motor Peak Speed 10000 rpm Transmission Gear Ratio 13.2/4.4 Axle Wheel-Side Gear Ratio 3.478 Rim Mounting Distance 1822 mm Brake Type Drum Brake / φ410×220 Maximum Brake Torque (0.8MPa) 2×18000 N.m 2×18000 N.m PTO N.A. Optional Differential Lock Optional Solution Features IP67 water and dust protection, along with rigorous high/low temperature and vibration testing, ensures outstanding system reliability. One-piece axle housing provides high load-bearing capacity while maintaining ease of maintenance. Driveshaft eliminated, allowing more space in the chassis for flexible and efficient battery pack installation. Integrated design results in lighter weight, higher efficiency, and better energy savings. Technology Highlights Our e-axle for trucks features a 2-speed AMT. It enables active speed synchronization between the motor and the transmission input shaft, allowing for rapid and smooth gear shifts. By combining gear profile modification with in-depth analysis of casing and shaft tooth deformation, the system achieves optimal meshing conditions, minimizing transmission error and reducing efficiency loss. Shorter gear shifting time Higher transmission efficiency Lower operating noise How We Ensure the Reliability of Our E-Axle for Trucks Our e-axle system undergoes a rigorous multi-level validation process to guarantee long-term performance, safety, and durability under real-world operating conditions. Component-Level Testing Over 50 tests are conducted on individual components to verify structural integrity, strength, and consistency. These include: Vibration Salt spray Tensile Torsion Hardness Full-dimension inspections Subsystem-Level Testing More than 90 tests are performed across all core subsystems – including the shifting mechanism, gearbox, motor, high/low voltage controllers, wiring harnesses, and software. These tests fall into six major categories: Module validation Functional testing Performance testing Durability testing Reliability testing Environmental resistance System-Level Testing Over 50 tests are carried out at the system level using specialized test benches and real-vehicle road trials, including: High and low temperature cycling Thermal shock testing Salt spray and corrosion resistance Waterproof and dustproof validation Vibration and noise testing System integration and special-condition simulation R&D and Manufacturing Excellence Comprehensive and Integrated R&D Capabilities The R&D team is built on a robust, cross-functional framework encompassing structural engineering, electronic hardware, system architecture, software development, testing, and manufacturing processes. We maintain a full-spectrum development capability that spans from concept design to real-world validation. With in-house expertise in mechanical design, control unit development, computer-aided simulation, bench testing, and complete vehicle road testing, we are equipped to support rapid iteration and innovation across the entire product lifecycle. Hybrid and pure electric powertrains Transmission systems and controllers Electric motors and motor controllers Shift and clutch actuators Vehicle control units (VCUs) Quality Management & Full Lifecycle Traceability The factory strictly adheres to IATF 16949, ISO 14001, and other international standards, ensuring precise control over every production process and uncompromising quality in every product. The digital management system enables a full lifecycle traceability and control, ensuring that every component is trackable and accountable from production to delivery. In 2025, the e-axle for trucks production capacity is expected to exceed 10,000 units, further demonstrating our ability to scale with quality and consistency. Application Example This e-axle for trucks has been successfully deployed in 6×4 battery electric semi-trucks, which are now in mass production. Key vehicle specifications include: curb weight: 11 tons; gross vehicle weight:25 tons; maximum towing capacity: 37 tons; top speed: 89 km/h 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

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