Technologies

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

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

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

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

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

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

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

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