Technologies

80kW / 160kW Electric Axle for Bus This 80kW / 160kW electric axle for bus integrates a high-speed electric motor, gearbox, and rear axle into a compact, lightweight system, optimizing both vehicle efficiency and chassis layout flexibility. Featuring a two-stage helical gear transmission, it achieves an impressive 70% energy recovery efficiency. By eliminating the driveshaft and spiral bevel gears, the system significantly reduces weight, further enhancing energy efficiency and overall vehicle performance. Whatsapp: +8619352173376 Email: contact@brogenevsolution.com Get Custom Quote Key Features of Brogen 160kW Electric Axle for Bus Compact Design The motor, gearbox, and axle utilize a highly integrated parallel-axis design, resulting in a lightweight system with high transmission efficiency. Improved NVH Performance The gearbox is engineered for all operating conditions, featuring in-house manufactured DIN 4-grade high-precision gears, ensuring low noise levels. Flexible Vehicle Layout By eliminating the driveshaft, the chassis provides additional space for battery placement, allowing for a more flexible vehicle layout. Technical Parameters The specific parameters vary depending on the configuration. For more details, please contact us: contact@brogenEVsolution.com Model OEEA85 Load 8500 kg Rim mounting distance 1838 mm (adjustable) Speed ratio 20.475 Maximum output torque 9214 N.m Type of hub bearing Maintenance-free Brake specification Pneumatic disc type 19.5″ Rated / Peak power 80 kW / 160 kW Rated / Peak torque 200 N.m / 450 N.m Rated / Maximum speed 3600 rpm / 12000 rpm Weight 525 kg More Power Options Model OEEA30 OEEA50 OEEA60 OEEA95 OEEA100 Load 3000 kg~ 3500 kg 4000 kg ~ 5500 kg 6000 kg 9500 kg 10000 kg Rim mounting distance 1605 mm (adjustable) 1760 mm (adjustable) 1515 mm (adjustable) 1916 mm (adjustable) 1832 mm (adjustable) Speed ratio 12.665 16.141 16.473 19.220 Gear 1: 55.2 Gear 2: 17.24 Maximum output torque 4433 N.m 5730 N.m 7412 N.m 14415 N.m 41400 N.m Type of hub bearing Maintenance-free Maintenance-free Maintenance-free Maintenance-free Maintenance-free Brake specification Hydraulic disc-type two-cylinder φ43 Pneumatic disc type 17.5″ Pneumatic disc type 17.5″ Pneumatic disc type 19.5″ Pneumatic disc type φ410 Rated / Peak power 65 kW / 120 kW 65 kW / 120 kW 80 kW / 160 kW 200 kW / 320 kW 200 kW / 320 kW Rated / Peak torque 160 N.m / 350 N.m 170 N.m / 355 N.m 235 N.m / 450 N.m 350 N.m / 750 N.m 350 N.m / 750 N.m Rated / Maximum speed 3580 rpm / 12000 rpm 3600 rpm / 12000 rpm 4100 rpm / 12000 rpm 4093 rpm / 12000 rpm 4093 rpm / 12000 rpm Weight 205 kg 255 kg 300 kg 583 kg 887 kg Brogen 160kW Electric Axle for Bus – Solution Advantages Central Direct Drive Powertrain for Bus Brogen Electric Drive Axle for Bus Higher Efficiency & Stronger Performance – A highly integrated two-stage helical gear transmission shortens the drivetrain, reduces axle load, and improves energy recovery efficiency by 10% compared to traditional central electric drive systems. Lightweight Design & Lower Energy Consumption – Removing the driveshaft and spiral bevel gears simplifies the system, significantly reducing weight and further enhancing energy efficiency. Improved NVH & Quieter Operation – Eliminating the driveshaft eliminates issues like shaft angles and dynamic balancing, reducing noise at the source for a smoother and quieter ride. Case Study – 8.5-meter City Bus As public transport operators face growing challenges and evolving industry demands, efficiency and service quality have become critical for sustainable operations. To meet these needs, a public transport company deployed the  8.5-meter battery electric city buses featuring our high-speed motor + high-speed gearbox + rear axle in an advanced 3-in-1 e-drive system.  Enhanced Safety & Reliability The axle head is welded using internationally advanced friction welding technology, ensuring superior strength and durability. The electric powertrain system has successfully passed a 1-million-kilometer durability test, guaranteeing long-term reliability for intensive daily operations. Optimized Space & Weight The integrated e-powertrain system reduces space usage by 25% and weight by 50% compared to conventional setups. The overall vehicle weight is reduced by 2,000 kg, cutting energy consumption by 10%, which extends driving range without increasing battery capacity. Improved Accessibility A single-step entry reduces passenger boarding and alighting time, improving operational efficiency. A fully flat floor design increases standing capacity, enhances layout flexibility, and eliminates interior steps, reducing step-related passenger injuries by 46%. 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

This 190 kW / 320 kW electric portal axle for bus is characterized by its highly compact design, incorporating dual motors.

Electric Bus Powertrain: Wheel-Side Drive Motor – Introduction and Analysis Electric buses have traditionally relied on centralized drive systems. Two main configurations have dominated the market: Direct-Drive Motor System In these systems, the electric motor directly replaces the internal combustion engine. This approach offers a simple and straightforward system architecture, with mature vehicle structural design technology that has made it the mainstream configuration for battery electric buses. Motor + Gearbox Systems This configuration, which combines an electric motor with an Automatic Manual Transmission (AMT) gearbox, delivers superior performance on steep slopes, meeting the demands of mountainous or scenic areas. Although it borrows extensively from conventional fuel vehicle technology and is relatively mature, including an automatic shifting mechanism can compromise reliability, leading to practical challenges in real-world operations. As electric bus powertrain systems evolve toward higher speeds, greater integration, and lightweight designs, distributed electric drive technology—exemplified by wheel-side drive motors—has begun to enter the practical stage. Compared with centralized drive systems, wheel-side drive configurations eliminate the need for transmission shafts, main reduction gears, and differentials. This results in a shorter power transmission chain, higher transmission efficiency, and a more compact structure.  In addition, precise control of wheel-side motor speed and torque enables integrated functions such as vehicle propulsion, braking, differential action, and energy recovery. Owing to its high degree of freedom and functional expandability, the wheel-side drive system has become a focal point in the research and development of pure electric bus powertrain systems. In addition, precise control of wheel-side motor speed and torque enables integrated functions such as vehicle propulsion, braking, differential action, and energy recovery. Owing to its high degree of freedom and functional expandability, the wheel-side drive system has become a focal point in the research and development of pure electric bus powertrain systems. Electric Bus Powertrain: Wheel-Side Motor Drive Configurations Wheel-side motor solutions for battery electric buses bridge the gap between centralized and hub motor designs. They typically integrate a motor with a fixed-ratio reducer mounted on the chassis, directly driving the wheels via short axles. Two primary configurations exist: A. Fixed-Motor Configuration The fixed-motor configuration usually takes the form of an integrated wheel-side drive axle. In this design, the conventional axle housing and half-shafts are eliminated, and the drive motor is mounted adjacent to the wheel. Despite maintaining a rigid axle structure, this design can employ either steel leaf springs or a combination of air springs and coil-over shock absorbers.  Brogen wheel-side drive system with fixed motors Key advantages: Reduced Weight and Space: By removing the axle housing, casing, and half-shafts, the overall structure is significantly lighter and more compact. High-Speed Motor Integration: With the use of high-speed motors paired with high reduction ratios (often through a planetary gear structure), the design minimizes motor volume and weight while increasing power density. Robust Performance: Our integrated wheel-side drive axle, for example, features two high-speed motors mounted on either side of the axle. With a two-stage reduction system, it delivers enhanced torque and is capable of handling high axle loads—ideal for heavy-duty, low-floor city buses. B. Swing-Motor Configuration In the swing-motor configuration, the traditional rigid axle is abandoned in favor of an independent air suspension system. Here, both the drive motors and reducers are mounted directly on the suspension, and the reducer can be designed as either a two-stage or planetary gear system. Brogen wheel-side drive system with swing motor and independent suspension Key advantages: Lower Unsprung Mass: The elimination of the rigid axle structure reduces unsprung mass. A well-designed suspension can effectively transfer the motor’s mass to the vehicle body, improving ride comfort and handling. Enhanced Cabin Design: This configuration enables increased interior space, a wider aisle, and lower floor heights—critical factors in the design of modern low-floor city buses. Benefits of Wheel-Side Drive Motors in Electric Buses The adoption of a wheel-side drive motor for an electric bus powertrain – where flexible electrical connections replace some mechanical linkages – offers significant benefits in electric bus design and performance. Below are the primary advantages:  1. Increased Cabin Space and Lower Floor Height Low-floor city buses are a growing trend. In these designs, the area from the front passenger door to the last axle forms a continuous, step-free zone. Lowering the interior floor not only reduces the number and height of steps – making boarding and movement inside the bus easier, safer, and more accessible for all passengers – but also increases headroom in key areas. For instance, the structural dimensions of an integrated wheel-side drive axle can reduce floor installation height by approximately 70 mm, achieving a floor clearance as low as 290 mm. This enhanced design meets both interior space and passenger safety requirements. 2. Vehicle Lightweighting Reducing the overall vehicle weight directly contributes to lower energy consumption. Research indicates that a 10% reduction in vehicle weight can lead to a 6% – 8% reduction in energy consumption. The wheel-side drive motor configuration achieves significant weight savings through: High-speed motor design: Increased motor speeds allow for lower torque requirements, which in turn reduces cost and weight. System integration: Consolidating components (motor, reducer, controller) into an integrated design reduces the need for additional attachments and cabling, thereby lowering both the weight and cost of the powertrain. 3. Enhanced Vehicle Dynamics Mainstream single-motor direct-drive configurations often struggle with steep climbs and mid-to-high-speed acceleration, while dual-motor systems face challenges in weight and cost. Additionally, motor+AMT configurations can suffer from power interruptions during gear shifts. In contrast, the wheel-side motor configuration: Dual-Motor Advantage: By deploying two motors, the power demand on each unit is reduced while maintaining overall system performance. Elimination of the Main Reducer: Replacing the main reducer with a high-reduction ratio gear system (using helical gears) not only simplifies the transmission patch but also improves strength, reduces manufacturing complexity, and lowers costs. 4. Improved Transmission Efficiency Eliminating the traditional main reducer and differential from the electric bus powertrain means that power is transmitted through a shorter chain – enhancing efficiency. The use of helical gears in the

How an e-Axle with Independent Suspension is Shaping the Future of Electric Bus Design? As the world shifts toward sustainable transportation, the demand for energy-efficient, high-performance solutions in electric buses and other Zero Emission Buses (ZEBs) is steadily increasing. One of the key innovations at the forefront of this transformation is the wheel-side e-axle with independent suspension system for public transportation electrification. This solution is reshaping the way we think about electric bus powertrains, improving overall passenger experience, and enhancing operational efficiency. The Next Level of Efficiency: Wheel-Side Distributed Drive E-Axle With Independent Suspension The wheel-side distributed drive e-axle with independent suspension system is designed to offer a lighter, more efficient, and more compact solution for EV buses. This technology effectively reduces vehicle weight and energy consumption. The result? More spacious interior, greater energy savings, and increased passenger capacity flexibility. Our e-Axle with independent suspension showcased at Automechanika Shanghai 2024 What sets this system apart is its unique design: the left and right wheel-side motors replace the traditional differential and gearbox, applying torque directly to the wheels. This not only simplifies the drivetrain but also minimizes energy loss, making the electric bus more efficient. The integration of high-speed motors and reducers ensures that the system delivers large torque in a small form factor, enhancing the vehicle’s power output. The wheel-side drive e-axle and its controller operate based on the same principles as the motor and controller systems used in other pure electric or hybrid buses. However, the key challenge in wheel-side distributed drive control for buses lies in achieving the differential speed function between the drive e-axles. As a result, the control strategy and functionality of wheel-side drive e-axles differ from those in other battery electric or hybrid buses. 1.1 Three Configurations of the ePowertrain System for Electric Buses The distributed wheel-side e-Axle solution eliminates the need for a differential, half-shaft, and shortens the transmission chain. This results in higher transmission efficiency, a lighter vehicle, and reduced energy consumption. The compact motor size and wide central aisle make it suitable for low-floor layouts. Before in-hub motor technology become fully mature, wheel-side distributed drive e-axles remain the best matching solution for electric buses. 1.2 Basic Structure of the Wheel-Side Distributed Drive e-Axle with Independent Suspension Independent Suspension System: Featuring a four-airbag double wishbone design, this system offers reduced unsprung mass, resulting in a smoother ride with improved comfort and stability. Dual Wheel-Side Motors: With high torque and power density, the dual motors provide a strong and reliable output. Reducer: Reduces the motor output power to increase torque. Motor Controller: Controls the motor to operate at the desired speed, angle, direction, and response time. Electronic Components: Includes accelerator pedal sensors, brake pedal sensors, Hall-effect wheel speed sensors, Hall-effect steering angle sensors, roll angle sensors, yaw rate sensors, and controller hardware. 1.3 Working Principles of the Wheel-Side Distributed Drive e-Axle with Independent Suspension At the heart of the wheel-side distributed drive e-axle system is the Vehicle Control Unit (VCU), which calculates the total torque demand based on the driver’s acceleration or deceleration intent. The electronic differential system allocates the total torque between the left and right drive motors based on the steering angle. vehicle posture sensors, and road surface traction coefficients. The left and right motor controllers, upon receiving the instructions, convert the energy from the battery to the necessary power for the drive emotors, ensuring the vehicle’s stability and handling. 1.4 Operating Modes of the Wheel-Side Distributed Drive e-Axle with Independent Suspension Driving Mode: The battery supplies energy to the drive motor through the motor controller, which then directly drives the wheels. Regenerative Braking Mode: The rolling wheels drive the motor (regenerative generation) to charge the battery (energy recovery). Applications of the Distributed Drive e-Axle With Independent Suspension on Electric Buses The wheel-side e-axle with 4-airbag independent suspension system is not just about technological innovation; it’s about transforming the way we experience and operate electric buses in urban environments. The system offers several key advantages: Increased Safety: With a low-floor layout, passengers, including the elderly, children, and people with disabilities, can easily board and disembark. The design also reduces the risk of accidents caused by falls on traditional steps, offering a safer and more inclusive experience for all. Enhanced Comfort: The independent suspension system significantly improves ride quality, with reduced vibration and a smoother overall journey. Improved Operational Efficiency: For an 8.8-meter electric bus, the weight of the e-powertrain system can be reduced by more than 700 kg; for a 10-meter electric bus, the weight of the e-powertrain system can be reduced by more than 800 kg, offering significant energy savings, improved range, and lower maintenance costs. Real-World Impact: Proven Performance The independent suspension e-axle has already been deployed successfully on electric buses in several countries. Statistics show that after one year of use of a city’s 200 units of electric buses, the passenger injury accident rate has dropped by about 70%, largely due to the elimination of high-step entryways and the vehicle’s stable ride quality. These buses are proving to be a safer, more efficient, and comfortable choice for city transportation. Advantages of our Electric Bus Powertrain Solution The wheel-side distributed drive electric axle system is a leading-edge solution for electric buses, offering a future-proof EV technology that enables operators to meet sustainability goals while improving passenger experience and operational performance. As the global market for electric buses expands, this innovation is paving the way for more sustainable, energy-efficient public transit systems in cities across the globe.  Optimized Interior Space – Enables an 800 mm wide aisle and a fully flat low-floor design for enhanced accessibility and passenger comfort. Enhanced Maneuverability & Safety – Integrated steering function allows the rear wheels to track the front wheels, significantly reducing right-turn accidents caused by wheel differences. Proven Reliability – Features a mature and dependable electronic differential system, with tire replacement mileage exceeding 100,000 km. Technical Parameters Item Parameters Motor type PMSM Motor power 2×55 kW / 2×90 kW Maximum motor speed 9500 rpm Motor torque 2×140