Technologies | Page 3 of 4 | Brogen EV Solution | Shanghai OE Industrial Co., Ltd.

Electric Power Steering for Light Trucks

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

R-EPS for Light Commercial Vehicles Rack-assist Electric Power steering (R-EPS) positions the motor directly on the steering rack, making it ideal for medium to large vehicles that require significant power assistance. Typically, a ball screw and belt mechanism is used to transit motor assistance to the rack. This electric power steering for light trucks is of the rack-assist type. The R-EPS, with its rack-mounted direct assist and minimal internal friction, offers an exceptional steering feel. It delivers high rigidity and outstanding dynamic performance, making it one of the most efficient steering systems available today. Model R008 Technical Parameters Applications RH / Light truck Rated Current 80A@DC12V, 60A@DC24V Operating Voltage DC12V / 24V Rack Stroke & Ratio ±80mm & 50.27mm/rev Maximum Pull-Push Force 16kN@12V; 18kN@24V Applicable Vehicle Specs Front axle load 3000 kg (reference) Sensor Type TAS Protection Level IP67 Features Compact design: optimized for space efficiency in vehicle layout. High rack force: the integration of belt and ball screw structures enables a rack force of up to 18 kN Proven reliability: utilizes a mature hardware and software platform, with established production processes, to ensure stability and reliability. Enhanced steering feel: provides a smooth and refined steering experience. Upgraded functionalities, including end-point control, return-to-center, and drift compensation, position this system at the forefront of steering technology. Superior NVH performance: incorporates advanced motor active noise reduction algorithms and production line calibration algorithms to deliver a quiet and serene vehicle environment. Frequently Asked Questions How’s your R&D strength? We have 52 R&D team members for the EPS systems, with a core specialist who has designed and developed steering and suspension systems for world-class vehicle manufacturers such as Toyota, Mitsubishi, Lexus, Honda, etc. What’s your typical annual production volume for EPS systems? Our annual manufacturing capacity for EPS is about 1,100,000 sets. Do you offer custom EPS solutions in addition to standard products? Sure, as we have a professional R&D team, we provide OEM / ODM service and can customize a system for your project. Do you have other EPS products for cars, or trucks? Yes, you can visit here to learn more about our electric power steering systems: https://brogenevsolution.com/electric-power-steering-solutions/ What are the steps of working with you? You may fill in the form below to get in touch with us first. Remember to describe your project info and product requirements as detailed as possible. Then we will arrange an expert to get back to you shortly and provide a customized solution for you. If necessary, our engineering team will discuss with your engineering team to check if our system can work well on your platform and if we need further modification, etc. Then we will provide the quotation to you. 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

160 kW / 360 kW Electric Axle for Trucks

Leave a Comment / Heavy Transport, Technologies / July 15, 2024

160 kW / 360 kW High-Voltage Electric Axle for Trucks System Introduction This electric axle for trucks boasts a rated power of 160 kW and a peak power of 360 kW. Utilizing a distributed drive system, it integrates two PMSM electric motors within the e-axle. The advanced gear-shifting control strategy ensures uninterrupted power delivery during gear changes, enhancing driving safety. Additionally, in the event of a single motor failure, the remaining motor continues to provide power, offering an extra layer of safety redundancy to the eAxle system. Benefits of Our Electric Axle for Trucks – Safe Core Strategy Controlled by the distributed drive electronic differential system; equipped with EASR, IESS safety configurations. Benefits Reduce the vehicle energy consumption, and increase vehicle safety and stability in harsh environments; the electronic differential lock can effectively get out of trouble on the road. Lower Gravity Center The gravity center of the battery system is lowered by 1620 mm. Benefits Provide ample space for the bottom placement of the battery and increase the stability of the whole vehicle. Dual Motor Design Integrating the dual motor structure and advanced gear-shifting control strategy to ensure uninterrupted power delivery during gear changes. Beneifts It’s safer and more comfortable to drive the vehicle. Benefits of Our Electric Axle for Trucks – Economical 0 % The transmission system features a simple structure with a concise transmission chain, enhancing overall system efficiency by up to 4% 0 % Enhanced Energy Regeneration by 100%: The gear’s forward and reverse torques are balanced, significantly improving energy regeneration efficiency and extending the driving range. Benefits of Our Electric Axle for Trucks – Powerful & Lightweight 0 N.m The maximum output torque for a single axle can reach 51480 N.m. The maximum motor generation torque can also reach 51480 N.m, reducing brake heat fade on long downhill stretches and eliminating the need for additional water cooling for the brakes. 0 kg The single e-axle weight is about 920 kg. For 4×2 tractor-trailers, the distributed drive system reduces weight by 462 kg compared to direct drive systems and by 300 kg compared to central drive electric axle systems, increasing payload capacity. Product Parameters Motor type: PMSM Motor power (rated/peak): 2×80 kW / 2×180 kW Motor speed (max.): 9500 rpm Motor torque (rated/peak): 2×260 N.m / 2×520 N.m Rated voltage: 540 VDC IP rating: IP68 E-axle weight: 950 kg Rated axle load: 13000 kg Wheel speed (max.): 620 rpm Gear ratio: 49.4/15.3 Rim size: 22.5 inch Tire size: 12R22.5 Brake: Air disc brake Contact Us Get in touch with us by sending us an email, using the Whatsapp number below, or filling in the form below. We usually reply within 2 business days. Whatsapp: +8619352173376 Email: contact@brogenevsolution.com ContactFill in the form and we will get in touch with you within 2 business days.Please enable JavaScript in your browser to complete this form.Please enable JavaScript in your browser to complete this form. Name * FirstLast Work Email *Company Name *Your EV Project Type *– Please select –BusLight-duty truckHeavy-duty truckConstruction machineryVesselOthers (please write it in the note)Your Interested Solutions *– Please select –MotorBatteryChassise-AxleAuxiliary inverterOBC / DCDC / PDUAir compressorEPS / EHPSBTMSOthers (please write it in the note)Do you have other contact info? (Whatsapp, Wechat, Skype, etc.)Please introduce your EV project and your request here. * Checkbox * I consent to receive updates on products and events from Brogen, and give consent based on Brogen’s Privacy Policy. Submit

Public Transportation, Technologies

Electric Power Steering (EPS) for Hybrid & Full Electric Buses

Leave a Comment / Public Transportation, Technologies / July 12, 2024

Electric Power Steering System (EPS) for Bus Our rack-assist type electric power steering system (R-EPS) for large commercial vehicles like buses is designed with integration, lightweight construction, and energy efficiency in mind, making installation much more efficient. It’s about 15 kg lighter and more compact than traditional EHPS systems. Plus, it only activates during steering, saving 4 kWh of energy per day. Over five years, this adds up to about $3000 in savings on electricity and battery costs. Whatsapp: +8619352173376 Email: contact@brogenevsolution.com Download Brochure Get Custom Quote Working Principle of the EPS for Bus After the motor outputs torque, it is reduced and amplified through the worm gear system. The worm gear drives the ball screw, which moves the piston rod in a linear motion. The piston rod, connected to the outer tie rod via a ball joint, pushes or pulls the steering arm, turning the wheels. Unlike traditional hydraulic power steering systems, this EPS for hybrid or battery electric buses provides a smoother ride. This innovative system controls the operation and torque output of the electric power steering motor according to the driving speed of the vehicle and the steering torque and steering angle of the driver’s steering wheel after processing and calculation by the steering electronic control unit (ECU). It’s a device that optimizes the effect of power steering. Our EPS for Bus VS EHPS for Bus Item Our EPS for Bus EHPS for Bus Layout & Installation Easy to install with high assembly capacity. Requires additional installation space; hydraulic system installation is complex and labor-intensive. Parts Management & Cost Fewer parts, only EPS and ECU. More components, including electro-hydraulic pumps, hydraulic lines, and assist oil; higher procurement, maintenance, and quality costs. Size & Weight Lightweight, approximately 15 kg lighter than EHPS; compact and space-efficient. The hydraulic steering system housing is made of cast iron, resulting in greater weight and environmental pollution during production, particularly in surface coating. Efficiency >83% Approximately 55% Steering Feel Responsive and precise Rigidity Direct push-pull type with high rigidity. Energy Consumption Only operates during steering; saves about 4 kWh per day, leading to savings of about $3000 in electricity and battery costs over 5 years. Operates continuously after vehicle startup; energy consumption is 2-5 times higher than EPS. Pollution, Recycling, Maintenance Maintenance-free, no oil leakage, no environmental pollutions. Hydraulic oil usage and disposal increase environmental burden; regular oil changes required. ADAS & Autonomous Driving Support Lack of control precision may lead to difficulties in autonomous systems. Features of Our Electric Power Steering System (EPS) for Bus Easy installation: adapts to existing layouts for a smooth transition. Simplified design: fewer parts for efficient assembly. Precise handling: delivers sharp steering and exceptional maneuverability. Quiet operation: engineered for low friction and minimal noise. Compact & integrated: boasts a compact design for seamless integration. Advanced sensors: utilizes non-contact sensors for accurate angle measurement. Safety features: equipped with overheating and under-voltage protection. Reliable performance: maintains some steering assistance even under certain failure modes. Future-proof design: IP67-rated and adapts to the needs of advanced driver assistance systems (ADAS) and autonomous driving, particularly for large steering-by-wire chassis. Technical Parameters Type: Rack-assist type Power supply current: 50 A Operating voltage: DC 24 V Rack stroke & ratio: 274 mm & 50.4 mm/rev Maximum pull-push force: 18 kN – 20 kN Applicable vehicle information: Front axle load 4500 kg (reference) How We Work Requirement Analysis After signing the NDA, the client provides the maximum axle load for the steering axle, as well as the 3D models and drawings for the steering axle, suspension, part of the chassis, and wheels if necessary. Steering Torque Calculation and Motion Verification Based on the data provided by the client, we calculate and verify the relevant parameters for the steering system. Client Confirmation The client confirms the mechanical structure and the integration with the complete vehicle assembly. Electrical and Bus Protocol Integration We provide the electrical parameters and bus protocol; the client confirms if any modifications are needed. Signing the Technical Agreement Both parties sign the technical agreement, and we provide the final quotation. 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 municipal vehicle water truck with our electric truck axle

Heavy Transport, Specialty Equipment, Technologies

18-ton Battery Electric Water Truck With Our Electric Truck Axle

Leave a Comment / Heavy Transport, Specialty Equipment, Technologies / July 3, 2024

Introduction This case highlights our collaboration with an EV manufacturer to deliver a highly efficient, 100% electric water truck. Specializing in municipal and specialty vehicles, the EV manufacturer serves an environmental resources company as their end customer. This innovative vehicle incorporates our advanced electric truck axle technology. Application of Our Electric Truck Axle Our electric truck axle utilizes the latest e-axle technology, featuring a distributed approach that offers numerous benefits including low noise, extended cruising range, intelligent control, energy efficiency, and high performance. For instance, the 18-ton water truck in this project is equipped with a 231 kWh EV battery system. Thanks to the energy-saving and efficiency-boosting design, it achieves a cruising range comparable to a similar vehicle with a 280 kWh battery system. This allows up to 8 hours of operation on a single charge, significantly reducing costs for fleet operators. More features about this water truck: Versatility and Safety of Our Electric Truck Axle Our electric drive axle is also suitable for heavy-duty trucks, tractors, and trailers. The distributed approach enhances safety redundancy, ensuring that even if one motor fails, the other can continue to operate normally. Advanced software technology further ensures vehicles’ safety and reliability. Learn more about our innovative e-axle solutions here. Benefits of Upfit Electrification We also provide electric motors for the upfit of specialty and hybrid vehicles, such as street sweepers, water trucks, and concrete mixers, etc. Upfit electrification separates the power source for retrofitting from the vehicle’s drive systems. This enables specialty vehicles like hybrid concrete mixers to shut off their engines during loading and unloading while maintaining retrofit operations. Drivers can also benefit from air conditioning in hot weather. For fleet operators, this significantly reduces annual fuel costs. Learn more about our electric motor solutions here. EV Battery Systems At Brogen, we offer standard LFP EV battery packs for electric trucks, as well as fast-charging LMO battery packs for PHEVs, FCEVs, HEVs used in applications such as mining trucks, dump trucks, forklifts, and AGVs. Learn more about our EV battery systems here. Contact Us for Comprehensive Electrification Solutions We offer a wide range of customizable electrification solutions for EV manufacturers. Our product lineup includes electric motors, electric axles, EV batteries, on-board chargers, and more. If you are seeking an EV solution for your project, please contact us by filling out the form below or by emailing us at contact@brogenevsolution.com. We typically respond within two business days.

electric recirculating ball steering system

Industry Insight, Technologies

Electric Power Recirculating Ball Steering (eRCB) for Commercial Vehicles

Leave a Comment / Industry Insight, Technologies / July 1, 2024

Electric Power Recirculating Ball Steering (eRCB) for Commercial Vehicles As the commercial vehicle industry trends towards electrification, intelligent systems, and connectivity, the power steering systems in commercial vehicles are also moving towards electrification. The evolution of commercial vehicle steering technology has progressed through several stages: from mechanical steering, to hydraulic steering, to electro-hydraulic steering, and now to fully electric steering, such as the electric power recirculating ball steering. Our eRCB installed on hybrid electric trucks What is the Electric Power Recirculating Ball Steering (eRCB) System? Unlike traditional mechanical recirculating ball steering systems, the electric power recirculating ball (eRCB) steering system integrates an electric motor and a reduction mechanism at the input end of the mechanical recirculating ball steering gear. This system uses steering signals, vehicle speed signals, and active control commands to control the motor, generating steering torque. This allows for different levels of power assistance and enables active steering functions. How Does the Electric Power Recirculating Ball Steering Work? When the steering wheel is turned, a torque sensor sends a torque signal to the controller. This signal is generated by a torsion bar inside the steering shaft, where the ends of the bar twist relative to each other under external force, reflecting the angle of twist to the torque sensor. The steering torque is directly proportional to the torsion bar’s twist angle. A vehicle speed sensor sends a speed signal (a square wave signal) to the controller. The controller then processes the torque signal and the speed signal from the dashboard and uses a pre-set force model to control the DC motor. By adjusting the current to the motor, the output torque changes, which is amplified by the reduction mechanism to directly assist the steering gear. What Are the Advantages of Electric Power Recirculating Ball Steering Systems? Compared to traditional hydraulic power steering, electric power recirculating ball steering offers the following advantages: 1. Reduced Procurement Costs Traditional hydraulic power steering systems for electric vehicles require an additional electric motor and controller, as there’s no engine-driven hydraulic pump. This setup can cost significantly more than electric steering. 2. Fewer Components and Lighter Weight Hydraulic steering for electric vehicles requires extra components like hoses, reservoirs, pumps, motors, and controllers. In contrast, electric power steering is an integrated system that saves time and effort during assembly. It’s approximately 50% lighter than hydraulic steering, making it easier to install and maintain, while also enhancing vehicle layout and safety. 3. Extended Driving Range by 25% Hydraulic steering systems need a motor with at least 2 kW power that runs continuously. In contrast, electric steering only requires a 12V (or 24V) power source, with a bus only needing around a 400W motor. The system only consumes power when steering, leading to minimal energy loss. Tests show that this can extend the driving range by over 25%. 4. Improved Steering Ease and Stability The eRCB system adjusts the steering assistance based on vehicle speed—light and easy steering at low speeds and stable, secure handling at high speeds, improving vehicle stability and control. 5. No Hydraulic Fluid, No Leaks Since the eRCB system doesn’t use hydraulic fluid, it eliminates the risk of leaks and reduces environmental pollution. 6. High Reliability and Maintenance-Free The eRCB system is highly reliable, maintenance-free, and performs well even in low temperatures. 7. Broad Applicability The eRCB system is versatile, suitable for fuel-powered vehicles, and hybrid vehicles, and is the ideal choice for pure electric vehicles. Brogen’s eRCB Solutions System Functions Speed-sensitive power assistance Active return Dampling compensation function Friction compensation function Rack end protection function Inertia compensation function Temperature management Motor thermal protection System Advantages Provides eRCB products supporting L2 autonomous driving Configurable interfaces, compatible with various TAS sensor types Supports CAN/CANFD interface Supports Cybersecutiry hardware encryption Supports OTA upgrades Download Brochure Contact Us Get in touch with us by sending us an email, using the Whatsapp number below, or filling in the form below. We usually reply within 2 business days. Email: contact@brogenevsolution.com Respond within 1 business day Whatsapp: +8619352173376 Business hours: 9 am to 6 pm, GMT+8, Mon. to Fri. LinkedIn channel Follow us for regular updates > YouTube channel Ev systems introduction & industry insights > ContactFill in the form and we will get in touch with you within 2 business days.Please enable JavaScript in your browser to complete this form.Please enable JavaScript in your browser to complete this form. Name * FirstLast Work Email *Company Name *Your Project Type *– Please select –Car, SUV, MPVBus, coach, trainLCV (pickup truck, light-duty truck, etc.)HCV (heavy-duty truck, tractor, trailer, concrete mixer, etc.)Construction machinery (excavator, forklift, crane, bulldozer, loader, etc.)Vessel, boat, ship, yacht, etc.Others (please write it in the note)Your Interested Solutions *– Please select –Motore-AxleBatteryChassisAuxiliary inverterOBC / DCDC / PDUAir brake compressorEPS / EHPS / SbW / eRCBBTMSOthers (please write it in the note)Do you have other contact info? (Whatsapp, Wechat, Skype, etc.)Please introduce your project and your request here. * Checkbox * I consent to receive updates on products and events from Brogen, and give consent based on Brogen’s Privacy Policy. Submit

Light Commercial Vehicles, Technologies

30kW / 60kW Electric Motor for Light Commercial Vehicles

Leave a Comment / Light Commercial Vehicles, Technologies / June 11, 2024

30kW / 60kW Electric Motor for Light Commercial Vehicles This 30kW / 60kW electric motor is designed for light commercial vehicles, such as battery-electric light vans, light trucks, pickup trucks, and minibusses. Featuring a PMSM motor with high energy efficiency, it has been deployed in over 10,000 electric vehicles globally and is currently in mass production. Maximum Power 60 kW Rated Power 30 kW Maximum Torque 223 N.m Rated Torque 90 N.m Maximum Speed 9000 rpm Rated Speed 3183 rpm Maximum Phase Current 260 Arms Rated Phase Current 120 Arms Cooling Method Liquid Cooling Benefits of Our 30kW / 60kW Electric Motor for EV LCVs This system is designed to address customer requirements and is tailored for the microvan and micro truck market. It boasts exceptional safety, a compact and lightweight design, high power density, superior efficiency, and outstanding reliability, making it an ideal solution for modern vehicle applications in this segment. Built-in ASR (Anti-Slip Regulation) Improves overall vehicle safty by preventing wheel slippage. Compact and Lightweight Controller Design 5 L, 5 kg, power density 21.5 kW/L High EMC Design Meets Class 4 standards for electromagnetic compatibility. High System Efficiency Achieves up to 95% peak efficiency. Comprehensive Safety Strategies Includes active vibration suppression, hill start assist, slope operation, and regenerative coasting. ASR Function Overview Developed in-house, the ASR module eliminates the need for additional hardware or sensors. By leveraging precise road surface recognition and wheel slip rate calculations, the system optimizes motor and motor controller performance based on finely tuned calibrations. This enhances both the safety and drivability of vehicles, particularly during straight-line driving or cornering under slippery conditions. Efficiency Map Motor Power Map Motor Efficiency Map Simulation Conditions: Battery Voltage DC628V, Peak Current 285Arms, Magnet Temperature 130°C Output Power at Different Torque-Speed Operating Conditions External Characteristics Under Different Voltage Platforms and Different Operating Modes Peak external characteristics at rated operating voltage in electric mode Peak external characteristics at rated operating voltage in regenerative mode Peak external characteristics at minimum operating voltage in electric mode Peak external characteristics at minimum operating voltage in regenerative mode Peak external characteristics at maximum operating voltage in electric mode Peak external characteristics at maximum operating voltage in regenerative mode Gallery 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

blade battery for battery electric truck

Heavy Transport, Industry Insight, Light Commercial Vehicles, Technologies

How Blade Battery Packs Benefit the Electric Truck?

Leave a Comment / Heavy Transport, Industry Insight, Light Commercial Vehicles, Technologies / May 20, 2024

Electric Trucks Equipped With Blade Batteries: Higher Energy, Lower Consumption The latest all-electric truck from BYD features blade battery packs. Introduced by BYD four years ago, these LFP blade battery packs eliminate the module design, reducing many structural components. The close connection between the upper and lower casings and the battery cells significantly increases volumetric energy density, reaching levels comparable to high-energy-density ternary lithium batteries. This battery electric vehicle model boasts a battery capacity of 94.3 kWh, providing a pure electric range of over 275 kilometers, surpassing the typical 100~200 kilometer range of industry-standard electric light trucks. In addition to the impressive energy density, blade battery technology offers higher thermal stability, lower thermal runaway temperature, smaller thermal runaway reactions, and a reduced likelihood of thermal runaway compared to ternary lithium and standard LFP batteries. This makes the light-duty truck, which operates over longer distances annually, safer. The blade battery’s exceptional thermal management extends battery life, improves charging and discharging efficiency, and shortens charging time. This all-electric truck can achieve over 100 kilometers of range with just half an hour of charging, further enhancing operational efficiency. Electric Truck Chassis Optimization: Better Layout, Higher Load Capacity Unlike traditional electric light trucks that position the standard battery boxes on the sides of the chassis or hang them in the middle, this electric truck’s blade battery is semi-embedded within the chassis frame. This structure integrates the battery into the chassis, making it part of the vehicle’s framework, providing both an energy source and structural rigidity. This design completely revolutionizes traditional electric light truck chassis layouts. Additionally, the semi-embedded design increases the chassis’ ground clearance, improving overall vehicle possibility. The flat-laying design of the chassis battery allows the truck to use a direct-drive system with an integrated electric drive axle. This system features a flat-wire motor and reducer within a shared casing, improving slot fill rate and efficiency. The lightweight aluminum alloy casing enhances transmission efficiency and reduces energy loss compared to traditional direct-drive systems. In terms of the suspension design, the vehicle uses a 3/5+6 leaf spring, with significantly more leaves in the rear axle springs, directly boosting the vehicle’s load capacity. Cabin Design: More Space, Lower Wind Resistance Building on the previous generation electric light truck, which positioned the integrated controller and battery systems on the sides of the chassis under the body, this EV truck continues this design, thanks to the more compact blade battery pack. This allows for a more spacious cabin layout. The cabin details have been optimized, upgrading the traditional mechanical handbrake to an electronic handbrake for increased comfort during driver rest periods while charging. Additionally, the vehicle’s battery system is split into two sets: one located on the side of the chassis under the body, and the other under the tilting cab, powering the low-voltage system of the cabin. This separated design enhances the stability and safety of the cabin’s power supply system. Summary In summary, the new electric light-duty truck, equipped with a 94.3 kWh blade battery, not only significantly improves vehicle range but also addresses user-identified issues through comprehensive upgrades to the chassis structure and cabin design. By leveraging blade battery technology, the vehicle reduces costs and increases efficiency for users. With competitive blade battery prices and enhanced electric truck battery capacity, BYD’s approach to batteries for electric vehicles sets a new standard in the industry. Looking for an EV Battery System for Your Project? Here at Brogen, we provide customized EV battery solutions, including standard LFP battery packs and advanced LFP blade battery systems for trucks, buses, vans, and other construction equipment or specialty vehicles. Contact us through the form below and we’ll get back to you shortly to discuss how we can empower your EV project!

E-axles that integrates motors, MCU , transmission system electric drive axle

Heavy Transport, Technologies

Introduction of the Electric Drive Axle for Heavy Duty Trucks

Leave a Comment / Heavy Transport, Technologies / April 12, 2024

Introduction of the Electric Drive Axle for Heavy Duty Trucks Sales of electric trucks have continued to rise in 2023 compared to 2022, driven by strong and ambitious government policies. For heavy-duty vehicle manufacturers, adopting a reliable and powerful electric powertrain system is crucial to staying competitive in this rapidly expanding market. As demand for sustainable transportation grows, integrating advanced electric systems will be key to their long-term success. The Evolution of the Electric Drive Axle for Heavy Duty Trucks The evolution of heavy-duty trucks has gone through three distinct phases, with a vision of the future of electric mobility shaping the landscape. First, traditional fuel-powered trucks dominated the roads, with cabs that were flat and high drag coefficient. These trucks relied on engine-based power systems located at the bottom of the cab. The next phase saw the emergence of gas-electric heavy-duty trucks, which retained the central drive model but swapped the engine for electric motors. However, these vehicles retained conventional propulsion systems that were bulky, inefficient, and compromised cargo space due to rear-mounted battery boxes. Today, all-electric heavy-duty trucks typically use the electric axle as the e-powertrain system. EV solutions with electric drive axles provide increased transmission efficiency and space flexibility. At the same time, cabin structures are redesigned to lower the center of gravity and improve aerodynamics. Why The Electric Drive Axle is a Better Choice for Battery-Electric Trucks Building on the advanced design of the electric axle drive system, the structural design of the chassis for pure electric heavy-duty trucks can be further optimized, resulting in more efficient use of space. For example, all-electric heavy-duty trucks using our e-axle solution can eliminate traditional driveshafts, allowing the chassis structure to be redesigned to accommodate the battery spread flat across the chassis. This layout has many advantages: Placing the battery flat at the bottom allows for a larger battery capacity, extending the range while minimizing intrusion into the cargo area. By using a box-shaped beam frame structure, the battery pack is placed within the box frame structure, ensuring both battery safety and full utilization of the chassis load capacity. Lowering the vehicle’s overall center of gravity reduces the risk of rollover during cornering and improves driving stability and maneuverability. The overall appearance of the vehicle is improved. Analysis of Different Electric Powertrain Systems for Heavy Trucks At present, the primary e-powertrain configurations for electric heavy trucks encompass several distinct forms: Different configurations of electric powertrains for heavy-duty trucks Analysis of configuration characteristics of different electric drive axles Comparison of dual-motor central drive and dual-motor distribute drive systems An Example of Our Electric Drive Axle for Heavy Duty Trucks Let’s take our 360 kW eAxle as an example, which is suitable for 6×4 and 4×2 tractors and heavy-duty trucks. Compared to similar eAxle products on the market, our eAxle integrates two motors, providing higher system power and torque with a smaller footprint, and has 100% regenerative braking capability, eliminating mechanical differentials. This results in lower space requirements, weight, and cost. Our electric drive axle installed on the heavy-duty truck Additional Safety Redundancy In addition, our distributed drive system minimizes layout losses, reduces weight, and incorporates fault and safety strategies. The two drive systems are completely independent, consisting of a motor + 2-speed AMT and wheel-side reducer, using electronic differential technology and independently controlling the left and right drive systems. In the event of a single motor failure, the other motor can continue to operate normally, ensuring system safety. 23% System Weight Reduction Weight of different electric powertrain solutions for heavy trucks In contrast to the central drive system, our distributed drive system has achieved a weight reduction of 23.6%. Similarly, compared to the motor gearbox integration system, our distributed drive system has managed to reduce weight by 23.9%. Good Passability The distributed drive system boasts a 7.3% increase in ground clearance compared to the central drive system. Moreover, it achieves an even greater elevation of 11.7% when compared to the motor gearbox integration system. Higher Transmission Efficiency Compared to the central drive system, our distributed drive system demonstrates a 6% enhancement in overall transmission efficiency. High Security Currently, heavy-duty trucks are only equipped with ABS and lack ASR, ESC, and EDL. With our EV motor’s electronic differential system strategy control, heavy trucks can be equipped with ASR/ESC safety configurations, improving vehicle traction, stability, and safety. Technical Parameters for Brogen Electric Drive Axle for Heavy Duty Vehicles Our e-axle for heavy trucks showcased at Automechanika Shanghai 2023 Motor power (peak/rated): 2×180 kW / 2×80 kW Motor speed (max.): 9500 rpm Motor torque (peak/rated): 2×520 N.m / 2×260 N.m Maximum output torque: 50000 N.m Rated voltage: 540 VDC Axle weight: 950 kg Rated axle load: 13000 kg Wheel speed (max.): 620 rpm Gear ratio: 49.4/15.3 Solution Advantages The dual motor structure ensures uninterrupted power during gear shifts. Reduces vehicle weight by 300 kg, boosting loading capacity. A compact design saves chassis space and lowers the center of gravity for better stability. Maximum output torque of 50,000 N.m, ideal for 4×2 tractors. Passed 1 million load-bearing tests with 2.5 times load capacity, ensuring reliability. Equipped with ASR function for enhanced grip on slippery surfaces, ensuring safer driving. Relevant Solution All Posts EV Industry EV Products EV Projects Electric Axle for Heavy-duty Truck Read More Contact Us Get in touch with us by sending us an email, using the Whatsapp number below, or filling in the form below. We usually reply within 2 business days. 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,

Public Transportation, Technologies

R-EPS System for (Hybrid) Battery Electric Bus

Leave a Comment / Public Transportation, Technologies / April 7, 2024

R-EPS System for (Hybrid) Electric Buses Introduction In 2023, an OEM (automotive manufacturer) for buses enlisted our expertise for the electric power steering system implementation in their buses. We recommended our latest R-EPS solution, specifically engineered for large commercial vehicles like buses. Our R-EPS (Rack-assist Electric Power Steering) system operates as a pure electric power steering system, regulating the power steering motor’s operation and torque output. This control is facilitated through the processing and calculation of inputs from the vehicle’s driving speed, steering torque, and steering angle, managed by the steering electronic control unit (ECU). The system serves as a pivotal device, optimizing the power steering effect to ensure smooth and precise vehicle maneuverability. Technical Features of Our R-EPS System for Buses Here are the key features of our R-EPS system for buses: Streamlined modification process and excellent adaptability to the recirculating ball hydraulic steering system layout. Reduced component count ensures high assembly efficiency. Responsive steering and exceptional maneuverability. High-efficiency design with low friction and operating noise. High product integration and compact structure for space optimization. Utilizes non-contact sensor with angle signal for precision. Equipped with overheating and under-voltage protection for enhanced reliability. Maintains steering assistance even during normal failure modes. Features IP67 protection for robust performance in varied conditions. Tailored to meet the demands of ADAS and automatic driving, particularly for large steering-by-wire chassis applications. Installation of the R-EPS on the Battery Electric Bus We’ve successfully integrated our EPS into the 8.5-meter pure electric bus, which has a maximum front axle load capacity of 4500 kg. Our electric power steering system has replaced several electro-hydraulic steering components originally present in the bus. Real Vehicle Calibration and Testing Our EPS system has undergone real vehicle calibration, ensuring optimal performance and functionality. Power Supply: Aligning with the original low-voltage wiring harness of the vehicle chassis, the power line is routed to the 24V battery, which then supplies power to the EPS. CAN Communication Integration: Receives vehicle speed signals in accordance with the vehicle CAN communication protocol. Activation of EPS System: Initiate the vehicle by shifting to the START gear, thereby entering the ready mode. Steering Function Implementation: Experience enhanced maneuverability with our EPS system’s responsive steering capabilities. From spot steering to normal road driving, our EPS provides noticeable power assistance, resulting in lighter steering torque and precise steering response. Active Return to Center Functionality: While navigating urban roads, our system ensures a smooth and seamless return to the center position when the steering wheel is released after turning to any angle, enhancing the overall driving experience and safety. Learn More About This R-EPS System All Posts EV Industry EV Products EV Projects Electric Power Steering for Hybrid & Full Electric Buses July 12, 2024/No Comments Electric Power Steering System for Bus Our rack-assist type electric power steering system (R-EPS) for large commercial vehicles like buses… Read More Contact Us Get in touch with us by sending us an email, using the Whatsapp number below, or filling in the form below. We usually reply within 2 business days. Email: contact@brogenevsolution.com Respond within 1 business day Whatsapp: +8619352173376 Business hours: 9 am to 6 pm, GMT+8, Mon. to Fri. LinkedIn channel Follow us for regular updates > YouTube channel Ev systems introduction & industry insights > ContactFill in the form and we will get in touch with you within 2 business days.Please enable JavaScript in your browser to complete this form.Please enable JavaScript in your browser to complete this form. Name * FirstLast Work Email *Company Name *Your Project Type *– Please select –Car, SUV, MPVBus, coach, trainLCV (pickup truck, light-duty truck, etc.)HCV (heavy-duty truck, tractor, trailer, concrete mixer, etc.)Construction machinery (excavator, forklift, crane, bulldozer, loader, etc.)Vessel, boat, ship, yacht, etc.Others (please write it in the note)Your Interested Solutions *– Please select –Motore-AxleBatteryChassisAuxiliary inverterOBC / DCDC / PDUAir brake compressorEPS / EHPS / SbW / eRCBBTMSOthers (please write it in the note)Do you have other contact info? (Whatsapp, Wechat, Skype, etc.)Please introduce your project and your request here. * Checkbox * I consent to receive updates on products and events from Brogen, and give consent based on Brogen’s Privacy Policy. Submit

Light Commercial Vehicles, Technologies

Mini Truck Project Powered by Blade Battery Solution

Light Commercial Vehicles, Technologies / February 29, 2024

Discover our EV battery solution for urban delivery with innovative Blade battery technology. This all-electric light-duty truck, powered by the Blade battery pack, is ideal for urban delivery. With zero emissions and exceptional performance, it offers a sustainable solution for urban logistics. With a 45 kWh Blade battery pack, it achieves a range of 280 km, and even 260 km at half load, ensuring reliable and efficient transportation. Compared to traditional EV battery packs, our blade battery packs offer higher energy density by eliminating the battery module, which significantly increases volume utilization. In addition, they prioritize safety by passing the nail penetration test without flame or explosion, ensuring reliable quality and stability. In the urban delivery market, electric commercial vehicles offer unmatched advantages over conventional fuel trucks, with operating costs as low as $0.03 to $0.05 per kilometer. This new generation of electric trucks offers superior battery technology, capacity and range, as well as superior flexibility, chassis load capacity and driving comfort. More parameters about this electric truck: At Brogen, we offer comprehensive EV solutions for commercial vehicles, including motors, e-axles, batteries, chassis, and more, designed to electrify your fleet and reduce operating costs. Contact us at contact@brogenevsolution.com to discuss how we can empower your EV project. Click the button below to explore our blade battery solution.