Distributed Drive Electric Axle For Heavy-duty Truck

brogen electric axle for heavy duty truck

Electric drive axles represent the future of commercial vehicle electrification. Designed specifically for heavy-duty applications, our dual-motor distributed drive electric axle for heavy-duty truck delivers high power and torque output, making it ideal for heavy commercial vehicles, including trucks, semi-trucks, tractors, dump trucks, and electrified trailers.

Unlike traditional designs, this distributed drive solution eliminates the mechanical differential, resulting in a lighter, more compact system with lower oil churn losses and improved overall efficiency. It also enhances vehicle safety through electronic differential control and offers greater reliability with built-in redundancy.

Email: contact@brogenevsolution.com

Solution Details

Our electric axle for heavy-duty truck features a dual-motor distributed drive scheme. This setup ensures complete independence between the left and right power systems. Each power system comprises a PMSM motor, a 2-speed AMT, and a wheel-side reducer. With the adoption of electronic differential technology, the left and right drive systems are independently controlled, enhancing overall performance and maneuverability.

Basic Structure

distributed electric axle structure
  • With high torque and power density, the two PMSM drive motors provide a strong and reliable output. 
  • The wheel-side reducers on each side reduce the motor output speed while amplifying the torque delivered to the wheels.
  • The 2-in-1 motor controller controls the left and right motors to operate at the desired speed, angle, direction, and response time.
  • Integrated with advanced motor control and shifting logic, the 2-speed AMT improves hill-climbing ability, optimizes cruising efficiency, and reduces the need for oversized motors, while maintaining driving comfort and vehicle stability.

Working Principle

brogen electric axle
  • The VCU calculates the total torque demand based on the driver’s acceleration or deceleration intent. 
  • The electric drive control unit (DCU) 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 (or 2-in-1 integrated motor controller), upon receiving the instructions, convert the energy from the battery to the necessary power for the drive motors, ensuring the vehicle’s stability and handling.

Technical Specifications

ModelOEEA5000N-1OEEA5000N-2
Cooling methodLiquid-CooledOil-Cooled
Rated axle load capacity11500/13000/16000 kg
Maximum output torque2×27262 N.m2×22397~25740 N.m
Motor rated/peak power2×80/180 kW2×200/300 kW
Maximum wheel speed615 rpm
Brake typeAir disc/drum brakes
Gear ratio61.955/19.18
Weight856~950 kg (depending on the configuration)
Rated voltage600 VDC600/800 VDC
Suspension typeAir suspension / Leaf spring
PTOOptional integrated PTO

The parameters may vary depending on the configuration. For more parameter information, please contact us at contact@BrogenEVSolution.com

Leading the Way in Innovative Electric Powertrain Technology

1. Software Defines Hardware

Our distributed drive control algorithms have been continuously optimized over more than a decade across various vehicle types and operating conditions. Today, they are among the most advanced in the commercial vehicle sector. Our engineering team has in-depth expertise in key control strategies such as EDS, EASR, IRBS, and IESS.

electric truck without EASR
electric truck with EASR
electric truck without IESS
electric truck with IESS

2. Hardware-Driven Reliability

Our electric axle for heavy duty truck featrues a compact, fully integrated design with a symmetrical front-rear layout and a centralized center of gravity, contributing to improved reliability and ride stability. This symmetrical structure eliminates cantilevered loads, effectively preventing issues such as oil leakage at the mounting surface and bolt failures.

electric truck axle with single motor
brogen electric axle for heavy duty truck structure

With a short dimension in the X-axis and high-positioned wiring interfaces, the axle is especially well-suited for dump trucks and tipper applications, as it minimizes the risk of cargo falling during unloading and damaging the motor or high-voltage cables, thereby enhancing operational safety.

Three-Piece Axle Housing

  • In a three-piece axle housing, there are mechanical joints at key load-bearing sections, which can compromise structural reliability.
  • These joints increase the risk of oil leakage under heavy loads, and during maintenance, the entire axle must be disassembled to service the motor and drivetrain.

One-Piece Axle Housing

brogen distributed drive electric axle for heavy duty truck
  • Cast as a single unit, the one-piece axle housing structure provides continuous and uniform load distribution without any breaks in critical stress areas. This design ensures higher durability, especially under complex road conditions, and eliminates oil leakage risks, simplifying routine maintenance.

The one-piece axle housing offers superior reliability, with no joints at critical load-bearing sections, effectively reducing the risk of oil leakage. The motor and drivetrain can be installed or removed from the front or rear as a complete assembly, greatly enhancing maintenance convenience.

1. Strengthen Your Electric Truck Design

Currently, most electrified heavy-duty trucks follow a diesel-to-electric retrofit model, where the central drive system of traditional fuel trucks is retained, and only the engine is replaced with an electric motor. This approach continues to rely on conventional powertrain architecture, resulting in excessive weight, large volume, and lower overall efficiency.

In contrast, purpose-built electric heavy-duty trucks allow for a more comprehensive optimization of the entire electric drivetrain. Our electric axle solution for heavy-duty truck is a forward-designed e-drive system tailored for heavy vehicles. It enables further optimization of the chassis structure and significantly improves space utilization.

Diesel to electric heavy duty truck
gas to electric truck
Battery electric heavy duty truck
central direct drive motor vs electric truck axle

2. Why Distributed Drive Approach?

Traditional Electric Powertrain

traditional drive approach
  • Centralized Drive → Poor driving maneuverability
  • Centralized Brake → Long braking distance
  • Centralized Steering → Large turning radius
  • Long Mechanical Transmission Chain
  • Significant energy transmission losses;
  • Poor applicability across vehicle models;
  • Insufficient passenger space

Distributed Drive Electric Powertrain

distributed drive electric powertrain
  • Drive / Brake Decoupling
    • Distributed Drive → Enhanced control on complex surfaces
    • Distributed Brake → Reduced braking distance on complex surfaces
  • Distributed Steering
    • Four-wheel Independent Steering → Reduces turning radius; enables lateral movement and zero-radius turns; significantly enhances maneuverability
    • Eliminates Mechanical Transmission → Increases user space; reduces energy transmission losses

Dual-Motor Centralized Drive

Mechanical differential

Dual-Motor Distributed Drive

electronic differential system
Comparison
Dual-Motor Centralized Drive
Dual-Motor Distributed Drive
Efficiency Optimization Across Speed Ranges
Yes
Yes
Oil Churning Losses
Large
Small
Weight
Heavier (With Mechanical Differential)
Lighter
Fault Management Strategy
No
Yes (Limp Mode)
Safety Strategy
No
Yes (ASR, ESP)
Electronic Differential Lock
Yes
Yes
  • The dual-motor electric axle delivers higher power and torque, offering clear advantages for applications such as semi-trucks.
  • Among dual-motor configurations, the distributed drive system stands out due to the elimination of the mechanical differential. This results in reduced weight, a more compact design, lower oil churn losses, and enhanced safety performance.
  • In demanding applications where high torque and power are essential – such as semi-trucks or dump trucks – the distributed drive architecture offers significant advantages over centralized drive systems.

Rich Experience in E-Powertrain R&D

Our core founding team includes highly experienced vehicle design experts who have been engaged in the development of electric vehicles and e-powertrains since 2009. Over the years, they have built deep expertise in industry standards, specifications, FMEA methodologies, and practical engineering know-how.

The team also has strong simulation and analysis capabilities across all levels – from individual systems and subsystems to complete vehicles.

our stronng R&D capabilities
Brogen electric axle factory

Modern Production Facilities

We currently operate two dedicated production bases for distributed electric drive axles, with an annual production capacity of approximately 8,000 units. An additional headquarters and manufacturing facility is under construction and is expected to be operational by the end of this year, bringing the total projected annual capacity to 20,000 units.

Our intelligent manufacturing lines for distributed drive eAxles are among the most advanced in the industry, both in terms of process sophistication and quality control. Every product undergoes 100% full-function testing in a custom-built acoustic testing room, covering load performance, temperature rise, rotational speed, ABS, NVH, and safety compliance.

Applications

Our heavy-duty electric axle is designed for a wide range of applications, including 4×2 electric semi-trucks, 6×4 tractors, various heavy-duty trucks, electric trailers, mining trucks, and battery electric municipal vehicles such as electric street sweepers, water tankers, and garbage trucks.

The system has already been exported to countries including the UAE, Brazil, Canada, and more, where it has demonstrated stable and reliable performance in real-world operation, primarily in logistics, express delivery, and port terminal applications.

The system is now in mass production and ready for large-scale deployment.

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eAxle Delivery

eAxle Delivery

eAxle Delivery

eAxle Delivery

eAxle Delivery

eAxle Delivery

eAxle Delivery

eAxle Delivery

Frequently Asked Questions

Yes, our liquid-cooled electric axle is already in mass production and has been widely deployed in both domestic and international heavy-duty vehicles.

Our electric axles are suitable for 4×2 and 6×4 semi-trucks, electrified trailers, and highway coaches.

For bulk orders, we can replace components with the customer-specified brands upon request.

We follow a strict quality management system. However, for clients we haven’t yet partnered with, these documents are considered confidential and cannot be shared.

We provide standard or extended warranties depending on the product. For bulk orders, we prepare spare parts in advance to minimize downtime and ensure efficient handling of any warranty claims.

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.

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