Distributed Dual-Motor Electric Axle For Heavy-duty Trucks
As heavy-duty commercial vehicles transition toward electrification, drivetrain architectures must evolve to meet significantly higher demands for power density, durability, and operational reliability. Our distributed dual-motor electric axle for heavy-duty trucks delivers high power and high torque output while addressing the limitations of conventional centralized drivetrains. It is well-suited for applications such as electric semi-trucks, tractors, dump trucks, tippers, and electrified trailers.
This architecture reduces system mass, shortens the power transmission path, lowers oil churn losses, and improves overall efficiency. Electronic differential system further enhances vehicle stability and safety, while the dual-motor layout provides inherent redundancy – an essential requirement for heavy-duty applications.
Email: contact@brogenevsolution.com
Distributed Dual-Motor Electric Axle Architecture Overview
Our electric axle for heavy-duty trucks adopts a distributed dual-motor drive architecture, in which the left and right wheels are driven by two independent power systems. This layout enables precise torque control, improved redundancy, and superior traction performance under high-load operating conditions.
System Composition
Each side power system includes:
- High-torque PMSM traction motor
- 2-speed AMT for wide efficiency coverage
- Wheel-side reducer
- Integrated motor control unit (2-in-1 optional)
Control & Working Principle
- The VCU calculates total torque demand based on driver inputs and vehicle state.
- The Electric Drive Control Unit (DCU) dynamically distributes torque between the left and right motors according to steering angle, vehicle dynamics, and road surface conditions. An electronic differential system ensures vehicle stability, traction, and handling across varying operating scenarios.
Technical Specifications
The parameters may vary depending on the configuration. For more parameter information, please contact us at contact@BrogenEVSolution.com
| Model | Truck eAxle-G-1 | Truck eAxle-G-2 |
| Cooling method | Liquid-Cooled | Oil-Cooled |
| Rated axle load capacity | 11500/13000/16000 kg | |
| Maximum output torque | 2×27262 N.m | 2×22397~25740 N.m |
| Motor rated/peak power | 2×80/180 kW | 2×200/300 kW |
| Maximum wheel speed | 615 rpm | |
| Brake type | Air disc/drum brakes | |
| Gear ratio | 61.955/19.18 | |
| Weight | 856~950 kg (depending on the configuration) | |
| Rated voltage | 600 VDC | 600/800 VDC |
| Suspension type | Air suspension / Leaf spring | |
| PTO | Optional integrated PTO | |
*This distributed dual-motor electric axle is part of our Electric Axles for Trucks solution portfolio. Click to learn more.
Leading the Way in Innovative Electric Powertrain Technology
1. Software Defines Hardware
Our distributed drive control algorithms have been refined over more than a decade across multiple vehicle platforms and operating conditions. Key strategies such EDS, EASR, IRBS, and IESS enable precise torque distribution, enhanced traction, and stable vehicle dynamics under heavy loads.
Electronic Differential System (EDS)
Regulates the speed or torque of the drive motors on each side during cornering, enabling precise differential steering for smoother and more controlled turns. Our EDS has been proven over millions of kilometers.
Electronic Acceleration Slip Regulation (EASR)
Leading torque control algorithm with millisecond response time enhances safety and reduces tire wear.
Intelligent Regenerative Braking System (IRBS)
Ensure braking performance while recovering energy in various driving conditions to reduce overall energy consumption and extend driving range.
Intelligent Electronic Stability System (IESS)
Adjust the torque of various components in real-time based on the overall vehicle status to ensure safety and stability of the vehicle under extreme conditions.
- Without EASR: Tire slippage and directional instability may occur on wet or slippery surfaces, leading to reduced control.
- With EASR: The vehicle maintains smooth and stable operation on slippery roads by actively regulating wheel slip.
- Without IESS: During high-speed cornering or sudden obstacle avoidance, insufficient or excessive steering may cause the vehicle to deviate from its intended path or even result in rollover.
- With IESS: In unstable driving conditions, the system enhances vehicle stability by intelligently adjusting the torque or braking force of individual drive wheels.
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.
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
- 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 Electric Truck Platform Design
Most electrified heavy-duty trucks today are still based on diesel-to-electric retrofit architectures, where the central driveline layout is retained, and only the engine is replaced by an electric motor. This approach results in excessive system weight, large packaging volume, and limited efficiency gains.
Our distributed electric axle is designed specifically for purpose-built electric heavy-duty platforms. By rethinking the drivetrain architecture from the ground up, it enables optimized chassis layout, improved weight distribution, and significantly better space utilization – laying a stronger foundation for next-generation electric truck design.
Diesel to electric heavy duty truck
- The tapered cabin structure of the diesel-to-electric heavy truck has higher aerodynamic drag.
- The rear-mounted battery box occupies cargo space, limiting both the available space and the vehicle's range.
- The chassis space utilization is suboptimal, leading to inefficiencies in transmission.
Battery electric heavy duty truck
- The battery electric trucks undergo a cabin redesign that lowers the center of gravity and minimizes aerodynamic drag.
- Our electric truck axle ensures high transmission efficiency and enables more flexible space utilization.
- The electric truck axle is seamlessly integrated into the chassis alongside the frame and battery pack, allowing for increased battery capacity and extendend range.
- Enhanced power and range: placing batteries flat at the bottom maximizes power output, extends vehicle cruising range, and minimizes cargo volume occupation.
- Improved stability: by adopting a box-shaped beam frame structure and housing the battery pack within it, the overall chassis structure becomes more stable, ensuring better vehicle stability and handling.
- Lower center of gravity: with the battery pack positioned lower, the vehicle's center of gravity decreases, reducing the risk of rollover during turns and further enhancing driving stability and maneuverability.
2. Why Distributed Drive Architecture?
Traditional Electric Powertrain
- 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
- 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
Dual-Motor Distributed Drive
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
|
For high-load and high-power applications such as semi-trucks and dump trucks, distributed drive offers clear advantages over centralized electric drivetrains. Engineering benefits include:
- Higher power and torque scalability through dual-motor architecture
- Elimination of mechanical differential, reducing weight and mechanical losses
- Improved efficiency under high load conditions
- Electronic differential control for enhanced vehicle stability and safety
- Built-in redundancy, improving reliability for mission-critical operations
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.
- 108 design specifications and technical guidelines
- 188 high-level in-house simulation and analysis standards
- 510 key design metrics and review checkpoints
- 600+ PCR library and FMEA cases
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 distributed drive electric axle is engineered for a broad range of heavy-duty electric vehicle applications, including 4×2 electric semi-trucks, 6×4 tractors, heavy-duty trucks, electrified trailers, mining vehicles, and battery electric municipal vehicles such as street sweepers, water tankers, and refuse trucks.
The system has been successfully deployed in real-world operations across multiple international markets, including the UAE, Brazil, and Canada, where it has demonstrated stable, reliable performance in demanding use cases such as logistics, express delivery, and port terminal operations.
Now in mass production, the system is validated and ready for large-scale commercial deployment.
Electric Semi-Truck
Electric Trailer
Electric Truck
Electric Trailer
Battery Electric Truck
18T Electric Municipal Vehicle
4x2 Electric Truck
4x2 Battery Swapping Truck
Finished E-Axles Mass Delivery
Finished E-Axles Mass Delivery
eAxle Delivery
eAxle Delivery
Frequently Asked Questions
This distributed electric axle is designed for high-load, high-power heavy-duty applications, including electric semi-trucks, 4×2 and 6×4 tractors, heavy-duty trucks, mining vehicles, electric trailers, and battery electric municipal vehicles. It is especially well-suited for platforms with demanding duty cycles and high torque requirements.
For heavy-duty trucks, distributed drive offers clear advantages in power scalability, efficiency, and reliability. By eliminating the mechanical differential and shortening the power transmission path, the system reduces mechanical losses, improves efficiency under high load, and provides built-in redundancy, making it more suitable for mission-critical heavy-duty applications.
The distributed electric axle supports high axle load ratings typically required by heavy-duty trucks with up to 16,000 kg, with scalable torque and power output enabled by the dual-motor architecture. Specific load ratings and torque levels can be configured based on vehicle class, duty cycle, and performance targets.
Vehicle stability is achieved through an electronic differential system, which dynamically distributes torque between the left and right drive motors based on steering input, vehicle state, and road conditions. This allows precise torque control while enhancing traction, handling, and safety.
The distributed architecture improves reliability through functional redundancy. Each side operates independently, allowing the vehicel to maintain limited drivability even in the event of a single motor or power electronics issue – an important advantage for heavy-duty and commercial operations.
Typical inputs include target axle load, vehicle mass, power and torque requirements, duty cycle, operating environment, and packaging constraints. Based on this informaiton, a system-level configuration and integration proposal can be developed.
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 >