Distributed Drive 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
- With high torque and power density, the two PMSM drive motors provide a strong and reliable output.Â
- 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
- The VCU calculates the total torque demand based on the driver’s acceleration or deceleration intent.Â
- 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.Â
- 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
| Model | OEEA5000N-1 | OEEA5000N-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 | |
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.
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 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
- 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 Approach?
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 |
- 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.
- 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 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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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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