Electric Axles for Trucks

Our electric axles for trucks integrate one or two PMSM motors, delivering powerful and efficient performance across various heavy commercial vehicles, including heavy-duty trucks, garbage trucks, and municipal vehicles. By consolidating previously separate components, our design simplifies assembly for OEMs, reducing system complexity and enhancing overall product quality. This integration also minimizes the need for multiple suppliers, lowering management costs and streamlining operations. With advanced engineering and control strategies, our electric axles ensure superior safety, reliability, and efficiency, making them a smart choice for modern electric truck platforms.

Email: contact@brogenevsolution.com

Why Choose Brogen

Strengthen Your Electric Truck Design With eAxle Solutions

The solution of electric axles for trucks significantly enhances the design of pure electric trucks. Through the compact integration, it boosts transmission efficiency and facilitates a more optimal vehicle layout.

Typical Gas-to-electric heavy duty truck

Pure electric heavy duty truck

The pure 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.

Building upon the positive design of the distributed electric drive system, further optimization of the structural design for pure electric truck chassis is achievable, enhancing space utilization rates. For instance, integrating our electric axle into the pure electric truck allows for the removal of the traditional drive shaft and enables the redesign of the frame structure to accommodate a flat arrangement of batteries within the chassis. This approach offers several benefits:

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.

Why Choose Brogen

Solution Features

Truck

E-Trailer

Tractor

Wide Applications

We offer a complete range of electric truck axles suitable for trucks from Class 1 to Class 8, and even trailers.

Scalable

Our modular e-axles support high voltage platforms and can be customized to meet specific requirements.

Reliable

We implement advanced monitoring and alerting strategies to esnure the safety and reliability of our electric drive axles.

Versatile

We provide electric axles with different approaches such as distributed drive, central drive, catering to diverse needs.

Our Offerings

Solutions of Electric Axles for Trucks

Centralized Electric Axles for Trucks

The centralized electric axles for trucks feature a high-speed motor, a high-ratio reducer, and an integrated axle in a compact 3-in-1 design, replacing traditional direct-drive systems (motor+driveshaft+axle). This integration improves transmission efficiency and optimizes chassis space, addressing key challenges in heavy truck design.

Parallel-Axis Electric Axles for Trucks - Solution Introduction

For the parallel-axis eAxle system, the electric drive motor and reducer are mounted on the drive axle, with the motor positioned parallel to the axle housing. Utilizing cylindrical gear transmission for a high gear ratio, the integrated design removes unnecessary transmission components, resulting in a more compact structure and increased transmission efficiency.

Advanced Technologies

Integrated One-Piece Formed Axle Housing (Expansion-Formed)
High load-bearing capacity, lightweight design, and reduced risk of oil leakage.
Optimized Housing Design
A single-piece housing minimizes oil leakage risks, while a smooth, curved inner cavity reduces oil churning losses.
High-Precision Two-Stage Helical Gear Transmission
Features dual-surface precision grinding for improved efficiency, lower noise, and extended lifespan.
Compact Motor and Axle Integration
Minimizes offset distance between the motor and axle housing, further reducing the risk of oil leakage at the reducer interface.

Value for Clients

Compact e-axle layout for better chassis integration
Lightweight design for improved efficiency
Precision-ground gears for low noise and comfort
High transmission efficiency, reducing energy consumption
100,000 km interval oil change, maintenance-free wheel ends
Real-time monitoring of key components for enhanced safety

Our Offerings

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

Model	OEEA60	OEEA85	OEEA95	OEEA100	OESTEA40000Z-1.5	OESTEA40000Z-1.6
Rated axle load capacity	6000 kg	8500 kg	9500 kg	10000 kg	13000 kg	13000 kg
Speed ratio	16.473	20.475	19.22	55.2/17.24	13.2/4.4	13.2/4.4
Motor rated/peak power	100/200 kW	80/160 kW	200/320 kW	200/320 kW	121/250 kW	135/290 kW
Motor rated/peak torque	220/426 N.m	200/450 N.m	350/750 N.m	350/750 N.m	320/850 N.m	326/860 N.m
Motor peak speed	12000 rpm	12000 rpm	12000 rpm	12000 rpm	10000 rpm	10000 rpm
Weight	382 kg	525 kg	710 kg	876 kg	1030 kg	1030 kg
Brake type	Pneumatic disc type	Pneumatic disc type	Pneumatic disc type	Pneumatic drum type	Drum brake	Drum brake

Controller for Electric Axles for Trucks

According to clients’ different requirements, we can provide standalone MCUs or high-voltage integrated controller systems, integrating MCU, PDU, DC-DC, and steering and braking DC/AC.

Note: Controllers are usually supplied as part of the electric powertrain system and are not sold separately.

Advanced Technologies

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

ISO 26262 Compliance
Functional safety requirements and software/hardware development meet ASIL C standards.
Dual-Integration Design
Combines functional and physical integration to significantly reduce size, weight, and manufacturing costs.
Dual-Inverter Control Technology
Minimizes losses and achieves a maximum efficiency of 98.5%.
Modular & Scalable Architecture
Designed for flexibility and easy expansion.
Digital Simulation & Optimization
Uses digital modeling for simulation analysis, enabling more efficient and cost-effective component selection.
Advanced EMC Design
Multi-stage filtering, optimized wiring layout, enhanced shielding, and structural improvements ensure Class 5 compliance under no-load conditions.

Distributed Drive Electric Axles for Trucks

For the distributed drive electric axle solutions, we have integrated two electric motors with the axle, significantly reducing system weight and enhancing vehicle power efficiency. The distributed drive approach allows for independent and precise control of each motor’s torque and speed. It also provides additional safety redundancy: in the event of a single motor failure, the remaining motor can compensate, ensuring continuous power delivery and improving overall vehicle safety.

Distributed Drive Electric Axles for Trucks - Solution Introduction

The distributed drive 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. We also provide the 2-in-1 integrated MCU and DCU (with TCU) for the whole e-powertrain system.

Solution Advantages

Minimizes space usage with a symmetrical layout and centralized center of gravity, enhancing reliability and ride comfort.
Integrated axle housing eliminates weak points, reducing the risk of oil leakage.
Motor and powertrain can be installed from either the front or rear of the axle housing for easier maintenance.
Advanced lubrication system and precision-engineered gears ensures excellent oil temperature control and NVH performance.
Distributed drive algorithm refined over 10 years of testing across various vehicle types and conditions, leading in HCV applications.
1250-hour transmission test with no abnormalities.
Withstands 1 million cycles of 2.5x load impact without failure.

Software-Driven Hardware

Electronic Differential System (EDS)
The advanced Electronic Differential System (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 energy consumption and extend driving range
Intelligent Electronic Stability System (IESS)
Adjust the torque of various components in real-time based on the vehicle status to ensure safety and stability under extreme conditions

Our Offerings

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

Model	OEEA5000N-1	OEEA5000N-2
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
PTO	Optional

Distributed Drive Electric Powertrain Controllers

For distributed drive electric axles for trucks, our solution includes the necessary controllers, such as the integrated motor control unit (MCU), and the distributed drive control unit (DCU), which also incorporates the transmission control unit (TCU).

Advanced Technologies

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 enhancing maneuverability
- Eliminates Mechanical Transmission → Increases user space; reduces energy transmission losses

Comprehensive Torque Control System
Ensures precise and efficient power distribution
Advanced Software Decoupling
Enhances system responsiveness and integration
Electronic Differential Module
Enables intelligent torque distribution between wheels
Electronic ASR (Anti-Slip Regulation)
Improves vehicel stability on low-traction surfaces, ensuring smooth starts and acceleration
Electronic ESP (Electronic Stability Program)
Enhances safety and maneuverability on icy or snowy roads by adjusting wheel torque and speed to optimize yaw control

How We Work

Navigating Our Process

Demand Analysis & Project Evaluation

Once we receive your inquiry, our experts will connect with you within two business days to understand your specific requirements for the EV solution and conduct an initial feasibility evaluation of your project.

Project & Technical Coordination

If the project is deemed feasible, our engineering team will collaborate closely with your team on both hardware and software aspects to develop a viable solution. We will also provide a detailed quotation based on the technical requirements.

Development, Manufacturing & Testing

For customized or modified systems, we proceed with product development, including hardware and software adaptations. Our EV systems undergo rigorous testing to ensure quality, reliability, and full functionality before deployment.

In-Time Global Shipping & Delivery

We have established strong partnerships with international shipping providers, ensuring safe and timely delivery of products to your specified location. This guarantees a smooth and efficient deployment of your EV project.

Full-Stage Remote/Onsite Technical Support

We provide technical support throughout the entire project lifecycle, including consultancy, hardware and software development, calibration, and both onsite and remote debugging, ensuring optimal performance and long-term success.