Electrified Trailer Solution
System-Level Electrified Trailer Solution for EV Builders and Trailer Manufacturers
As global demand for low-carbon, environmentally friendly transportation grows, vehicle decarbonization is becoming a key driver for sustainability goals. Among these trends, electrified trailers are emerging as a practical solution, offering reduced emissions, improved power performance, and intelligent control.
Our electrified trailer solution is a system-level propulsion and energy solution designed for OEMs, EV builders, and integrators developing electrified or hybrid trailer platforms. The solution integrates with diesel, battery-electric, hydrogen fuel cell, and hybrid tractors.
An adaptive trailer control strategy ensures coordinated operation, energy optimization, and safe torque delivery under real-world duty cycles.
Email: contact@brogenevsolution.com
System-Level e-Trailer Solution Provider
We deliver system-level EV solutions specifically designed for semi-trailer applications, covering electric drive axles, controllers, traction battery systems, and auxiliary inverters. Co-developed hardware and control software ensure validated compatibility, streamlined integration, and a shortened development timeline.
14+
years of EV industry experience
30+
countries of EV system presence
01
Integrated System Solution
We provide a coordinated electrified trailer system covering electric drive axles, controllers, traction battery systems, and inverters. All systems are developed and validated under a unified architecture, ensuring interface compatibility and reducing multi-supplier integration complexity. This approach helps shorten development timelines and lowers coordination and technical integration risks.
02
High Platform Compatibility
Our electrified trailer solution is engineered to meet the power, range, and performance requirements of electrified semi-trailers operating under different duty cycles. It is compatible with trailers paired with a wide range of tractor platforms, including diesel, battery-electric, and hydrogen fuel cell vehicles, without requiring fundamental changes to the tractor powertrain architecture.
03
Intelligent Control
An adaptive control strategy automatically regulates propulsion and braking output based on vehicle load, speed, and operating conditions. This enables coordinated operation between trailer and tractor, improving drivability, energy efficiency, and braking stability across varying duty cycles under real-world operating scenarios with defined system boundaries and clear integration responsibility.
04
Software + Hardware Integration Capabilities
Provides customizable TCU, MCU, and CAN protocol integration on the software side, paired with field-proven hardware components tested under extreme conditions – including high temperature, vibration, high altitude, and salt fog. Technical documentation and remote diagnostic tools for seamless deployment and support.
05
Flexible Procurement for All Project Stages
Supports small-batch pilot orders and low MOQ, enabling a smooth transition from prototyping to full-scale mass production. Streamlines the development process by ensuring shorter lead times, faster iteration cycles, and agile response for new model launches. Minimizes risks and adapts to evolving project requirements.
06
Reliable Manufacturing & Scalable Supply Chain
Combines in-house R&D and production with strategic partnerships with Tier-1 factories, supported by certified facilities and robust quality assurance systems. Offers a stable supply chain with flexible production capacity and customizable shipping terms (FOB, CFR, CIF) to suit different project needs.
Brogen Electrified Trailer Solution Overview
For electrified trailer applications, our solution portfolio covers the core trailer-side propulsion and energy systems, including a dual-motor electric drive axle with a 2-speed AMT and standardized CATL traction battery packs. A standardized VCU is available to support customers without an existing control system, providing validated control logic for propulsion and energy management.
By developing and supplying both key hardware components and control software within a unified system architecture, we ensure interface compatibility, system reliability, and long-term product availability.
Functions
Auxiliary Traction Support
Delivers additional driving force to assist the tractor during acceleration, hill climbing, and heavy-load conditions, enhancing overall drivability and performance.
Intelligent Regenerative Braking
Decouples electric braking from mechanical transmission braking, allowing for precise control and maximized energy recovery without compromising braking performance.
Integrated Retardation Function
Replaces conventional retarders by enabling controlled deceleration through the electric drive system, with the added advantage of recovering energy during braking events.
Adaptive Power Management
Dynamically optimizes the balance between energy consumption and torque output based on real-time operating conditions, improving overall system efficiency.
Solution Features
System-Level Electrified Trailer Solution
Deliver integrated electrified trailer solution, covering electric axle, controller, and battery system. Hardware + software co-developed for seamless performance, simplified integration, and faster time-to-market.
High Adaptability And Customization
Adapt to the trailer's power needs, operating range, and other performance targets. Applicable to trailers paired with different types of tractor units, including diesel, pure electric, and hydrogen fuel cell systems.
Environmental Benefits
Recover kinetic energy during deceleration, converting it into usable electrical energy. Enable the tractor to operate in its high-efficiency range more often, reducing fuel consumption. Lower carbon footprint compared to traditional fuel-only systems, contributing to compliance with global environmental standards.
Leading the Way in Innovative Electric Powertrain Technology
Electric Drive Axle
- The dual-motor structure, combined with an advanced gear shifting control strategy, ensures uninterrupted power delivery during gear shifts, enhancing vehicle safety.
- With a maximum single-axle output of over 50,000 N · m, abundant power is provided for various driving needs.
- Verified through 1 million load-bearing reliability tests at 2.5 times the maximum loading capacity, ensuring heightened load-bearing safety.
- The distributed drive design of the e-axle enables increased power redundancy. In the event of a single motor failure, the remaining motors can continue operating normally.
- Equipped with ASR function, enhancing traction on wetlands and preventing vehicle skidding. This feature ensures starts on rainy or snowy roads, enhancing vehicle safety in challenging driving conditions.
Standard EV Battery Pack from CATL
Battery Pack |
L095D01 |
L095D02 |
|---|---|---|
Battery Type
|
LFP
|
LFP
|
Configuration
|
1P96S
|
1P81S
|
Energy
|
29.36 kWh
|
24.78 kWh
|
Rated Capacity
|
95 Ah
|
95 Ah
|
Size
|
1350*660*243 mm
|
1090*660*243 mm
|
Working Environment Temperature
|
-35°C ~ 65°C
| |
Storage Environment Temperature
|
-40°C ~ 65°C
| |
Case Studies​
Pure Electric Tractor + Electrified Trailer
Ideal for short-haul, heavy-duty, and uphill operations. Effectively address power and range concerns.
- Test location: a port
- Vehicle full load weight: 90 T
- Trailer battery energy: 340 kWh
- One-way distance: 175 km
- Test condition: Long-distance continuous uphill climbing
A traditional fuel vehicle weighing 49 tons consumes 31.9 liters per 100 kilometers for a round trip. If each vehicle makes 2 trips daily for 300 days a year, our solution results in the reduction of an annual carbon emission of 191.2 tons per vehicle.
In single-container transportation, the electric vehicle’s initial cost is estimated to be $72,286 USD higher than that of the fuel vehicle. However, annual operational savings of $39,286 USD suggest a payback period of around 1.84 years.
For double-container transport, the electric vehicle’s upfront cost may be $52,429 USD higher than acquiring two fuel vehicles. Nevertheless, annual operational savings of $130,857 USD, along with reduced driver expenses by $28,571 USD, indicate a payback period of approximately 0.32 years.
Fuel Tractor + Electrified Trailer
Ideal for mountainous regions as well as hilly terrains, mining sites, factory areas, and other challenging work environments.Â
- Test location: a mining area
- Vehicle full load weight: 53 T
- Trailer battery energy: 141 kWhÂ
- One-way distance: 110 kmÂ
- Test condition: Predominantly uphill and downhill terrain
Fully loaded, each trip covers a distance of 110 kilometers with the engine achieving a fuel efficiency rate of 31.2%. With each vehicle making 2 trips per day for 300 days a year, it results in a reduction of carbon emissions of 43.8 tons per vehicle annually.
When considering the transportation of a single container, the electric vehicles’s purchase price is estimated to be $25,286 USD higher than that of a fuel vehicle. However, with annual operatinal savings of $14,429 USD, the investment is projected to be covered in approximately 1.75 years.
Operation​
Electrified Trailer Solution - FAQ
This electrified trailer solution is designed for trailer and tipper manufacturers, OEMs, and professional vehicle integrators developing or expanding into electrified trailer applications.
It’s well suited for traditional trailer manufacturers without prior EV drivetrain experiencce, as long as they have an internal engineering team capable of handling mechanical integration, electrical interfacing, and vehicle-level validation.
Prior EV experience is not mandatory. However, customers are expected to have:
- An internal engineering team
- Basic electrical and control system integration capability
- The ability to perform vehicle-level testing and validation
No. The electrified trailer solution is not plug-and-play and not a turnkey vehicle solution. Project-specific integration work is required, including:
- Mechanical installation
- High-voltage electrical integration
- Vehicle-level validation and testing
For this solution, a standardized VCU is available as part of the solution. Custom VCU strategy development or deep control logic customization is not included by default and would require a separate development scope.
The solution uses CATL standardized traction battery packs. These packs are validated, produced using standardized designs and manufacturing processes, and supplied with defined electrical and communication interfaces.
The CATL standardized battery pack structure, internal architecture, and PDU configuration are fixed and not customizable. For other battery pack options, please discuss with our team: contact@BrogenEVSolution.com
To evaluate project feasibility and system suitability, customers are expected to provide:
- Trailer or tipper type and dimensions
- Target payload and axle configuration
- Operating duty cycle and use cases
- Target markets and regulatory requirements
- Intended tractor power source
Clear and complete project information is essential for an efficient evaluation.
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 >