Electrified Trailer Solution
As global demand for low-carbon and environmentally friendly transportation intensifies, the decarbonization of vehicles, especially in the commercial transport sector, is becoming a key driver for achieving sustainability goals. Among these trends, the electrified trailer solution is emerging as a promising solution, offering advantages such as reduced emissions, enhanced power performance, and greater system intelligence.
With an advanced adaptive control algorithm, our electrified trailer solution is engineered to seamlessly integrate with a wide range of tractor/semi-truck power sources, including conventional internal combustion engines, battery-electric systems, hydrogen fuel cells, and hybrid configurations.
Email: contact@brogenevsolution.com
Why Brogen
Our robust capabilities go beyond numbers.
14+
years of EV industry experience
30+
countries of EV system presence
350+
global clients
200%
expected revenue growth rate 2024-2025
Basic Electrification Strategy for e-Trailers
The electrified trailer solution builds upon the foundation of traditional semi-trailers by integrating advanced regenerative energy systems, significantly reducing fuel consumption and harmful emissions. Core components of the system include a traction battery system, a high-efficiency electric drive axle, and intelligent control modules—working together to support both propulsion and energy recovery.
When the vehicle decelerates—whether through coasting or braking—the electric drive axle initiates regenerative braking, converting kinetic energy into electrical energy. This recovered energy is efficiently stored in the trailer’s battery system, reducing reliance on the main vehicle’s fuel and improving overall energy utilization.
This function becomes especially advantageous during long downhill segments, where regenerative braking not only reduces wear on mechanical brakes and improves safety but can also lead to fuel savings exceeding 20% under certain operating conditions.
Beyond energy recovery, the electrified trailer solution lays the groundwork for intelligent e-trailer systems. With the integration of electric powertrains, the trailer can support a wider range of smart electronic functions, offering enhanced control, diagnostics, and adaptability.
By combining sustainability, performance, and digital readiness, this solution transforms conventional trailers into intelligent, low-emission transport platforms—ready to meet the demands of modern logistics and regulatory requirements.
Brogen Electrified Trailer Solution Overview
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 Mannagement
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.
Our Electric Axle for Electrified Trailer
- 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 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 heightended 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.
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.
- Test location: a mining area
- Vehicle full load weight: 53 T
- Trailer battery energy: 141 kWh
- One-way distance: 110 km
- 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
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Email: contact@brogenevsolution.com
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