Standard EV Battery Pack for Electric Bus / HCV

The EV battery system is the core component of a battery electric bus, and its importance cannot be overstated. Our standard EV battery pack for electric buses and HCVs is designed with modular flexibility, allowing tailored configurations to meet various vehicle requirements. This approach reduces redundant design and production efforts, enhancing efficiency across R&D, procurement, and manufacturing processes for OEMs (automotive manufacturers) and ultimately lowering costs. Additionally, the standardized battery pack design ensures high levels of protection, safety, and reliability, supporting large-scale production demands.

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Email: contact@brogenevsolution.com

Our EV Battery System Benefits

Premium Battery Cell
We use battery cells from top global EV battery suppliers such as CATL, paired with a cushioning design in the battery cell and module space. This design quickly absorbs expansion due to battery "breathing" and provides added protection in collisions, enhancing overall battery safety.
Excellent Thermal Management
Our standard EV battery pack features a liquid-based thermal control system that manages heating and cooling. This system optimizes battery consistency, enabling efficient heat dissipation, high durability, and reliable long-term performance.
Lightweight Design
With aluminum alloy composites, the battery box achieves reduced material thickness without compromising structrual integrity. This approach ensures a lightweight design, further enhancing the energy density of the EV battery system.

Highly Integrated EV Battery Solution for Enhanced Quality, Efficiency, Safety

High Integration for Maximum Energy Density

Comprehensive active safety system with integrated wiring harnesses, aluminum busbars, temperature sensors, pressure monitoring, explosion-proof valves, electrolyte detection, and BMS sensor board.
Saves 5%-10% of battery pack space.

Enhanced Insulation & Voltage Resistance for Safety

Meets 2000 V insulation standard between adjacent aluminum busbars and between busbars and temperature sensors.
Meets 6000 V insulation standard between aluminum busbars and PC module.
Significantly lowers risks associated with insulation aging, fractures, and short circuits commonly seen in traditional wiring harnesses.

Standard EV Battery Pack Offerings

System Features

Independent slave control: simplifies installation and maintenance.
Integrated liquid cooling: strong adaptability in high-temperature environments.
All-aluminum casing: lightweight design with high energy density.
Protection level: IP67.
Standard charging: 1C.
Standard equipped with heating film.

EV Battery Pack Parameters

Dimension (mm)	1060630240
Cell Capacity (Ah)	105	173	230	280	304
Battery Packing Scheme	2P48S	1P63S	1P48S	1P36S	1P36S
System Capacity (Ah)	210	173	230	280	304
Nominal Voltage (V)	153.6	202.86	153.6	115.2	115.2
Energy (kWh)	32.256	35.095	35.328	32.256	35.02

Custom EV Battery System Example Configurations

280 kWh Battery System for 8 - 10 M Bus / 25 T Truck

Battery System		Parameters	Note
System nominal voltage		614.4 V	The monomer is 3.2 V
System operating voltage range	min	480 V	Monomeric 2.5 V~3.65 V
	max	700.8 V
System rated capacity		460 Ah	25 ± 2℃, 1 / 3C, 100% DOD, the shipment capacity is not less than 98% of the rated capacity
System storage energy		282.62 kWh	25 ± 2℃, 1 / 3C, 100% DOD, the shipped power is not less than 98% of the rated power
System life end remdual capacity		≥368 Ah	5 years, not less than 80% of the rated capacity
System group mode		2P192S	Series and parallel connection
Battery system weight		About 1920 kg
Specific energy of the system		About 150 Wh/kg
Maximum continuous charging current		230 A	Maximum duration of 0.5C
Maximum pulse charging current (30s)		460 A	30s max. 1C
Maximum continuous discharge current		460 A	Maximum duration of 1C
Maximum pulse discharge current (30s)		920 A	30s maximum of 2C
Maximum allowable feedback charging current (10s)		920 A	50% SOC, 20 – 55℃ / 10s max 2C
SOC working range		10~100 %
Insulation requirements		≥200 MΩ	500 VDC, total positive / negative against the shell
Protection level of the battery box body		IP67
System cooling mode		water cooling system
System heating mode		water cooling system
Charge on shipment (SOC)		20%~50%	The SOC status is consistent with the same batch of shipment

350 kWh Battery System for 12 M Bus / 40 T Truck

Battery System		Parameters
System nominal voltage (V)		576 V
System operating voltage range	min	450 V
	max	657 V
System rated capacity		608 Ah
System storage capacity		350.21 kWh
System end of life remaining Capacity		≥ 212 Ah
System grouping		1P180S
Shipment Charge Capacity (SOC)		20%~50%
System specific energy		about 145 Wh/kg
Maximum continuous charging current		304 A
Maximum pulse charging current (≤30s)		608 A
Maximum continuous discharge current		608 A
Maximum pulse discharge current (≤ 30s)		1200 A
Maximum allowable feedback charging current (≤10s)		608 A
SOC working range		10~100%
Insulation requirements		≥ 200 MΩ
Protection level of battery box		IP67
System cooling method		Natural cooling
System heating method		Heating film

Why Choose Us

Exceptional R&D Expertise

BMS Design & Development
Independently develop BMS software; design control strategies and diagnostic analysis algorithms in-house; design the controller main board, control circuits, monitoring circuits, and communication circuits
Pack Structural & Electricial Design & Development
Independently design integrated battery pack structures to accommodate various battery cell types and capacity needs; independently design electrical circuits and select components, with electrical testing and verification environments to ensure compliance with standards
Battery System Integration Design & Development
Independently design electrical systems and structures; capable of integrating third-party systems, equipment, and components

Modern Manufacturing Plant

Case Study

8-Meter and 12-Meter Electric Bus Project in Turkey

In 2022, a leading commercial vehicle manufacturer in Turkey approached us for a custom EV solution for their 8-meter and 12-meter electric bus project. Drawing on our expertise in EV battery systems, we delivered a tailored solution that included a 282 kWh battery system, a custom Battery Management System (BMS) with a Power Distribution Unit (PDU), and Battery Thermal Management System (BTMS).

This battery system was adapted from our standard EV battery packs, but the buses’ 700 V high-voltage motors posed a unique challenge, as this voltage is uncommon in battery packs. To address this, our engineering team conducted detailed simulations and calculations based on the vehicle specifications and developed custom battery packs with varied capacities to meet the specific requirements of each bus model.