Heavy-Duty Truck Electrification Solutions
System-Level HCV Electrification Solutions for Truck OEMs, EV Manufacturers, and Engineering Service Providers
Heavy-duty truck electrification is critical for reducing carbon emissions and operating costs in commercial road transport. Electric heavy-duty trucks offer a true zero-emission alternative while significantly lowering operating costs, reducing per-mile energy expenses by up to one-third compared to conventional diesel vehicles.
At Brogen, we deliver tailored heavy-duty truck electrification solutions, developed for truck OEMs, EV manufacturers, and engineering service providers. Our solutions support both forward-looking platform development and diesel-to-electric conversion projects, offering flexible EV system architectures with dedicated system software support for vehicle-level integration.
Email: contact@brogenevsolution.com
Our Heavy-Duty Truck Electrification Solution Advantages
Medium Truck
Heavy Truck
E-trailer
Tractor
01
Lightweight-Oriented Design
Our electric powertrains for heavy trucks are engineered for lightweight construction, optimizing energy efficiency and vehicle dynamics. Reduced weight enhances payload capacity and operational efficiency for fleet operators.
02
Proven Safety & Reliability
Brogen EV systems for heavy-duty trucks have been validated in mass-production trucks from leading OEMs. Rigorous testing ensures industry-standard safety, reliability, and long-term performance under demanding operational conditions.
03
Mature and Scalable Technology
We provide flexible powertrain configurations that integrate high-performance PMSM motors, intelligent controllers, and modular software interfaces. Designed for OEMs and EV builders with in-house engineering teams, our solutions enable future-ready electric heavy trucks.
Project Scope & Intended Use
Target Applications
- OEM EV Platform Development:
- Electrification of new heavy commercial vehicle platforms, including heavy-duty trucks, municipal vehicles, and construction machinery
- Applicable to forward-thinking OEM platform development projects with a defined vehicle architecture and control strategy
- Structured Commercial Conversion Projects:
- Diesel-to-electric conversion for commercial fleet vehicles
- Project-based delivery with clear performance targets and operational requirements
Vehicle Platforms & Project Scope
- Designed for HCVs, typically ranging from 8 tons to over 55 tons GVW
- Applicable to projects with a defined vehicle platform, duty cycle, and operating conditions
- Intended for truck OEMs, professional EV builders, and engineering teams with in-house or partner-level system integration capability
*Responsibility for vehicle-level integration, system calibration, and validation remains with the OEM or integrator.
Our Heavy-Duty Truck Electrification Solutions
Electric Powertrain Solutions for Heavy-Duty Truck Electrification
We provide modular electric powertrain solutions for heavy-duty trucks, engineered to support a wide range of vehicle architectures and operating requirements. Our portfolio covers central direct-drive systems, centralized electric drive axle (e-axle) solutions, and distributed drive configurations, enabling OEMs and engineering teams to select the most appropriate topology at the vehicle level.
Built around PMSM with high power density, compact packaging, and low acoustic noise, our e-powertrain systems are designed to improve integration efficiency and overall vehicle performance. Depending on project scope and control strategy, solutions can be configured with standalone MCUs or integrated multifunction controllers to support flexible E/E architectures and VCU integration.
The electric drive axle is a highly integrated e-powertrain solution that integrates electric motors, transmission, and power electronics directly into the axle, eliminating conventional drivetrain components such as the driveshaft. This architecture improves overall system efficiency while reducing mechanical complexity and packaging constraints.
For heavy-duty trucks, electric drive axles enable a more optimized vehicle layout, providing greater flexibility for battery placement and chassis design. The simplified drivetrain also contributes to extended driving range and reduced maintenance requirements over the vehicle lifecycle.
Centralized eAxle Solution
Centralized eAxle Solution
Key Characteristics
Compact Design
The motor, gearbox, and axle utilize a highly integrated parallel-axis design, resulting in a lightweight system with high transmission efficiency.
Improved NVH Performance
The gearbox is engineered for all operating conditions, featuring in-house manufactured DIN 4-grade high-precision gears, ensuring low noise levels.
Flexible Vehicle Layout
By eliminating the driveshaft, the chassis provides additional space for battery placement, allowing for a more flexible vehicle layout.
Engineering Highlights
- High load-bearing capacity with reduced weight, minimizing the risk of oil leakage.
- Integrated gear housing design reduces oil leakage risks, while the smooth curved internal surface minimizes oil churn losses.
- High-precision two-stage helical cylindrical gear transmission with double-sided precision grinding for superior efficiency, lower noise, and extended lifespan.
- Reduced motor offset relative to the axle housing decreases the risk of oil leakage at the reducer joint.
Technical Specification Range
Parameter |
Specification Range |
|---|---|
Axle Load Rating
|
3,500 - 13,000 kg
|
Target Vehicle Segment
|
4.5-6 t truck; 6×4 / 4×2 truck
|
E-Axle Architecture
|
Multi-speed centralized single/dual-motor e-axle
|
Motor Rated Power
|
60 - 190*2 kW
|
Motor Peak Power
|
120 - 310*2 kW
|
Maximum Wheel Output Torque
|
5,300 - 45,000 N.m
|
Distributed Drive eAxle Solution
Distributed Drive eAxle Solution
Key Characteristics
Short Transmission Chain
The distributed drive eAxle solution ensures each motor drives one wheel, significnatly shortening the transmission chain, minimizing transmission loss and maximizing efficiency..
Compact Structure
The distributed drive axle systems save space and contribute to a more compact vehicle structure.
Improved Tire Grip Distribution
The distributed eAxle enables individual adjustment of motor torque, optimizing the grip distribution, enhancing vehicle handling and driving stability, providing a safter and more controlled driving experience.
Enhanced Drive Efficiency
Aligning the motor's optimal efficiency range with the vehicle's operate at peak performance.
Engineering Highlights
- Integrating two electric motors with the axle for strong power and additional safety redundancy.
- Equipped with EDS, EASR, IESS, and other safety configurations to increase vehicle safety and stability in harsh environments.
- The integrated design of the electric truck axle lowers the gravity center of the battery system, increasing the stability of the whole vehicle.
- Distributed drive approach adds additional safety redundancy to the vehicle, offering a flexible power distribution strategy for different working conditions.
Technical Specification Range
Parameter |
Specification Range |
|---|---|
Axle Load Rating
|
11,500 - 16,000 kg
|
Target Vehicle Segment
|
6×4 / 4×2 truck; trailer; bus; coach
|
E-Axle Architecture
|
2-speed distributed dual-motor e-axle
|
Motor Rated Power
|
80*2- 200*2 kW
|
Motor Peak Power
|
180*2 - 300*2 kW
|
Maximum Wheel Output Torque
|
50,000 N.m
|
We provide central drive solutions for heavy-duty vehicles, including standalone electric motors and controllers or integrated X-in-1 e-powertrain systems that combine motor and gearbox. These solutions improve energy efficiency, reduce fleet operational costs, and lower carbon emissions.
Designed for reliable performance in demanding commercial vehicle applications, our systems are proven across leading OEMs.
Direct Drive Motor
Central Direct Drive Motor
Key Characteristiccs
Easy Conversion
Ideal for retrofitting traditional fuel vehicles with minimal modifications and low risk.
Cost-Effective & Fast Development
Short development cycle with manufacturing costs similar to conventional vehicles.
High Efficiency
Over 95% peak efficiency with a broad high-efficiency range for optimal performance.
Wide Applicability
Suitable for heavy-duty trucks, tractors, mining trucks, garbage trucks, and more.
Engineering Highlights
- Utilizes advanced designs such as thin silicon steel laminations, high magnetic permeability materials, and sinusoidal air-gap flux density optimization.
- Features rotor segmented skewing and optimized auxiliary slot parameters at the rotor's outer edge, effectively reducing motor noise.
- Incorporates a dual-helical water channel design to enhance heat dissipation and stability while maintaining optimal water resistance and pressure differential.
- Equipped with a flange dustproof structure to prevent mud, sand, and wastewater from entering the motor, improving long-term reliability.
Integrated E-Powertrain
Integrated E-Powertrain (Motor+Gearbox/Transmission)
Engineering Highlights
Powerful & Smooth Performance
The multi-speed transmission enables fast and seamless shifting, eliminating jolts during gear changes. High output torque improves climbing capability, while the powerful motor ensures strong acceleration.
Automated AMT Transmission
The AMT transmission shifts gears automatically based on vehicel speed and motor RPM, eliminating the complexity of manual shifting and enhancing driving comfort.
Flexible PTO System
The power take-off (PTO) system is optional and can be tailored tto specific vehicle needs. Integrating PTO into the drivetrain reduces additional installation costs.
Proven Track Record
Developed with globally recognized transmission manufacturers, the system has undergone road trials, ensuring durability and real-world validation.
The Motor Control Unit (MCU) is supplied as a matched component with the electric motor or electric axle, ensuring validated compatibility, optimized performance, and simplified vehicle integration. Designed to support flexible powertrain architectures, the MCU helps reduce system complexity and streamline HCV electrification projects.
Engineering Highlights
- Dual integration design: combines functional and physical integration to reduce size and weight while lowering manufacturing costs.
- High-efficiency dual inverter control: reduces energy losses and achieves a peak controller efficiency of 98.5%.
- Advanced filtering & shielding: features multi-stage filtering, optimized wiring layout, enhanced structural processing, and reinforced enclosure shielding for improved electromagnetic compatibility.
- Modular & scalable architecture: designed with a modular and platform-based approach, allowing greater flexibility and expandability.
- Digital simulation & optimization: utilizes digital modeling for simulation analysis, enabling more versatile and cost-effective component selection.
Traction Battery Solutions for Heavy-Duty Trucks
We provide customized traction battery solutions for heavy-duty trucks, designed to meet specific customer requirements. Our offerings include complete battery packs, battery management systems (BMS), battery thermal management systems (BTMS), and cloud-based services for full lifecycle management, ensuring reliable performance, safety, and long-term efficiency.
Our standardized LFP traction battery packs are deployed across various applications. These packs are built using high-quality, industry-standard materials and proven manufacturing processes. With a standardized and modular design, we optimize the battery system structure layer by layer, achieving energy density levels that surpass the industry average for both battery modules and complete packs.
Key Characteristics
High Safety & Reliability
Built on a high-safety LFP system, with battery cells sourced from top-tier manufacturers such as CATL, EVE, and Gotion. The robust pack design meets relevant safety standards.
Wide Capacity Options
Offer multiple battery capacity configurations to meet diverse market demands, including extended range and high-load applications.
Lightweight & High Energy Density
Optimized design achieves an energy density of ≥140 Wh/kg, enhancing vehicle efficiency.
Superior Temperature Adaptability
Can be equipped with liquid cooling or heating systems based on customer requirements, ensuring reliable performance in extreme heat or cold conditions.
Strong Mechanical Protection
Features IP67-rated protection, making it highly resistant to harsh environmental conditions.
Engineering Highlights
- Independently designed pack integration structure, adaptable to various battery cells and capacity requirements.
- Custom-designed electrical circuits and component selection, with in-house electrical testing capabilities to ensure compliance with industry standards.
- Highly integrated safety system, including harnesses, aluminum busbars, temperature sensors, internal pack pressure monitoring, explosion-proof valves, electrolyte leakage detection, and BMS collection boards, providing comprehensive and reliable active safety protection.
- Thermal runaway protection: equipped with insulation barriers between battery cells. If a cell reaches 900°C due to thermal runaway, the safety valve automatically releases pressure to prevent further hazards.
Technical Specification
Parameter \ Pack |
1 |
2 |
3 |
4 |
5 |
|---|---|---|---|---|---|
Battery Cell
|
105 Ah
|
173 Ah
|
230 Ah
|
280 Ah
|
304 Ah
|
Grouping
|
2P48S
|
1P63S
|
1P48S
|
1P36S
|
1P36S
|
System Capacity
|
210 Ah
|
173 Ah
|
230 Ah
|
280 Ah
|
304 Ah
|
Rated System Voltage
|
153.6 V
|
202.86 V
|
153.6 V
|
115.2 V
|
115.2 V
|
System Energy
|
32.256 kWh
|
35.095 kWh
|
35.328 kWh
|
32.256 kWh
|
35.020 kWh
|
Dimension
|
1060*630*240 mm
| ||||
The Battery Management System (BMS) is a critical component designed to monitor and manage battery performance. Working alongside battery cells, the BMS acts as the system’s intelligent monitoring unit to ensure safety and efficient operation. Key functions of BMS include continuously tracking essential battery parameters, preventing overcharging and over-discharging, safeguarding the battery from potential damage; and optimizing performance and longevity by maintaining optimal operating conditions.
Our R&D Capabilities
- Independently develop BMS software for battery management control.
- Custom-designed control strategies and diagnostic analysis algorithms.
- Proprietary design of controller mainboards, control circuits, monitoring circuits, and communication circuits.
Engineering Highlights
- High-Precision Calculations: SOC accuracy ≤3%; SOH health assessment accuracy ≤5%.
- Three-Tier Architecture: Ensures precise battery cell management, reduces error margins, and enables full lifecycle battery management.
- High-Speed Daisy-Chain Communication: Faster data transmission, lower power consumption, enhanced stability, strong anti-interference capability, and high voltage resistance.
- High Integration: BMS and PDU integration increases battery energy density, saving approximately 30% of space and reducing weight by 10%.
- Comprehensive Smart BMS Platform: Covers the entire system, from BMS controller software to an integrated edge-side BMS+EMS system and an EMS/battery management cloud platform, ensuring full-process security and control.
The Battery Thermal Management System (BTMS) is an integrated cooling and heating system designed to regulate the temperature of onboard batteries. The primary goal of BTMS is to keep the battery pack within an optimal temperature range, ensuring peak performance and longevity. By managing thermal energy across the vehicle, the system effectively reduces waste heat emissions, enhances energy efficiency, and minimizes environmental impact.
Key Capabilities of the BTMS
- Accurately measures and tracks battery temperature in real time.
- Effectively dissipates heat when battery temperature is high, preventing thermal runaway.
- Warms the battery in low temperatures to ensure safe and efficient charging and discharging.
- Reduces temperature differences within the battery pack, preventing localized overheating and extending overall battery lifespan.
Engineering Highlights
- Aluminum alloy frame reduces weight and improves efficiency.
- Optional PTC liquid heater with standby, cooling, heating, and self-circulating modes.
- CAN bus communication for real-time fault self-diagnosis and status updates.
- Optional add-ons: tube-fin condenser, DC-DC, expansion tank.
EV Charging Solutions for Heavy-Duty Trucks
We provide customized EV charging solutions for heavy-duty trucks, designed to support shift-based operations where multiple vehicles operate continuously over extended periods. With larger battery capacities and flexible operating locations, these vehicles rely on fast-charging solutions during work breaks to maintain productivity and minimize downtime.
Other EV Systems for Heavy Duty Vehicles
Onboard Charger, DC-DC Converter, PDU
Experience peak performance and reliability with our integrated EV on board charger (OBC), DC/DC converter, and PDU combo tailored for electric vehicles. Engineered for top-tier power conversion efficiency and remarkable power density, our chargers cover a broad power spectrum, ranging from 3.3 kW to 40 kW.
Auxiliary Inverter
We provide modular and scalable X-in-1 auxiliary inverters for public transport vehicle applications. Our auxiliary inverters cater to various types of new energy vehicles, including hybrid electric vehicles (HEV), battery electric vehicles (BEVs), and hydrogen fuel cell electric vehicles (FCEVs).
Electric Power Steering (EPS)
The Electric Power Steering System (EPS) is a type of power steering solution that uses an electric motor to assist the driver in steering. We offer various EPS systems based on the positioning of the assist motor, including C-EPS, P-EPS, DP-EPS, and R-EPS, each designed to meet the specific needs of different vehicle types.
Electro-Hydraulic Power Steering (EHPS)
The Electro-Hydraulic Power Steering (EHPS) system is an upgraded version of the traditional hydraulic power steering (HPS) system. In this system, the steering pump is no longer driven directly by the engine but by an electric motor, coupled with an electronic control unit. This allows the steering assist to be adjusted not only based on the steering angle but also in response to the vehicle’s speed, providing a more efficient and responsive steering experience.
Electro-Hydraulic Recirculating Ball Steering (EH-RCB)
We provide electro-hydraulic power recirculating ball steering systems designed for heavy commercial vehicles, including large buses and medium-to-heavy trucks. Based on conventional hydraulic power steering (HPS) architecture, the electro-hydraulic power recirculating ball steering system integrates electronic control units (ECU) and actuators – most importantly, a servo motor to enhance steering performance.
Air Brake Compressor
Our two-stage oil-free electric air brake compressors ensure the delivery of oil and water-free air, eliminating concerns associated with oil emulsification, leaks, and fire hazards. Its innovative structural design minimizes energy wastage during the compression process, thereby optimizing overall efficiency.
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.
Case Studies
40-ton Electric Truck Project in Portugal
In 2021, a Portuguese company approached us for their first electric heavy truck project. From the initial discussions to project completion, we maintained close communication to fully understand their requirements and provide a tailored EV solution that met their exact specifications.
Throughout the process, we helped them navigate technical challenges, offering expert guidance and ensuring seamless integration of our EV systems. Our solution included a 350 kW e-powertrain, 4 kW EHPS, 4 kW air brake compressor, and an integrated 3-in-1 auxiliary inverter.
Beyond delivery, we continue to provide remote technical support and collaborate with their team to address ongoing technical concerns, ensuring long-term performance and reliability.
Electric Semi-Truck Project in Canada
Edison Motors is a Canadian clean technology company that specializes in manufacturing electric semi-trucks. For their heavy commercial vehicle (HCV) projects, we supplied tailored electric drive solutions, including electric axles, PMSM drive motors, and the compact auxiliary inverter systems.
Designed for versatility, our solution supports HEVs, BEVs, and FCEVs, making it suitable for a wide range of applications, including logistics vehicles, trucks, municipal vehicles, trailers, and semi-trucks. By enhancing efficiency and performance, our system helps meet the evolving demands of modern electric transportation.
FAQ – Project Scope & Collaboration Requirements
No. Our HCV electrification solutions are intended for OEMs, EV builders, and professional engineering service companies. We do not support individual or personal EV conversion projects.
Yes. Customers are expected to have an in-house engineering team capable of vehicle-level integration. Our solutions are designed to be integrated into a complete vehicle platform rather than delivered as standalone or consumer-ready systems.
Yes. Customers must have the capability to integrate and calibrate the VCU to manage vehicle-level functions and coordinate with our supplied systems. VCU development is not included as a standard scope. If VCU development is required, it typically involves additional engineering costs.
No. We do not offer turnkey or plug-and-play electrification solutions. Our role is to supply defined, application-matched systems with software support limited to the subsystems we provide.
We provide software support for the systems we supply, such as motors, MCUs, e-axles, and battery systems. Vehicle-level software integration, VCU logic, and overall vehicle calibration remain the customer’s responsibility.
We can provide technical documentation and supporting materials related to the supplied systems. However, vehicle-level certification and homologation are typically handled by the customer.
To evaluate project suitability, customers should be able to clearly define key parameters such as vehicle type, target payload, performance requirements, duty cycle, operating environment, and project scope. Clear inputs are essential for accurate system selection and feasibility assessment.
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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