Light Commercial Vehicle Electrification Solutions
As e-commerce and express delivery thrive, the demand for eco-friendly, efficient logistics vehicles is soaring. Electric light commercial vehicles (LCVs) are rapidly expanding in urban delivery and short-haul transport. With zero emissions and low noise, they are the top choice for logistics companies, driving market growth. In fixed-route, high-frequency operations, their operating costs are just 1/3 of fuel-powered vehicles. Electrifying LCVs cuts carbon emissions, lowers maintenance costs, and improves operational efficiency.
At Brogen, we provide tailored EV solutions for LCV manufacturers, ensuring longer range, enhanced safety, and optimized cargo space with advanced technology and proven reliability to keep them ahead in this fast-growing market.
Email: contact@brogenevsolution.com
Our Light Commercial Vehicle Solution Advantages
Pickup Truck
Van
Light Truck
Bus
01
Lightweight Design
Our EV solutions for LCVs are engineered with a lightweight approach, reducing energy consumption while improving vehicle dynamics, safety, and payload capacity, enabling end clients to enhance operational efficiency.
02
Proven Safety & Reliability
Our EV systems undergo rigorous testing and have been deployed in mass-production LCVs from leading OEMs. With real-world validation, they deliver exceptional safety, reliability, and compliance with industry standards.
03
Advanced Technology
We integrate advanced EV technologies. By combining state-of-the-art hardware and intelligent software, we empower OEMs to develop high-performance, future-ready electric LCVs that stand out in the market.
Our Light Commercial Vehicle Electrification Solutions
Electric Powertrain
We offer a range of electric drive solutions for light commercial vehicles with different technical configurations, including central direct-drive motors, high-speed motors with single-reduction gearbox or transmission, and electric drive axle systems. Our solutions utilize PMSM motors, featuring high power density, compact size, and low operating noise, making vehicle integration more efficient. Depending on customer and project requirements, we also provide standalone MCUs or integrated multi-function controllers.
The electric drive axle is a highly integrated system that incorporates a PMSM directly into the rear axle. By eliminating traditional transmission components such as the drive shaft, this solution significantly enhances energy efficiency while reducing mechanical complexity. The compact design optimizes chassis space utilization, improves vehicle layout, and enables greater flexibility in battery placement, ultimately contributing to an extended driving range and overall vehicle performance.
Solution Features
- The motor is integrated into the axle, creating a compact structure that optimizes chassis layout.
- Lightweight design enhances weight reduction, improving overall system efficiency.
- Precision-ground gears minimize noise, ensuring a quieter and more comfortable ride.
- High transmission efficiency reduces energy consumption.
- Maintenance-free design: no initial service required, with the main reduction gear oil change interval at 100,000 km. Maintenance-free wheel ends enhance uptime and extend service life.
- Action monitoring of gear rotation speed, real-time tracking of main reduction gear oil temperature and brake disc temperature, and friction plate wear alarms for enhanced safety.
Advanced Technology
- 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.
- Reduced motor offset relative to the axle housing decreases the risk of oil leakage at the reducer joint.
- High-precision two-stage helical cylindrical gear transmission with double-sided precision grinding for superior efficiency, lower noise, and extended lifespan.
We offer central direct solutions with various configurations, including a single motor, a motor integrated with a gearbox/transmission, and a motor integrated with a gearbox/reducer and MCU. These solutions are designed for simplicity and reliability.
The single-motor direct-drive solution is the most mature and widely adopted technology. A medium-speed direct-drive motor can be paired with a high-ratio rear axle, while a high-speed motor can be coupled with a single-stage reducer. This setup provides high output torque to ensure excellent capability, while the powerful motor enhances vehicle acceleration performance.
Solution Features
- Wide vehicle compatibility: suitable for sanitation trucks, short-haul cargo trucks, and light-duty trucks, compatible with range-extended vehicles.
- High system reliability: successfully deployed in large-scale production for major domestic OEMs' LCV models, ensuring stable operation.
- Strong power and climbing performance: delivers exceptional torque to meet overload demands.
- Efficient performance across speed ranges: maintains high-efficiency output over a broad speed range, making it ideal for urban distribution and intercity freight transport.
Advanced Technology
- Enhanced motor efficiency: utilizes advanced designs such as thin silicon steel laminations, high magnetic permeability materials, and sinusoidal air-gap flux density optimization. These innovations increase motor efficiency, with peak efficiency exceeding 97% and over 90% of the operating range achieving system efficiency ≥85%.
- Low-noise operation: features rotor segmented skewing and optimized auxiliary slot parameters at the rotor's outer edge, effectively reducing motor noise.
- Optimized cooling system: incorporates a dual-helical water channel design to enhance heat dissipation and stability while maintaining optimal water resistance and pressure differential.
- Mud and sand protection: equipped with a flange dustproof structure to prevent mud, sand, and wastewater from entering the motor, improving long-term reliability.
We can offer standalone Motor Control Units (MCU) or high-voltage integrated controllers customized to client requirements, integrating MCU, PDU, DC-DC, and steering and braking DC/AC.
Advanced Technology
- 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.
EV Battery
For light commercial vehicles, we provide tailored EV battery solutions based on specific customer requirements. Our comprehensive solutions encompass battery packs, battery management systems (BMS), battery thermal management systems (BTMS), and cloud-based services for full lifecycle management.
Our standardized EV battery packs are widely 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.
Solution Features
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.
Advanced Technology
- 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.
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.
Advanced Technology
- 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.
Solution Features
- 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.
Advanced Technology
- 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.
Other EV Systems for Light Commercial 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 light commercial 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.
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
3-ton Electric Pickup Truck in Thailand
In 2022, we provided an electric powertrain solution to our client in Thailand for their electric pickup truck project. The e-powertrain solution includes the 2-in-1 system integrating the electric drive motor and the reducer, and a motor control unit.
Once our e-powertrain system was integrated into the client’s electric pickup truck, they conducted rigorous testing, including water wading, high-speed performance, and other essential assessments. Our system successfully passed all tests, making the client highly satisfied.
Due to the successful outcome of this project, the client expanded their collaboration with us, requesting e-powertrain solutions for other models, including their 6-ton medium-duty trucks and 25-ton heavy-duty trucks. Throughout this collaboration, we also supplied other systems such as onboard chargers and battery thermal management systems.
Electric Light Truck in South Korea
In 2021, we provided the electric powertrain solution to one client in South Korea for their light-duty truck project. The solution includes the 120 kW electric motor, integrated with the gearbox and controller, and the water pump, EHPS, DC/DC converter, and air conditioning compressors. This combination ensured that our solution perfectly aligned with the unique demands of their EV projects.
Additionally, we provided professional technical support to ensure their electric light-duty trucks were operational quickly and efficiently. In just ten days, our electric powertrain solution had the customer’s vehicles up and running. The success made local news. The customer thanked us for a transformative journey that successfully converted the electric light-duty truck into their fleet and laid a solid foundation for their electric future. We’re currently in active discussions with the customer about electrification options for other models in their fleet.
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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