Light Commercial Vehicle Electrification Solution
Modular Electric Powertrain and Auxiliary Systems for OEM EV Platforms and Commercial Conversion Programs
Driven by the rapid growth of e-commerce and urban delivery, demand for efficient and low-emission light-duty trucks is accelerating worldwide. Electric light commercial vehicles are increasingly adopted for short-haul logistics thanks to their low operating cost, quiet operation, and suitability for fixed-route, high-frequency use.
Brogen supports this transition by supplying modular electric powertrain solutions and auxiliary components for light-duty truck electrification. Our traction motors, e-axles, tailored battery systems, matched inverters, and other electric auxiliary systems enable OEMs and professional integrators to develop reliable electric platforms optimized for real-world commercial operation.
Email: contact@brogenevsolution.com
Our Light Commercial Vehicle Electrification Solution Advantages
Pickup Truck
Van
Light Truck
Bus
01
Lightweight-Oriented Design
Our electrification solutions for light commercial vehicles are developed with a strong focus on weight optimization at the component and system level. Reduced mass contirbutes to lower energy consumption and improved vehicle packaging, supporting payload capaccity, handling stability, and overall operating efficiency.
02
Proven Safety & Reliability
Our electric powertrain systems have undergone structured validation and have been deployed in mass-produced light commercial vehicle platforms from established OEMs. Performance has been verified under real-world operating conditions, supporting long-term reliability, functional safety, and compliance with applicable industry standards.
03
Mature and Scalable Technology
Our EV solutions for light commercial vehicles are based on mature electric drivetrain technologies combined with configurable control strategies. This approach allows OEMs to develop elecctricc LCV platforms with consistent performance, scalability across vehiccle variants, and readiness for future regulartory and market requirements.
Our Light Commercial Vehicle Electrification Solutions
Electric Powertrain Overview
Our electric powertrain solutions for light commercial vehicles are designed to support multiple drivetrain architectures and project types, ranging from OEM platform development to commercial vehicle conversion projects. The portfolio includes central direct-drive motors, high-speed motors with single-reduction gearboxes, and electric drive axle systems, allowing drivetrain configurations to be selected based on vehicle layout, axle load, and operating requirements.
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.
Key Characteristics
- Integrated motor-axle architecture forming a compact drivetrain module that simplifies vehicle layout
- Lightweight structural design supporting reduced system mass and improved energy efficiency
- High-efficiency transmission optimized for electric drive applications
- Precision-ground gearing to reduce noise and vibration for improved NVH performance
- Low-maintenance design, with no initial service required and a main reduction gear oil change interval of up to 100,000 km
- Maintenance-free wheel ends, supporting extended service life and higher vehicle uptime
- Integrated condition monitoring: gear rotational speed, main reduction gear oil temperature, brake disc temperature, and friction plate wear status
Engineering Highlights
- High load-bearing capaccity with optimized mass distribution, supporting durability without unnecessary weight increase
- Integrated gear housing design that reduces potential oil leakage points
- Optimal internal housing geometry with smooth curved surfaces to minimize oil churning losses
- Reduced motor offset relative to the axle housing, lowering sealing stress at the reducer interface
- Two-stage helical cylindrical gear transmission with double-sided precision grinding, enabling high efficiency, low noise, and extended gear life
Technical Specification Range
Parameter |
Specification Range |
|---|---|
Axle Load Rating
|
2,000 - 5,500 kg
|
Vehicle GVW Coverage
|
Approx. 1.8 - 8 tons
|
E-Axle Architecture
|
Single-speed integrated e-axle
|
Motor Rated Power
|
30 - 100 kW
|
Motor Peak Power
|
70 - 180 kW
|
Maximum Wheel Output Torque
|
2,415 - 6,600 N.m
|
Our electric drive motor solutions are designed for central drive architectures commonly used in light commercial vehicles. Multiple configuration options are available, including standalone motors, motor–gearbox or transmission assemblies, and integrated motor–gearbox–MCU units, allowing drivetrain layouts to be selected based on vehicle architecture and integration preferences.
Depending on vehicle requirements, medium-speed motors can be paired with high-ratio rear axles, while high-speed motors can be combined with single-stage reducers. This flexibility enables sufficient wheel-end torque for launch and gradeability while supporting responsive vehicle acceleration.
Key Characteristics
- Broad vehicle applicability, supporting light-duty trucks, municipal and sanitation vehicles, and short-haul freight trucks.
- Proven system reliability, with deployment in large-scale production light commercial vehicle platforms
- High torque capability, supporting vehicle launch, gradeability, and occasional overload operation
- High efficiency accross a wide operating range, suitable for stop-and-go urban operations as well as steady intercity driving
- Flexible integration options, including motor-only, motor-gearbox, and motor-gearbox-MCU configurations
Engineering Highlights
- High-efficiency electromagnetic design, using thin silicon steel laminations, high-permeability magnetic materials, and optimized sinusoidal air-gap flux density distribution
- Advanced thermal management, featuring a dual-helical water cooling channel to improve heat dissipation while maintaining optimal water resistenace and pressure differential
- Enhanced environmental protection, with flange-based dust and debris protection to prevent mud, sand, and wastewater ingress, supporting long-term reliability in demanding operating conditions
- Optimized acoustic performance, achieved through rotor segmented skewing and refined auxiliary slot geometry to reduce electromagnetic noise
Technical Specification Range
Parameter |
Specification Range |
|---|---|
Target Vehicle Segment
|
Electric vans, light-duty trucks, minibuses, vocational LCVs
|
Vehicle GVW Coverage
|
Approx. 2.5 - 8 tons
|
Rated Power
|
30 - 90 kW
|
Peak Power
|
60 - 190 kW
|
Rated Torque
|
90 - 550 N.m
|
Peak Torque
|
223 - 1300 N.m
|
Maximum Speed
|
3,000 - 12,000 rpm
|
The Motor Control Unit (MCU) is always supplied together with the electric motor or electric axle, ensuring matched performance, validated compatibility, and simplified vehicle integration.
These controllers are developed to support flexible powertrain layouts, reduce system complexity, and streamline integration。
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 System for Light Commercial Vehicles
For light commercial vehicle applications, we provide application-matched traction battery systems configured to meet specific vehicle and duty-cycle requirements. Our offerings cover a complete battery system scope, including battery packs, battery management systems (BMS), thermal management systems (BTMS), and optional cloud-based monitoring tools to support system operation and lifecycle management.
Our standardized LFP traction battery packs are designed for light commercial vehicle applications and have been deployed across multiple vehicle platforms. Built with industry-standard materials and validated manufacturing processes, these packs employ a modular and standardized architecture that enables systematic optimization from cell to pack level. As a result, both module-level and pack-level energy density exceed typical industry benchmarks while maintaining robust safety margins.
Key Characteristics
High Safety & Reliability
Based on a high-safety LFP chemistry, with battery cells sourced from established Tier-1 suppliers. The pack structure and protection concept are designed to meet relevant automotive safety standards.
Flexible Capacity Configurations
Multiple capacity options are available to support different vehicle range targets and payload requirements, covering both standard-duty and extended-range applications.
Lightweight & High Energy Density
Optimized structural and electrical design enables a pack-level energy density of ≥140 Wh/kg, supporting improved vehicle efficiency and payload utilization.
Wide Operating Temperature Range
Liquid cooling and optional heating functions can be configured to ensure stable performance in high- and low-temperature operating environments.
Robust Mechanical Protection
IP67-rated enclosure design provides strong resistance against dust, water ingress, and harsh operating conditions.
Engineering Highlights
- Independently developed pack integration architecture adaptable to different cell formats and capacity configurations
- Custom-designed electrical topology and component selection, supported by in-house electrical validation and compliance testing
- Highly integrated safety architecture incorporating wiring harnesses, aluminum busbars, temperature sensors, internal pressure monitoring, explosion-proof valves, electrolyte leakage detection, and BMS interface boards
- Thermal runaway mitigation strategy using inter-cell insulation barriers and controlled pressure release mechanisms to limit propagation and enhance system-level safety
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) serves as the control and monitoring core of the traction battery system, responsible for ensuring safe operation, performance consistency, and long-term reliability. Working in coordination with battery cells and thermal management systems, the BMS continuously monitors key battery states, prevents abnormal operating conditions, and maintains the battery within defined safety and performance limits across varying duty cycles.
Our Development Capabilities
- In-house development of BMS control software and battery management logic
- Custom-designed control strategies and diagnostic algorithms tailored to different battery configurations and operating profiles
- Proprietary hardware design covering controller mainboards, control circuits, sensing circuits, and communication interfaces
- Hardware-software co-development approach to ensure consistency between control logic and physical architecture
Engineering Highlights
- High-accuracy state estimation: SOC accuracy ≤3%, SOH estimation accuracy ≤5%
- Three-tier BMS architecture: enables precise cell-level management, reducecs cumulative error, and supports long-term battery monitoring
- High-speed daisy-chain communiccation: delivers faster data transmission, lower power consumption, enhanced system stability, and strong resistance to electromagnetic interference and high-voltage stress
- High level of integration: optional BMS and PDU integration improves packaging efficiency, increasing effective energy density while reducing system volume and weight
- Scalable digital architecture: supports system-level data interfaces and optional edge-side or cloud-connected monitoring tools for battery operation analysis and service support
The Battery Thermal Management System (BTMS) is designed to maintain the traction battery within a defined operating temperature window under varying ambient conditions and duty cycles. By actively managing heat generation and dissipation during charging and discharging, the BTMS supports battery safety, performance stability, and service life, while enabling consistent operation across both high- and low-temperature environments.
Key Capabilities of the BTMS
- Real-time monitoring and control of battery temperature at pack and subsystem level
- Active heat dissipation under high thermal load conditions to prevent overheating and thermal propagation
- Battery heating functionality in low-temperature environments to support safe charging and stable power output
- Temperature uniformity control within the battery pack, reducing thermal gradients and supporting long-term durability
Engineering Highlights
- Lightweight aluminum alloy structural design to improve thermal efficiency and reduce system mass
- Optional PTC liquid heating module supporting multiple operating modes, including cooling, heating, standby, and self-circulation
- CAN bus communication interface enabling real-time system status reporting and fault diagnostics
- 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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