{"id":1755,"date":"2025-10-11T09:53:11","date_gmt":"2025-10-11T09:53:11","guid":{"rendered":"https:\/\/www.brogenmotors.com\/?p=1755"},"modified":"2026-04-27T03:05:20","modified_gmt":"2026-04-27T03:05:20","slug":"oil-cooled-hairpin-dual-motor-system-for-electric-loaders","status":"publish","type":"post","link":"https:\/\/www.brogenmotors.com\/ja\/oil-cooled-hairpin-dual-motor-system-for-electric-loaders\/","title":{"rendered":"Brogen Oil-Cooled Hairpin Dual Motor System for 5-6 Ton Electric Loaders"},"content":{"rendered":"<p class=\"wp-block-paragraph\"><mark style=\"background-color:rgba(0, 0, 0, 0)\" class=\"has-inline-color has-vivid-green-cyan-color\">Brogen officially launches its oil-cooled hairpin high-speed dual-motor system specifically engineered for 5-6 ton electric loaders. <\/mark>Delivering a robust <mark style=\"background-color:rgba(0, 0, 0, 0)\" class=\"has-inline-color has-vivid-red-color\">560kW<\/mark> of power with peak efficiency reaching <mark style=\"background-color:rgba(0, 0, 0, 0)\" class=\"has-inline-color has-vivid-red-color\">97.37%<\/mark> and a design <mark style=\"background-color:rgba(0, 0, 0, 0)\" class=\"has-inline-color has-vivid-red-color\">lifespan exceeding one million kilometers<\/mark>, this system offers OEMs, construction machinery fleets, and conversion workshops a power solution that combines high safety reliability with outstanding cost-effectiveness.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">5-6 ton loaders are essential construction machinery for mining transportation and construction site handling. Operating in demanding environments with high-intensity workloads, these machines require an efficient, reliable, and long-lasting electric powertrain. <\/p>\n\n\n\n<h2 class=\"wp-block-heading\">Core Technical Features of Brogen Oil-Cooled Hairpin Dual Motor System<\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">Brogen introduces the industry&#8217;s first dual-motor system with ten-layer hairpin oil-cooled technology. Designed for new energy commercial vehicles and construction machinery, it solves key problems of traditional electric loaders: lack of power, overheating, and short service life.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Unlike common air-cooled or single-layer hairpin motors, this system delivers a leap in performance through three major technological innovations.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\"><\/p>\n\n\n\n<h3 class=\"wp-block-heading\">Ten-Layer Hairpin Flat-wire Winding<\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">The Hairpin flat wire winding design increases conductor density by 40% compared to traditional round wires, achieving a motor slot fill rate exceeding 75% and significantly reducing copper losses. The ten-layer stacked structure further optimizes the electromagnetic path, <mark style=\"background-color:rgba(0, 0, 0, 0)\" class=\"has-inline-color has-vivid-green-cyan-color\">enabling peak motor efficiency of 97.37%. Over 90% of the operating range maintains efficiency above 90% <\/mark>(industry average is approximately 85%). Whether performing full-load lifting or hill-climbing operations, the motor maintains low-energy consumption.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\"><\/p>\n\n\n\n<h3 class=\"wp-block-heading\">Active Oil-Cooling<\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">Innovatively integrates an active oil-cooling circulation system where cooling oil directly contacts the motor windings and rotor core. <mark style=\"background-color:rgba(0, 0, 0, 0)\" class=\"has-inline-color has-vivid-green-cyan-color\">This achieves 50% higher heat dissipation efficiency than traditional liquid cooling<\/mark>, effectively maintaining motor operating temperatures below 80\u00b0C. Simultaneously, the oil-cooling system isolates moisture and dust from the air, significantly reducing the risk of internal motor condensation. <mark style=\"background-color:rgba(0, 0, 0, 0)\" class=\"has-inline-color has-vivid-green-cyan-color\">This extends the system&#8217;s design lifespan to one million kilometers \/ 100,000 hours<\/mark>.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\"><\/p>\n\n\n\n<h3 class=\"wp-block-heading\">Single-Stage Reduction Transmission<\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">Eliminating the commonly used two-speed transmissions in the market, <mark style=\"background-color:rgba(0, 0, 0, 0)\" class=\"has-inline-color has-vivid-green-cyan-color\">it adopts a customized single-stage parallel-shaft reduction structure with a gear ratio of 3.926. This perfectly matches the operating speed requirements of 5-6 ton loaders.<\/mark> This single-stage design reduces moving parts by 70%, lowers failure rates by 60%, and eliminates maintenance costs for shift mechanisms, saving construction fleets substantial annual repair expenses. The streamlined structure also reduces system weight by 15%, further lowering the loader&#8217;s overall energy consumption by 8%-10%.<\/p>\n\n\n\n<figure class=\"wp-block-image size-full\"><img decoding=\"async\" src=\"https:\/\/www.brogenmotors.com\/wp-content\/uploads\/2025\/10\/Features-of-Brogen-Oil-Cooled-Hairpin-Dual-Motor-System-for-5-6-Ton-Electric-Loaders.png\" alt=\"\" class=\"wp-image-1762\"\/><\/figure>\n\n\n\n<p class=\"wp-block-paragraph\"><\/p>\n\n\n\n<h2 class=\"wp-block-heading\">Unleash Power to Conquer All-Condition Challenges<\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">For 5-6 ton electric loaders, power parameters directly determine operational efficiency and adaptability. Brogen&#8217;s dual-motor system delivers \u201chigh power, high torque, high speed\u201d performance to cover all scenarios\u2014from mining heavy-duty applications to infrastructure earthmoving and port handling. Specific parameters are as follows:<\/p>\n\n\n\n<figure class=\"wp-block-table\"><table class=\"has-fixed-layout\"><tbody><tr><td>System Parameters<\/td><td>system power<\/td><td>420\/560 kW<\/td><\/tr><tr><td><\/td><td>system torque<\/td><td>2630\/6440 Nm<\/td><\/tr><tr><td><\/td><td>system speed<\/td><td>1528\/3180 rpm<\/td><\/tr><tr><td>Motor Parameters<\/td><td>motor power<\/td><td>210\/280 kW<\/td><\/tr><tr><td><\/td><td>motor torque<\/td><td>335\/820 Nm<\/td><\/tr><tr><td><\/td><td>motor speed<\/td><td>6000\/12500 rpm<\/td><\/tr><tr><td><\/td><td>motor rated voltage<\/td><td>618 VDC<\/td><\/tr><tr><td>Motor Controller<\/td><td>IGBT<\/td><td>800<\/td><\/tr><tr><td>Single Reducer<\/td><td>gear ratio<\/td><td>3.926<\/td><\/tr><\/tbody><\/table><\/figure>\n\n\n\n<h2 class=\"wp-block-heading\" id=\"challenges-in-pickup-truck-conversions\">Our Values<\/h2>\n\n\n\n<h3 class=\"wp-block-heading\">For Automotive Manufacturers<\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">Reduce R&amp;D cycles by 3-6 months; supports customized mounting points and cooling line interfaces without major chassis modifications.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\">For Construction Fleets<\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">Retrofitting requires no structural disassembly; electrification significantly lowers energy consumption and operating costs.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\">For Commercial Vehicle Conversion Teams<\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">Comprehensive technical training and engineer guidance ensure rapid mastery of conversion essentials; robust after-sales support minimizes maintenance risks.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\"><mark style=\"background-color:rgba(0, 0, 0, 0)\" class=\"has-inline-color has-vivid-red-color\">Choosing Brogen means choosing an electric future defined by \u201cEfficiency, Reliability, and Economy.\u201d<\/mark><\/p>\n\n\n\n<p class=\"wp-block-paragraph\"><\/p>\n\n\n\n<hr class=\"wp-block-separator has-alpha-channel-opacity\"\/>\n\n\n\n<h2 class=\"wp-block-heading\" id=\"contact-brogen-a-trustworthy-electric-motor-manufacturer\">Contact Brogen &#8211; Leading EV Solutions Provider for Commercial Vehicles<\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">At Brogen, we specialize in the development and production of high-performance e-powertrain systems and battery systems for commercial vehicles. Reach out to our experts at <em><a href=\"mailto:inquiry@brogenmotors.com\">inquiry@brogenmotors.com<\/a><\/em>. <\/p>\n\n\n\n<p class=\"wp-block-paragraph\">\u6700\u65b0\u30cb\u30e5\u30fc\u30b9\u306b\u3064\u3044\u3066\u306f\u3001\u3053\u3061\u3089\u3092\u3054\u89a7\u304f\u3060\u3055\u3044 <a href=\"https:\/\/www.linkedin.com\/company\/brogen-ev-solutions\/posts\/?feedView=all\">\u30d6\u30ed\u30fc\u30b2\u30f3\u306eLinkedIn<\/a>. For more videos please click <a href=\"https:\/\/www.youtube.com\/@BrogenPowertrain\/videos\">Brogen\u306eYouTube\u30c1\u30e3\u30f3\u30cd\u30eb<\/a>. Find more about Brogen&#8217;s <a href=\"https:\/\/www.brogenmotors.com\/ja\/\">ev solutions for commercial vehicles<\/a>.<\/p>","protected":false},"excerpt":{"rendered":"<p>Brogen officially launches its oil-cooled hairpin high-speed dual-motor system specifically engineered for 5-6 ton electric loaders.<\/p>","protected":false},"author":1,"featured_media":3799,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"rs_blank_template":"","rs_page_bg_color":"","slide_template_v7":"","footnotes":""},"categories":[115,116],"tags":[],"class_list":["post-1755","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-news","category-our-projects"],"yoast_head":"<!-- This site is optimized with the Yoast SEO Premium plugin v28.6 (Yoast SEO v28.7) - https:\/\/yoast.com\/product\/yoast-seo-premium-wordpress\/ -->\n<title>Oil-Cooled Hairpin Dual Motor System for Electric Loaders<\/title>\n<meta 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