Brogen Oil-Cooled Hairpin Dual Motor System for 5-6 Ton Electric Loaders

Brogen officially launches its oil-cooled hairpin high-speed dual-motor system specifically engineered for 5-6 ton electric loaders. Delivering a robust 560kW of power with peak efficiency reaching 97.37% and a design lifespan exceeding one million kilometers, this system offers OEMs, construction machinery fleets, and conversion workshops a power solution that combines high safety reliability with outstanding cost-effectiveness.

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.

Core Technical Features of Brogen Oil-Cooled Hairpin Dual Motor System

Brogen introduces the industry’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.

Unlike common air-cooled or single-layer hairpin motors, this system delivers a leap in performance through three major technological innovations.

Ten-Layer Hairpin Flat-wire Winding

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, enabling peak motor efficiency of 97.37%. Over 90% of the operating range maintains efficiency above 90% (industry average is approximately 85%). Whether performing full-load lifting or hill-climbing operations, the motor maintains low-energy consumption.

Active Oil-Cooling

Innovatively integrates an active oil-cooling circulation system where cooling oil directly contacts the motor windings and rotor core. This achieves 50% higher heat dissipation efficiency than traditional liquid cooling, effectively maintaining motor operating temperatures below 80°C. Simultaneously, the oil-cooling system isolates moisture and dust from the air, significantly reducing the risk of internal motor condensation. This extends the system’s design lifespan to one million kilometers / 100,000 hours.

Single-Stage Reduction Transmission

Eliminating the commonly used two-speed transmissions in the market, 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. 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’s overall energy consumption by 8%-10%.

Unleash Power to Conquer All-Condition Challenges

For 5-6 ton electric loaders, power parameters directly determine operational efficiency and adaptability. Brogen’s dual-motor system delivers “high power, high torque, high speed” performance to cover all scenarios—from mining heavy-duty applications to infrastructure earthmoving and port handling. Specific parameters are as follows:

System Parameters	system power	420/560 kW
	system torque	2630/6440 Nm
	system speed	1528/3180 rpm
Motor Parameters	motor power	210/280 kW
	motor torque	335/820 Nm
	motor speed	6000/12500 rpm
	motor rated voltage	618 VDC
Motor Controller	IGBT	800
Single Reducer	gear ratio	3.926

Our Values

For Automotive Manufacturers

Reduce R&D cycles by 3-6 months; supports customized mounting points and cooling line interfaces without major chassis modifications.

For Construction Fleets

Retrofitting requires no structural disassembly; electrification significantly lowers energy consumption and operating costs.

For Commercial Vehicle Conversion Teams

Comprehensive technical training and engineer guidance ensure rapid mastery of conversion essentials; robust after-sales support minimizes maintenance risks.

Choosing Brogen means choosing an electric future defined by “Efficiency, Reliability, and Economy.”

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Contact Brogen – Leading EV Solutions Provider for Commercial Vehicles

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 inquiry@brogenmotors.com.

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