Centralized Electric Drive Axle for Trucks Explained

Introduction: The Electric Revolution in Commercial Transport

The transition to electric mobility isn’t limited to passenger vehicles. Medium and heavy-duty trucks—the workhorses of global commerce—are undergoing their own electrification revolution, increasingly adopting the Centralized Electric Drive Axle as a core solution. But trucks present unique challenges: they demand exceptional durability, high efficiency under heavy loads, and cost-effective scalability for fleet operations.

O sistema integrado de eixo de acionamento elétrico centralizado da Brogen oferece uma plataforma madura e pronta para produção, projetada especificamente para veículos comerciais de 4,5 a 49 toneladas. Vamos explorar por que essa tecnologia representa o futuro do transporte elétrico de carga.

What Makes Centralized Electric Axles Different?

Unlike distributed wheel-hub motors that place individual motors at each wheel, a centralized e-axle integrates the motor, transmission, and gearing into a single compact unit mounted on the vehicle’s axle. This intelligent consolidation delivers multiple advantages:

✅ Fewer Moving Parts – By eliminating the traditional hypoid main reduction gear and minimizing drivetrain stages, the system reduces mechanical complexity and potential failure points.

✅ Higher Efficiency – The simplified transmission path minimizes energy losses, delivering more power directly to the wheels while improving regenerative braking performance.

✅ Simplified Integration – Vehicle manufacturers can integrate a complete drivetrain module rather than assembling multiple components, reducing assembly time and complexity.

✅ Enhanced Serviceability – Modular design allows for easier maintenance and component replacement, crucial for fleet operations where uptime is critical.

Integrated Centralized Electric Drive Axle System Architecture

Technical Excellence of Centralized Electric Axles

Robust Structural Design

The foundation of any reliable truck axle is its housing. Brogen’s solution utilizes a one-piece rigid axle housing manufactured through hydraulic expansion forming, stamping/welding, or casting processes depending on the application. This provides:

Exceptional structural strength for medium and heavy-duty applications
Reliable load-bearing capability up to 13,000 kg axle loads
Optimized weight distribution with mass centered near the axle centerline
Improved NVH characteristics through better vibration management

Optimized Transmission Architecture

The heart of the system lies in its innovative transmission design. By combining parallel-shaft gearing with a shiftable planetary gear set, Brogen achieves a compact 4-speed configuration with an impressive overall ratio range from 10.2 to 71.0.

Key Innovation: The planetary shifting mechanism reduces oil splash speed compared to conventional layouts, resulting in significantly lower lubrication losses—a crucial factor in long-haul efficiency.

Brogen Integrated Centralized Electric Axle

Brogen Centralized Electric Axle Portfolio

Brogen offers a comprehensive range of centralized drive e-axles tailored to different vehicle segments and applications:

Modelo	Vehicle	Carga por eixo	Motor Power	Wheel Torque	Wheel End Output Torque
OESTEA5300Z	4.5-6 t truck	3500kg	60/120 kW	145/335 N.m	5300 N.m
OESTEA6640Z	4.5-6 t truck	4500kg	80/160 kW	175/400 N.m	6640 N.m
OESTEA40000Z-1	6×4 / 4×2 truck	13000kg	121/250 kW	320/850 N.m	40000 N.m
OESTEA40000Z-2	6×4 / 4×2 truck	13000kg	136/290 kW	326/860 N.m	40000 N.m
OESTEA39000Z	6×4 / 4×2 truck	13000kg	150/252 kW	285/550 N.m	39089 N.m
OESTEA45000Z-1	6×4 / 4×2 truck	13000kg	150/252 kW (dual motor)	285/550 N.m (dual motor)	45000 N.m
OESTEA45000Z-2	6×4 / 4×2 truck	13000kg	190/310 kW (dual motor)	280/590 N.m (dual motor)	45000 N.m

Data is for reference. Contact us for detailed specifications or customization options.

Efficiency Performance

For commercial operators, efficiency translates directly to operating costs and range. Brogen’s system delivers exceptional efficiency across all operating conditions:

Highway Efficiency (90 km/h Example)

Motors	Relação de marchas	Motor Speed@ 90km/h	Zero-Torque Power Loss	Efficiency@50 kW
Motor A	10.3	4600 rpm	800 W	>96.5%
Motor B	13.2	5936 rpm	1500 W	>96.0%

Centralized Electric Drive Axle for Trucks features of Low losses and high efficiency at highway speeds

Optimized Gear Steps

The transmission features carefully calibrated ratio steps that eliminate the need for excessively high shift points. For example, the shift from 1st to 2nd gear has a ratio step of only 2.4, keeping the motor operating within its high-efficiency region across varying loads and throttle conditions.

Dual-Motor Strategy Advantage

For applications requiring dual-motor configurations:

Two motors with different gear ratios ensure optimal operation in respective efficiency zones
Single-motor neutral mode minimizes drag losses during light-load operation
Reduced inverter requirements through intelligent torque distribution

Seeking a production-validated e-axle that balances reliability, configurability, and scalable supply?

Engineered for Reliability: Rigorously Tested and Production-Proven

Every Brogen e-axle is subjected to exhaustive testing before production. This includes comprehensive bench tests—covering durability, thermal performance, efficiency, and waterproofing—as well as real-world vehicle trials spanning over 12,000 km of accelerated durability and rough-road conditions.

Now in mass production since 2024, multiple variants are actively integrated into global OEM platforms, ensuring a mature and field-proven solution.

Designed for Flexibility: Flexible Configurations for Diverse Applications

Brogen’s platform offers versatile configurations to meet diverse operational needs. From efficient single-motor setups ideal for regional logistics to robust dual-motor systems designed for heavy-duty tasks, each option is engineered for reliability and performance. Integrated features such as PTO support, hydraulic outputs, and differential locks further enhance functionality across varied terrains and specialized requirements.

Brogen's platform offers versatile configurations for single-motor system and dual-motor system to meet diverse operational needs.

From Prototype to Production, We Partner at Every Stage

We support flexible procurement and rapid prototyping, with smooth scaling to full production through our certified in-house facilities and stable supply chain. Our agile approach ensures quality, speed, and reliability from your first pilot order through to high-volume delivery.

Conclusion: Ready for the Electric Truck Revolution

The transition to electric commercial vehicles isn’t a matter of “if” but “when.” With tightening emissions regulations, increasing total cost of ownership advantages, and growing sustainability mandates, electric trucks are rapidly becoming the smart choice for forward-thinking fleets.

Brogen’s centralized electric drive axle represents more than just a component—it’s a complete, validated, scalable platform that addresses the core challenges of electric truck adoption:

✅ Proven reliability through rigorous testing

✅ Exceptional efficiency that reduces operating costs

✅ Production-ready maturity with SOP already achieved

✅ Global compliance for worldwide deployment

✅ Complete integration from hardware to software

✅ Flexible configurations for diverse applications

✅ Strong support network for long-term success

Whether you’re an OEM developing a new electric truck platform, a fleet operator planning your electrification roadmap, or a converter adapting existing vehicles, Brogen provides the technology, expertise, and partnership to ensure your success.

Brogen specializes in integrated electric drivetrain systems for commercial vehicles. With deployments in over 30 countries, certified manufacturing facilities, and complete in-house R&D capabilities, we deliver production-ready solutions that combine technical excellence with commercial practicality. Our mission: to accelerate the transition to sustainable transport through innovative, reliable, and cost-effective electric propulsion systems.

Entre em contato com a Brogen - líder no fornecimento de soluções de EV para veículos comerciais

Na Brogen, somos especializados no desenvolvimento e na produção de sistemas de e-powertrain de alto desempenho e sistemas de baterias para veículos comerciais. Entre em contato com nossos especialistas em inquiry@brogenmotors.com.

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