40-Ton Electric Heavy Truck Project in Portugal

This project marks a significant milestone as we partnered with a new energy company in Portugal to successfully deliver their first all-electric heavy-duty truck, signaling a decisive step towards zero carbon emissions. It embodies our mission and underscores our commitment to accelerating the transition to green renewable energy, advancing humanity’s journey to carbon neutrality, and driving societal progress.

Project Overview

Project timeline: 2021

Offered products: E-powertrain system, power steering system, braking system, 3-in-1 converter

Application: 40-ton pure electric heavy truck

Provided services: Pre-sales consultation; solution planning; technical coordination; product testing; shipping; post-sales technical support; remote debugging

Challenge

Collaborating with this company on their first electric heavy-duty truck project presents both exciting prospects and challenges for both parties involved.

For them, embarking on their first electric heavy truck endeavor poses a learning curve. Given their parent company’s background in construction and energy storage, their newly established new energy department may lack the technical expertise needed for designing and developing comprehensive EV solutions. Additionally, the R&D costs could be substantial, potentially leading to longer project timelines and delayed vehicle launches.

For us, our foremost task is to establish clear lines of communication and grasp a thorough understanding of their requirements, preferences, and expectations for the heavy truck project. From there, we must devise tailored EV solutions to precisely meet their needs. Effective collaboration with their team is paramount to address any technical hurdles, tackle challenges head-on, and ensure seamless project execution.

Our Approach

In assisting this company in its EV truck project, our approach has been anchored in robust communication from inception to completion, ensuring a thorough understanding of our client’s needs.

We’ve tailored the EV solution precisely to their specifications, guiding them through any technical challenges encountered along the way.

Furthermore, we extend ongoing remote technical support and engage in cooperative discussions with their team to address any lingering technical concerns.

Solutions We’ve Provided

E-Powertrain System

We’ve equipped the truck with our 350 kW 2-in-1 integrated e-powertrain system, seamlessly combining the EV motor and gearbox alongside an independent MCU.

• Rated / peak power: 220 / 350 kW
• Rated voltage: 618 V
• Rated / peak speed: 1400 / 3000 rpm
• Rated / peak torque: 1500 / 2500 N.m

• Rated / peak current: 340 / 610 A
• Cooling method: liquid cooling

Control and Application Features

• Integrated motor: a streamlined design for convenient vehicle layout, eliminating phase harness EMC radiation while minimizing energy loss.
• Real-time weight measurement: ensures precision within 10%, while dynamic slope measurement boasts an accuracy of ±0.2° and static accuracy of ±0.1°.
• Adaptive shift timing: responds to factors like vehicle weight, slope, and driver input, including throttle system, pedal depth, and acceleration, adjusting shift points dynamically. Shift time clocks in at under 0.7s.
• Digital intelligent shifting: employs an electronically controlled shifting system for precise gear changes, enhancing overall performance.

Power Steering System

We have applied the 4 kW electric hydraulic power steering system (EHPS) on the truck. With the integrated design that combines a motor, steering pump, ECU, DC power processing, and oil tank into a single unit, this maximizes space utilization, simplifies system integration, and offers compact size and lightweight.

• Rated / peak power: 4 / 10.75 kW
• Rated voltage: AC 380 V
• Rated / peak current: 7.4 / 19.2 A
• Rated / peak torque: 34.2 / 85.6 N.m
• Rated / peak speed: 1200/ 1281 rpm
• Rated efficiency: 92%
• Working frequency: 80 Hz

Braking System

We have used the 4 kW oil-free air brake compressor for the electric heavy truck. With the latest technology, our air compressor delivers air that's entirely oil and water-free, eliminating concerns of oil emulsification, leaks, and fire hazards. Its innovative structural design minimizes energy waste during compression, optimizing efficiency.

• Rated exhaust: 380 L/min
• Rated exhaust pressure: 1 Mpa
• Exhaust pressure: 1.2 Mpa
• Dimensions: 560*335*370 mm
• Motor power: 4 kW
• Weight: 65 kg
• Operating temperature: -40°C ~ + 60°C
• Protection class: IP67

Converter System

We have used the 3-in-1 converter for the project, which consists of a DC/DC converter, a DC/AC oil pump, and a DC/AC air compressor. This integrated and lightweight design significantly reduces system weight and size. It not only offers a lightweight solution but also delivers substantial space, wiring, and cost savings for electric commercial vehicles.

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