In March 2009, the China Automotive Manufacturers Equipment Innovation Alliance convened the “12th Five-Year Plan for Automobile Manufacturing Equipment Innovation Project†meeting of the China Automotive Equipment Manufacturing Innovation Alliance in Qiqihar. In just over six months, 39 projects were solicited. Several of these projects have world-class automotive advanced manufacturing technology and are the first answer for the China Automotive Manufacturing Equipment Innovation Alliance to respond to the world's green revolution in automobiles. They have distinctive features such as light weight, environmental protection, and green manufacturing.
Lightweight manufacturing equipment
Developed countries in the automotive industry, such as the United States, Japan and Europe, have spent many years researching and set a target of 3 liters of fuel consumption for 100 kilometers in 2010 for the car industry. Among the many measures to reduce fuel consumption and reduce emissions, measures to reduce the weight of the car body have gained widespread attention in the automobile manufacturing industry. The data shows that for every 100 kilograms of car weight, the fuel consumption per 100 kilometers can be reduced by 0.4 to 1.0 liters, and the reduction in vehicle weight by 10% can achieve a fuel saving rate of up to 8%. Reducing the weight of vehicles in order to reduce fuel consumption has become the key to improving the competitiveness of major auto manufacturers in the world. In the project applications we received, lightweight manufacturing equipment is one of the biggest hot spots. The areas involved are:
The first is the tailoring of laser tailored blanks to form forming technology and equipment; the second is the forming of cold and hot forming technology and equipment for high-strength/ultra-high-strength steel body stamping parts; the third is internal high-pressure forming technology and equipment; and the fourth is superplastic forming of aluminum alloys. Technology and equipment.
Among them, the fourth aluminum superplastic forming technology and equipment in use, aluminum parts weight loss effect of up to 30% to 40%. For every kilogram of aluminum used, the passenger car can reduce the emission of 20 kilograms of exhaust gas during its lifetime. At the same time, aluminum is a green material that can be recycled. The energy saved by using aluminum is 6 to 12 times the energy consumption of the primary aluminum used to produce the part.
At present, almost all famous car manufacturers in North America, Europe and Japan use aluminum alloy materials as much as possible on new models. In 1999, the A2 model launched by Audi Company, compared with the equivalent steel models, reduced weight by 43%; later appeared AudiA8, through the laser welding and riveting method to connect the aluminum alloy sheet metal parts to the aluminum alloy space frame, Nearly 50% weight loss. At Ford Motor Company, the all-aluminum structural body was used to commemorate the 100-year anniversary of the FordGT commemorative car. Nearly all of the covers were produced using superplastic forming technology. In Europe, the use of light alloys for each car has exceeded 120 kilograms, accounting for 10% of the car's own weight. In some structural parts, there is a trend of “aluminum substitute steelâ€. The use of aluminum alloy plates instead of steel plates for the manufacture of automotive panels has been one of the most important trends in the current automotive industry. However, only a few foreign companies can produce these 5083 aluminum alloy plates.
In China, the current use of light alloys per vehicle is about 50% of the advanced level in foreign countries, while the precision plastic forming parts of aluminum alloys are fewer, only one third of foreign countries, and there is an overall gap with foreign countries. The performance of light alloy components is small and the quality cannot meet the requirements for use. What is more important is that China has not yet developed special equipment for the near-net shape formation of light alloys. The key technologies and equipments need to be imported and controlled by others and have become a constraint on the development of automobile manufacturing technology in China. One of the bottlenecks.
To this end, research and development of processes and equipment suitable for the formation of advanced materials with independent intellectual property rights to form a technical platform for the research and development of aluminum alloy coverings is the need for China to transform itself from a large automobile manufacturing country to a strong automobile manufacturing country, and also to save energy and reduce emissions. The need to build a harmonious society and promote healthy global development.
Energy saving and environmental protection manufacturing equipment for traditional engines
After the output of automobiles exceeds 10 million, the pressure on energy conservation and environmental protection in China is increasing. At present, China’s gasoline consumption accounts for approximately 86% of gasoline production, emissions account for about 24% of atmospheric pollution, and will soon rise to more than 30% (the current Western countries account for 33% to 34%).
The energy saving and environmental protection technology route of the engine is divided into energy saving and environmental protection technologies for new energy engines and traditional engines. The energy saving and environmental protection technology route for traditional engines is divided into dieselization and miniaturization. It is very gratifying to note that we have received applications for these two routes.
——Electric Control Common Rail Diesel Injection System Key Parts Manufacturing Equipment
The diesel engine saves more than one-third of the fuel compared to the gasoline engine, but the conventional mechanically controlled diesel engine has poor emissions, and has great vibration and noise. Most multinational corporations have invested heavily in the development of electronically controlled diesel common rail fuel systems in the early 90s of last century. After the technology was applied to diesel engines, the vibration and noise were greatly reduced, and the emission and energy saving levels were also improved. In the late 1990s, the electronically controlled common-rail fuel system began to be marketed in a few developed countries. Due to its advantages of energy saving and environmental protection, the development speed is amazing. The electronically controlled common rail fuel system is widely used in commercial vehicles, cars and passenger cars, and has become a revolutionary breakthrough in the automotive industry.
The mechanical components of the electronically controlled common-rail fuel injection system are the high-pressure fuel supply pumps, common rails and injectors. In these assemblies, the plunger coupler, injector coupler, inlet and outlet valve coupler, inlet metering or control valve, injection control valve, injector coupler, restrictor valve, pressure relief valve, etc. The components are all high-precision couplings that require high levels of cooperation. It is not only required that the moving parts be flexible, but also that the clearance is small enough to make the leakage of 160-180 MPa high-pressure oil as small as possible, which will serve as a high-pressure seal. Thus, the basic requirements for manufacturing equipment are various micro-nanometer precision machine tools, as well as precision assembly and inspection equipment.
In addition to automobiles, the use of electronically controlled common rail systems includes all types of military vehicles, ships, and agricultural machinery. The long-term market demand will reach more than 10 million sets, and the industrialized reasonable scale will not be less than 500,000 sets. In view of this, the basic requirements for designing machining and assembly manufacturing systems are: lean, agile, and flexible automatic lines. Therefore, the design of the manufacturing system, the purchase of equipment, and the gradual localization are key issues.
——The turbocharger key components manufacturing equipment with independent intellectual property rights
Small-sized engines or the most practical energy-saving emission reduction routes. In terms of both fuel economy and power performance, the turbocharger technology of the engine solves this problem. At present, the turbocharged models used in the domestic market are more common in large-displacement vehicles of 1.8L and above, while turbocharged “Tâ€-powered cars have become popular recently in small-displacement vehicles of 1.6L and below. trend. The “turbine storm†that appeared in the automotive industry in China in the first half of this year has been scrapped to a wider range of small-displacement vehicles. It has also made turbocharging technology more and more “close to the peopleâ€. For example, Chang'an, Chery, etc. are carrying out a small-displacement power-raising strategy. It is proposed that 0.8T power can reach 1.3L, 1.0T power can reach 1.8L, and 1.6T power can reach 2.0L or more.
Turbocharging technology is becoming the mainstream of global vehicle development, and Europe is leading the world. According to statistics, by the end of 2008, 50% of vehicles in Europe were using turbocharging technology. In 2008, the global output of turbochargers was 18 million units, and domestic brands were only about 1 million. With the increasing demand for energy-saving and emission-reduction, turbocharger applications are increasing rapidly: the annual growth rate of diesel turbochargers is 50%, and the annual growth rate of gasoline turbochargers is 180%.
The powder injection molding turbocharger rotor is the core component of the turbocharger. It is superior to the casting in both performance and economy. The independent research and development of the powder injection molding turbine rotor is a key technology to promote the turbocharger industry in China.
The green revolution of the manufacturing process
Metal or ceramic powder injection molding technology combines the advantages of the injection molding process and powder metallurgy technology. It is an emerging net forming manufacturing technology that enables cost-effective production of three-dimensional, complex-shaped components in large quantities.
Powder injection molding key auto parts have been widely used in the automotive industry in Europe and America, including turbocharger rotors, guide vanes, synchronizer gear hoops and so on.
High-performance injection molding machines and degreased sintering furnaces that produce such products are basically monopolized by European and American companies. The world's powder injection molding process has developed extremely rapidly. In 2009, the global powder injection molding products exceeded US$1 billion, and the average annual growth rate from 2004 to 2009 was 8.4%. In 2008, the total annual production volume of metal injection molded auto parts in the world was 1205.6 tons, of which Europe accounted for 50%, Asia accounted for 28.2%, and the Americas accounted for 21.8%. Products in Asia are mainly produced in Japan, Singapore, and China Taiwan, and China is basically zero in powder injection molding products for key auto parts. According to the current annual growth rate of the powder injection molding market by 10%, by 2020, China's powder injection molding products will reach 9,000 tons/year (sales of approximately RMB 6.8 billion/year), of which auto parts will exceed 2,500 tons/year. Year (sales of approximately RMB 1.9 billion/year). If the average cost saving rate of powder injection molding is 20% compared with machining, the annual cost saving will be approximately RMB 1.4 billion by 2020, and the cumulative savings from 2009 to 2020 will be RMB 12 billion; by 2020, China will use There will be more than 1,700 high-performance injection molding machines for powder injection molding, and more than 270 continuous degreasing sintering furnaces (45 tons/year capacity). According to the current import equipment injection machine 500,000 yuan / Taiwan's price calculation, continuous sintering degreasing furnace 15 million yuan / Taiwan, cumulative equipment import savings 4.9 billion yuan savings.
Amulet for truck safety - Engine brake with independent intellectual property rights
The engine braking system is a safety amulet for trucks and is currently required by European and American countries for high-power diesel engines. In the North American market, 90% of heavy trucks are equipped with engine brakes. Because it is directly related to the safety of heavy-duty trucks, and can effectively avoid heavy-duty trucks caused by brake heat failure caused by the accident. In 2004, the number of cars in Europe reached 232 million, the number of road traffic deaths was 44,000, the number of deaths in road traffic/ownership per 10,000 cars was 1.9, the U.S. car ownership reached 235 million, and the number of road traffic deaths was 43,000. Traffic deaths/ownership per 10,000 vehicles = 1.83 people. The number of road traffic deaths/car ownership in China is more than 16 times that of Europe and the United States! Research shows that if comprehensive measures are not taken, the number of accident deaths in China before and after 2015 may exceed 200,000 people/year, causing a heavy social and economic burden.
The Chinese government has long seen the necessity of installing auxiliary brakes on heavy trucks, and in 1999 it issued regulations and regulations concerning auxiliary brakes (retarders) on heavy trucks, which are limited to two years. However, laws and regulations have not been implemented as scheduled due to inadequate technology or high prices.
So far, most of China's trucks have no engine brakes, only exhaust brakes (butterfly valves) or external tanks and plumbing systems that cool the brake pads/drums. The brake power of the vehicle is far from enough. Due to the heat failure of the service brake (friction type brake), the vehicle crash accident often occurs. In addition, frequent replacement of service brake components increases vehicle maintenance costs and reduces the vehicle's operating efficiency. Therefore, it is imperative for Chinese trucks to use engine brakes.
The project's declared product "solid-chain engine brake system integrated in the engine" is the first of its kind at home and abroad, so there is no competition for similar products. After the completion of the project, the safety performance of China's trucks will reach the international advanced level, and road traffic deaths will be greatly reduced. If the number of road traffic deaths/car ownership and the US-Europe gap between China and the United States drops to eight times after taking comprehensive measures, the number of deaths from accidents in China before and after 2015 may drop to 100,000 people per year.
(This article is an excerpt from a report made by Chen Changnian, Minister of Equipment, China Automotive Engineering Society)
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