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Integration - Engine Development Trends
Speaking of technology trends in heavy truck products, the first thing that comes to mind is intelligence. In the past, automatic transmissions, post-processing systems, ABS, navigation, fuel consumption meters, etc. all had their own respective ECUs (Electronic Control Units), which were independent of each other and were designed and manufactured by different companies. The mutual communication between these ECUs is difficult, usually through the CAN bus, but the CAN bus has a higher price, and the more CAN buses, the more fault points. Later, the engine manufacturers began to integrate all the control functions into the ECU of the engine. For example, the engine ECU can control the brakes, ABS, etc., so that the entire system is simpler and the communication speed is improved. This kind of intelligent development is not difficult. It needs to be solved by ECU developers and engine manufacturers. At present, GPS, installment management systems, etc. have been integrated into the engine ECU.
New materials help reduce weight
The lightweight design of Dongfeng Commercial Vehicle is not only to save materials and reduce its own weight, but also to reduce energy consumption, reduce emissions, improve operational efficiency and safety of driving. In particular, after the toll-by-weight, the transport industry was standardized. On the provincial and national highways, the total mass limit of 55 tons was well implemented, which also pointed out the direction for the design and manufacture of the manufacturers. China National Heavy Duty Trucks also attaches great importance to lightweighting. In 2010, Sinotruk introduced a lightweight system project and used high-strength alloy frames, rubber suspensions, aluminum alloy transmissions and other new technologies, new materials, and new technologies to realize complete vehicles. Lightweight.
Using new materials is an important way to achieve lightweighting. On February 21, 2011, China Steel Research Institute had successfully developed the third generation of automotive steel for the first time, and for the first time entered the development and trial production of industrial products, and it is expected to be commercially applied in 2014 at the earliest. The third generation of automotive steel was first proposed by the Americans in 2007 and initiated research and development projects. Compared with the previous two generations of automotive steel, the third generation of automotive steel achieved an effective combination of light weight and safety. The cost of the third-generation automotive steel is only 5% higher than that of ordinary steel, but its long life cycle also saves steel and saves oil. At the same time, the safety of the third-generation automotive steel is high, and the mortality rate under normal collisions is very low. The third-generation automotive steel hot-rolled coils and cold-rolled sheets have a strong plastic product exceeding 30 GPa% (a tensile strength of 900 MPa and an elongation of 35%), which is more than four times that of the first-generation automobile steel. The alloy content is less than 1/3 of the second-generation automotive steel.
In addition to adopting new materials, the lightweight design of domestic heavy trucks is mainly reflected in the following aspects:
1. Adopt a leaf spring with a small cross-section and a leaf spring. Since the leaf springs are all metal parts and have a large weight, the weight of the leaf springs is also an important measure to reduce the service quality. The variable cross-section leaf spring is composed of several leaf springs with variable cross-sections in the longitudinal direction, which can not only reduce the weight but also improve the comfort of driving and shorten the service life by reducing the friction between the leaf springs. In addition, the use of rubber suspension or air suspension can also reduce the weight of the suspension system.
2. Use single-layer frame girders. Compared to leaf springs, the weight of the frame is even greater, and effectively reducing the weight of the frame will greatly reduce the overall quality.
3. Use composite materials. The cab is the assembly with the most composite materials, especially the outer cover, including the front panel, angled panels, fenders, bumpers and even the top cover. On the one hand, it effectively reduces the weight of the entire vehicle; on the other hand, due to the good formability of the composite material, the molding structure can be more complex, more beautiful, and more precise in size than the metal stampings.
4. Use aluminum alloy material. Aluminum alloys have a lower density than steel, and some composite materials cannot be replaced with aluminum alloys, including sheet metal parts and castings. A large number of aluminum alloys are also used in rims, engine blocks, transmissions, etc. to ensure maximum strength and rigidity while minimizing weight.
5. Use high-strength steel. This can reduce the thickness of the steel plate, thereby reducing the weight. Cold-rolled steel sheets used to make the body and hot-rolled steel sheets used to make the frame can be made of high-strength steel to increase the strength of the car and reduce its own weight.
Increased reliability
To put it plainly, reliability is not a problem. According to the current market rules, what kind of car is usually set by the customer, what kind of product we will do, so there will be many new problems. The CAE method was used to analyze the fracture data of the stents to identify problems during assembly and design. CAE is mainly for structural analysis. In addition, there are CFD, collision, fatigue, and NVH analysis.
Reliability is also an area where Dongfeng Commercial Vehicles has recently paid close attention, and the focus is on reliability improvement. In the past 1-2 years, more work has been done in this area. In particular, tractors have a high demand for timeliness. More stringent requirements are placed on reliability. On the technical side, Dongfeng Commercial Vehicles has to prevent re-initiated processes and reduce the time for failures, such as increasing the damage to 80,000 kilometers after the vehicle has traveled 50,000 kilometers. In addition, we conduct checks on the quality of parts and components, build high-end supplier platforms, and establish strategic partnerships with outstanding suppliers.
New energy is mainly based on natural gas
Different from the new energy buses adopting hybrid, pure electric, and natural gas, the new energy trucks are mostly natural gas trucks because of the limited use conditions. Natural gas heavy trucks are gas-fueled heavy-duty vehicles that use natural gas as fuel (CNG is compressed natural gas; LNG is liquefied natural gas). According to different fuel use conditions, they can be divided into single-fuel natural gas vehicles (engines use only CNG or LNG as fuel), dual-fuel natural gas vehicles (using diesel + natural gas, or using gasoline + natural gas as fuel). The most widely used currently is a single-fuel natural gas vehicle.
At the 2010 Beijing International Auto Show, many truck companies brought natural gas products: The FAW Jiefang J5P natural gas traction vehicle uses a CA6SL2-30E3N engine with a displacement of 8.6 liters, a rated power of 231 kW and a maximum torque of 1,100 N•m. Beiben V3 series natural gas tractors, engine WP10NG300E40, the maximum power of 221 kilowatts, the maximum torque of 1230 cattle • meters. In addition, Changan Heavy Duty Truck also brought in CNG 6×2 tractors, LNG 6×4 tractors and CNG 6×4 dump trucks. The LNG truck market has a promising future. The Twelfth Five-Year Plan is a period of high-speed growth of natural gas heavy trucks and will surely become an important market segment for heavy truck companies.
Big horsepower becomes a trend
With the changes in economic development and market demand, the development of heavy trucks in the direction of high power has become a trend.
Still taking the 2010 Beijing International Auto Show as an example, among the engines that match the entire vehicle, the power of the engine carried by the combined truck is the largest, and the power of the YC6K460-40 engine on the 6×4 tractor is 460 horsepower. The combined truck dump truck with the YC6K420-30 also achieved 420 horsepower. The separate demonstration of the Yuchai YC6K12 engine's calibration power is as high as 400 horsepower to 520 horsepower. For Yuchai, which does not have much advantage in high-horsepower engine sales, it is just to promote the high-powered engine with the help of the new brand, the joint truck, so as to increase its market share in this field.
The Mercedes-Benz OM457LA engine at the Aumann booth is also large, covering 360 horsepower to 456 horsepower. The engines of other exhibitors' brands are mostly concentrated between 290 hp and 425 hp.
From the current situation of China's import of heavy trucks, large-tonnage, high-power heavy trucks also occupy an absolute dominant position in imported trucks, and the installed engine power range is 410-450 hp, which is increasing year by year. In 2001, the power of the domestic main truck model was only 180 horsepower. In 2002, it increased to 240 horsepower. In 2003, it was 280 horsepower. By 2009, it had reached 300 to 400 horsepower.
The trend of high-capacity domestic heavy trucks is also consistent with the international heavy truck industry. The sales volume of U.S. 4 to 5 trucks accounts for not more than one-fifth of their total sales; the sales of trucks of Grades 6 to 7 account for one-third of the sales; and the sales of vehicles with grades 8 and above account for more than 1/2. From the perspective of the structure of sales products, the higher the load level of products, the greater the market sales, and gradually occupy the dominant position. In Japan, the standard for heavy-duty vehicles in the past was extremely limited to a total mass of 26 tons. This is in contrast to the largest standards set for heavy vehicles in Europe and the United States. In order to bring heavy-duty vehicle standards into line with Europe, Japan plans to revise the standards by increasing the standard gross tonnage of heavy-duty vehicles to over 40 tons and the engine output power from 257 to 368 kilowatts. In accordance with the newly revised standards, a number of Japanese truck manufacturers are developing oversized vehicles such as Hino's “Super Dolphin†and Nissan’s “thumbs†heavy-duty vehicles. It is expected that in the next 10 years, the maximum power of the truck will reach 735 kilowatts (1000 horsepower) and the total mass will reach 100 tons.
Trains increase transportation efficiency
In 2010, the country’s road freight volume reached 16 billion tons and the total number of trucks was approximately 7 million. It is estimated that by 2020, the country’s road freight volume will reach 20 billion tons and the total number of trucks will be about 10 million. Among them, heavy trucks will become the main growth point due to their advantages in transportation efficiency. In the next 10 years, a new heavy truck market with a sales volume of about RMB 600 billion will be added.
When visiting Ordos, it was discovered that the mining area is popular with truck trains. Trains have obvious advantages, which can improve transportation efficiency and reduce fuel consumption per ton-kilometer. Trains are adapted to specific conditions, such as inter-provincial transportation.
The trend of specialization is obvious
Specialization is also a major development direction. Special vehicle products have strong functions and high technical content, and are mainly concentrated in the two major sectors of urban construction services and high-grade highway transportation management.
A heavy truck dealer in Shaanxi revealed that before, they could not sell several special vehicles each year, and now special vehicles have become an important part of sales.
According to statistics, the market share of China's special-purpose vehicles accounts for 40% of all trucks, and there is a clear gap between the market share of more than 70% of special-purpose vehicles in developed countries. In Europe and the United States, the light, medium, and heavy trucks have a ratio of 3:4:3, while China currently only has a ratio of 3:5:1. There are more medium-sized special vehicles and fewer heavy-duty vehicles. The irrational product structure contrasts with the increasingly diversified and individualized user demands, which reflects that there is still a certain gap between the technical level of China's special vehicles and advanced countries in Europe and America.
Increased security
Baotou Bei Ben Heavy Duty Truck Co., Ltd. introduced that with the increasingly mature logistics industry, the life safety of drivers has become an important consideration for truck manufacturers in design and R&D. Beiben heavy trucks are 0.2mm thicker than others, and at the same time, the engine will sink to a certain degree after impact, which can reduce the damage to the driver. So far, Beiben users have not been killed in traffic accidents.
In addition, the safety of China National Heavy Duty Truck A7 is also excellent. In 2010, a Haoqi A7 concrete mixer dropped from a viaduct in Harbin City, Heilongjiang Province. The driver was basically unharmed and the car could continue to drive. Coincidentally, one of the Haoyu A7 tractors purchased by a Nanjing user hit a bridge pier on the Nantong highway and the cab was severely damaged, but the two drivers suffered only minor injuries. It is understood that the main body of the A7 cab is an integral steel frame structure, which has strong resistance to impact and resistance to external forces. The body is welded on the automatic robot production line jointly designed with foreign experts. All the modern procedures control the operation and reach the world advanced level. At the same time, it has added a domestically-advanced lateral stabilizer for the driver's cab and is equipped with the first powerful anti-collision and anti-drilling protection armored in China.