Analysis of Lightweight Development Trend of Domestic Trucks in China
The final product will be 40%-45% tire oil (fuel oil), carbon black and 35% carbon black, 10% steel and another 5-10% recycled gas (CH4-C4H10). Plastic Recycling Production Line Waste Tyres Recycling to Fuel Machinery,Wastes to Energy Machinery,Wastes to Fuel Machinery Henan Lanning Technology Co., Ltd , https://www.lanningrecycling.com
With the acceleration of China’s economic development and urbanization process, the low-carbon life is gradually established and deeply rooted in people’s minds. The gradual establishment and implementation of energy conservation and emission reduction, green environmental protection policies and regulations, and the acceleration of the pace of building a resource-saving and environmentally friendly society Energy conservation has become a key research topic in the development of the automotive industry. The concrete manifestation is that the domestic logistics industry is developing in the direction of “high efficiency, high technology, and high environmental protectionâ€. 
The lightweighting of automobiles is a reflection of the improvement of the overall level of society and the improvement of transportation efficiency. Reducing the weight of the car is one of the effective measures to improve the fuel economy of the car and reduce the CO2 emission of the car. Especially in the truck industry, the application of new energy vehicle technologies such as hybrid, electric and fuel cells is difficult and the prospects are unclear. Therefore, lighter weight has become the most realistic and most effective technical measure for energy saving and emission reduction in the heavy truck industry.
The realization of lightweighting of trucks is a systematic project to optimize the design structure of vehicles. It involves the entire vehicle, engine, suspension and other fields, and even includes the application of new materials and new technologies. From the basic design, by optimizing the structure and rational use of new materials and new technologies, the overall lightweight achieved without reducing the load carrying capacity is achieved.
The automobile body accounts for about 30% of the total weight of the car. Under no-load conditions, about 70% of the fuel consumption is spent on the body weight. For every 100 kilograms of vehicle weight, 0.6-1.0 liters per 100 kilometers can be saved. If the vehicle's vehicle weight is reduced by 10%, the fuel efficiency can be increased by 8%-10%; if the rolling resistance is reduced by 10%, the fuel efficiency can be increased by 5%; if the transmission efficiency of the axle, transmission and other devices is increased by 10%, the fuel efficiency can be improved. Increase by 7%. Therefore, under the conditions of Chinese-style toll collection and “overcharging of arbitrary charges and random fines,†a light-weight truck has practical importance for the fuel economy, vehicle control stability, and collision safety of the vehicle. Lightweight trucks have formed a major trend of development.
However, in this case, for some truck manufacturers, the so-called “lightweight†is still a conceptual replacement process. If the technology fails to meet the requirements, it will cut corners by reducing the thickness of the steel plates and reducing the number of parts. On the surface, it is lightweight, but it goes beyond the bottom line, let alone light weight. At the same time, under the circumstance that the problem of unlawful and unlawful charging and overloading cannot be solved, the weight reduction of trucks must go into the wrong zone. Under the comprehensive effect of market competition factors, who can effectively reduce the weight of trucks under the premise of guaranteeing quality, and achieve light weight, will be the commanding heights for future major auto companies to snatch up the market.
From the point of view of new products introduced by all card manufacturers, the proportion of composite materials used in vehicles is gradually increasing, and the use of a large amount of composite materials is an inevitable trend. One of the ways to achieve lightweight design is to optimize the vehicle structure and the second is to apply new materials on the basis of optimizing the product structure. The former belongs to the lower stage and the latter belongs to the advanced stage. Self-respect becomes the main factor in choosing a car. Even if the price is slightly higher, trucks with light weight will be the first choice for customers. Because trucks with light weights not only pull much faster and save fuel, they are more popular.
A. Development trend of lightweight trucks The development trend of China's light trucks in terms of product technology is mainly in the following aspects: First, energy-saving technologies, and the economy of vehicles is the most directly profitable and perceivable performance of customers and countries; Second, safety, including active safety and passive safety, is a threshold that must be passed. Third, low pollution, including the continuous improvement of emission standards, vibration reduction, noise reduction, etc., is also a threshold that must be passed; fourth, functional , Including capacity, power, reliability, durability, driving, loading and unloading, convenience of maintenance, ride comfort, these are the factors of competition; Fifth, the application of electronic control, car networking information technology; the sixth light truck The major trends in the development of manufacturing technology are the application of new materials, new processes, new processes, new equipment, and new tools.
In addition, it can be seen from the past three years that the incremental structure of light trucks will change significantly, light trucks are developing in the direction of high technology, new materials, lightweight, digital, network intelligence, comfort, function diversification, and passenger use The development of humanization and humanization is mainly reflected in the use of low noise, safety, reliability, durability, convenient maintenance, energy-saving, low-emission, multi-function, and new energy. From the development trend of light truck products:
a. In the design of power systems, pressurised intercooling devices and high pressure common rails have been commonly used to optimize and improve the combustion performance. The performance and fuel economy of the engine have been greatly improved, which improves the matching of the engine and the vehicle. Sexuality makes the power output of the vehicle more powerful and faster, and it also meets the national emission standards for diesel engines. Power companies such as Cummins, Sophim, Fiat, Mann, and Navistar have adopted electronically-controlled turbocharged high-pressure common-rail engines, fuel and combustion optimization, intelligent electric control, emission treatment, and filtration systems. Core leading technology.
In addition, heavy-duty engines are extended to medium-light trucks, such as the first MC05 engine inline four-cylinder, water-cooled, four-stroke, supercharged intercooled, and high-pressure common-rail engines of Sinotruk Group's Hangfa Company. The power system adopts electronically-controlled turbocharging as a trend, and is the engine with the strongest autonomous power, the lightest weight, and the smallest volume. It can meet the national IV emission standards, and at the same time has an engine upgraded to Euro V and Euro VI emission potential, becoming a market competition. The weapon. For example, the Chery Karry Green Card is equipped with the new Cummins ISF2.8 engine with a light weight cylinder block and cylinder head. Without the cylinder liner, the final dry weight of the assembly is only 214 kg, and the German ZF transmission with all-aluminum housing is equipped. It is not only light weight but also very strong.
b. In the cab design, light-duty narrow-body, medium-body, wide-body and double-row, semi-row and single-row cabs tend to be more dynamic and sharp in the shape of the front face of the passenger car. The overall appearance is more atmospheric and heavy. . The headlamps are more full and sharp, absorbing European and American steel-lined elements, and keeping Japanese cars full of rounded genes at the corners. The buffer device uses a passenger car or a broken energy absorbing bumper bumper. In addition, the entire vehicle can be turned over hydraulic cab suspension, sound insulation, thermal insulation and shock absorbing materials and other details, all provide comparable quality of the car.
c. Functional design, integrated electronic throttle, power steering, clutch assistance, electric air conditioning, electric windows and other car-like comfort configuration, close to the passenger car standard. Such as hydraulic shock-absorbing seats, cruise control and many other car configuration. The ABS anti-lock braking system, inductive proportional valve and exhaust butterfly valve brake are standard configuration designs. It optimizes independent gas storage units, including dryers, four-circuit protection valves, spiral cooling pipes, multi-color piping and other systems.
d. The body frame design, in the vehicle design, wide (narrow) body cab, long (short) axis moment, long (short) body, reinforced chassis, large power, high-speed heavy-duty and car networking, etc. It has become the major trend of light truck R&D and the mainstream product of the future market. The use of high-strength riveted girders and corrosion-resistant frames, etc., these new designs can effectively enhance the vehicle's lightweight and high-speed stability and safety. In addition, abandoning the traditional steel plate material and adopting a new steel/bakelite structural container bolted with a newly designed bamboo rubber plate and a steel outer plate, the lighter weight and also the bearing capacity are ensured.
B. Development trend of lightweight heavy-duty trucks 1. Compared with leaf springs, the use of single-layer frame girders will increase the weight of the frame and effectively reduce the weight of the frame, which will greatly reduce the overall quality of the vehicle. With the improvement of design level, manufacturing process, and improvement of material properties, single-layer frames are fully qualified under standard load conditions.
2, using a variable cross-section less leaf spring structure leaf spring variable cross-section less leaf spring is composed of several leaf springs in the longitudinal direction of variable cross-section, not only can reduce weight, but also can improve the driving by reducing the friction between the leaf spring Comfort and long life. In addition, the use of rubber suspension or air suspension can also reduce the weight of the suspension system.
3, the use of composite cab is the use of composite materials up to the assembly, especially the outer cover: front panel, angled panels, fenders, bumpers, and even the top cover, have used a large number of composite materials. On the one hand, this 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 accurate in size than the metal stamping. At present, domestic heavy trucks still prefer the structure of the cab of an all-steel structure, which is mainly related to the harsh working environment of heavy trucks in China. From the perspective of new products introduced by heavy truck manufacturers in recent years, the proportion of composite materials in the materials used in vehicles has gradually increased, and the use of a large amount of composite materials has become an inevitable trend.
4, the use of aluminum alloy material Aluminum alloy is less dense than steel, so in some parts of the composite material can not be replaced, using aluminum alloy materials, including sheet metal parts and castings. Aluminum alloy sheet metal parts are the most representative of the fuel tank, aluminum alloy tank material, not only reduce the weight, and the oil tank is not easy to rust, eliminating the trouble of regular cleaning. The body can also use aluminum alloy instead of cold rolled steel. The rim, engine body, transmission body, etc., can also be cast aluminum alloys in a large amount, which can minimize the weight while ensuring sufficient strength and rigidity.
5, the use of high-strength steel using high-strength steel plate, can reduce the thickness of the steel plate, thereby reducing weight. In European and American heavy trucks, almost 100% of steel used in heavy trucks is high-strength steel. In the past, the proportion of high-strength steel plates used in domestic heavy trucks was relatively small, and they have been widely used in recent years. Even the cars of dump trucks have begun to use high-strength steel plates to increase the strength of the car and reduce its own weight.
6. The use of welded blanks The cab is stamped and welded from steel plates. Since the structure and force of each part are different, different sheet metal parts will also use different grades of steel plates. A heavy truck may use several cabs. Ten different steel plates with different thicknesses. However, with the development of CAE technology, through simulation experiments and analysis, it is possible to calculate the stress conditions of different parts of the same sheet metal part. In order to reduce the unnecessary thickness of some parts, laser tailor-welding technology has emerged. Laser welding technology is to combine two or more steel plates with different surface treatments, different steel types, and different thicknesses into one steel plate by laser welding.
7, using castings. Due to limitations of materials and manufacturing processes, traditional parts of the punched and welded structure can only be of equal thickness. In order to ensure the overall strength and rigidity of the parts, the punched and welded parts are often heavy. The structural parts can be analyzed by CAE through finite element software to optimize the structure. According to the force conditions of each part, the complex variable thickness and variable cross-section structure are designed to maximize the reduction of unnecessary Local thickness, which greatly reduces the weight of the parts.
8, using vacuum tires and ultra-wide tires. The use of vacuum tires and extra-wide tires can also reduce the weight to some extent. Compared with traditional tires, vacuum tires not only reduce the inner tube, but also reduce the structure of the rims. The entire vehicle is replaced with a vacuum tire and the running resistance is small, which can reduce the fuel consumption to some extent. The heavy-duty driving wheels generally use dual tires. If they are changed to ultra-wide single tires, they will not only reduce the number of tires, but also reduce the number of rims. In addition, the ground area of ​​the ultra-wide single tire is not smaller than that of the double tires. In addition to being able to reduce its own weight, it can also improve the running stability and avoid the “tipping†phenomenon of the dual tires. In addition, in the case of tires perforated with vacuum tires, the tire pressure does not drop sharply and can continue to travel, greatly improving the safety of high-speed driving, while the new steel/bakelite structural containers are resistant to abrasion, corrosion and vibration. With the anti-seismic function, the deformation caused by external collisions can be automatically repaired. It is safer to transport precision instruments and fragile goods.
9. Integrate the functions of parts and reduce the number of parts Integrate all parts functions, integrate multiple parts, realize multi-functional parts, reduce the number of parts, make its structure more compact, and can also reduce the weight of the vehicle to some extent. Such as: the tank and the platform pedal combination, the tank and SCR urea tank combination.
The main process is to pyrolyze the tire into oil and gas by directly heating the reactor;
The condenser or cooling tube will cool the gas to a liquid oil with the aid of circulating water;
Then, the remaining gas that cannot be cooled into liquid oil is recycled to the reactor heating system; after the oil and gas is completely discharged, the reactor is stopped to be cooled, and the reactor below 70 degrees is cooled; then the door can be automatically opened and the carbon black can be discharged. .
The capacity of each batch of products ranges from 5 tons to 20 tons.
LN-2200-6000 capacity 5-6 tons
LN-2200-6600 has a capacity of 7-8 tons
LN-2200-8000 has a capacity of 9-10ton
LN-2600-6600 has a capacity of 10-12ton
LN-2600-8000 has a capacity of 12-14ton
LN-2800-6000 capacity is 10-12ton
LN-2800-6600 has a capacity of 12-14 tons
LN-2800-8000 capacity is 15-20ton
If cut into small pieces, it can handle more.