"Slimming" is the pursuit of many women who love beauty. This is known to everyone. But have you ever heard of a cold engine that is also trying hard to "downsizing" it? It must be said that many people do not understand this very well and may not have heard of it at all.
Is the engine beautiful? There is no doubt that the appearance, shape and structure of the engine will all take into account the demanding aesthetic requirements of customers. However, the engine “slimming†to be said here is not the same as pursuing beauty. After all, the engine does not rely on beautiful appearance to attract users. The eyeball economy does not work in the engine industry.
“I'm thin and I'm proud. I'm saving for the national fabric.†This is a joke for lean people, but it is important to show that it saves raw materials and costs. For Yuchai, the "downsizing" of the engine can effectively reduce the consumption of raw materials and reduce the production cost of the company. For users loyal to Yuchai's products, the engine is "downsizing", the fuel consumption of the vehicle will be reduced, and the operating cost will be reduced. It will be reduced and more money will be made. At the same time, engine weight reduction is an important means of energy conservation and environmental protection.
This principle is well understood, but the engine "slimming" is easier said than done. According to relevant experts, the weight reduction of the engine is more demanding and it is more difficult to implement.
Chen Jinyuan, president of the Yuchai Technician Association and the Association for Science and Technology, said in an interview that engine weight reduction is a complex system project involving many aspects such as talent, design, manufacturing, technology, and materials.
Not only that, there are many engine parts, especially emission upgrades, the engine has added some necessary external accessories, each adding a component, are increasing the engine's own weight. Therefore, it can be said that Yuchai Engine's “downsizing†concerns the core interests of Yuchai, Yuchai’s suppliers and customers.
Make the structure better
It is very difficult to “shaping†the engine from the structure, because any changes are caused by the whole body. In spite of this, in order to achieve lightweighting and enhance product competitiveness, the necessary structural optimization was achieved with the efforts of R&D personnel.
According to Tan Dahui, vice president of the Yuchai Engineering Research Institute, the weight reduction of the YC6L cylinder head is typical of the structural optimization. By optimizing the design, we reduce the contact surface of the cylinder head, thereby reducing the machining area and achieving a weight reduction effect.
"For every small change, we must do a full CAE calculation and analysis to ensure its stable performance." Tan Dahui stressed.
It was learned from relevant technical personnel of the Yuchai Engineering Research Institute that the lightweighting of the engine is a continuing pursuit of Yuchai. This year Yuchai will achieve a weight reduction by removing the YC6L cylinder block stiffener, which has a weight reduction effect of up to 23.4 kilograms. Safety and stability are factors that must be taken into consideration when the engine is lightweight. "We are doing rig durability tests and vibration tests for them," the technician added.
On the basis of guaranteeing the performance of the casting, the design of the casting structure, such as miniaturization, thinning, and cavitation, etc., to remove the redundant parts is also an effective way to achieve lighter weight of the engine.
In order to save costs, the foundry also listed castings as a key work this year. The weight-reducing effect of the sand core in the second casting workshop was obvious. By adopting methods such as optimization of the casting process, the D30 body casting was reduced by 2 kg from the original weight. Do not underestimate the two kilograms of hot metal, according to the factory's annual production program, the cost savings due to casting weight loss and still considerable.
"High-strength ultra-thin body water jacket high-end technology" is the latest achievement of Chen Jinyuan and his manufacturing technology team. Using this new technology, the 2mm ultra-thin water jacket core can be made in the manufacturing technology department. The inner wall of the cast body is smooth, free of sticky sand, and has no sintering. Its technical level is in direct pursuit of Mercedes-Benz and BMW.
Chen Jinyuan is very confident about this. He said that the success of this technology has provided a brand-new platform for Yuchai's ultra-thin and high-strength water jacket manufacturing technology, and more importantly, it has developed an excellent team that pursues high-end technology.
The lightweight structure of the engine includes the modular design of parts and components, light weight of external accessories, finite element analysis of some components, optimization of topology, etc. Yuchai’s exploration on this road will continue.
Apply new material
The application of new materials is also an important way to reduce the weight of the engine. At present, the most prominent one is the application of high-strength materials and the application of some light alloy materials.
Vermicular graphite cast iron is a kind of high-strength material. Its mechanical and physical properties and casting process performance are between gray cast iron and ductile iron. It is very suitable for manufacturing parts with high strength requirements and requiring thermal cycle load, such as cylinder block, Cylinder head and so on.
Reducing the weight of a single component is also an effective way to reduce the total weight of the engine. As the largest core component in the engine, the engine occupies a quarter of the total weight, and Yuchai Engine's “thinning down†naturally starts with it.
Chen Jinyuan said: "Since January 2013, under the arrangement of Liang Qingyan, deputy general manager of Yuchai, the Manufacturing Technology Department took the initiative to carry out light-weight process tests on the four models, of which the D2500 body we are doing The weight is to replace the original gray cast iron with vermicular cast iron, achieving the purpose of high strength and thin wall thickness. Each casting can reduce the weight by 25 kg.â€
According to the current progress, the D2500 weight-reduction body mold has been completed and entered the trial mode verification stage. It is expected that small batch production will be possible in September and a large batch of production capacity will be formed at the end of the year, laying a good foundation for the 4D model upgrading country 4. According to estimates, weight loss can achieve a substantial reduction in the amount of money. Chen Jinyuan said that they are working hard to achieve higher cost reduction targets.
Chen Jinyuan has his own understanding of the lightness of the engine. He said: "Our general requirement is to reduce the intensity and weight, and to pursue 'two drops and one guarantee.' 'Two drops' means reducing weight and reducing costs, and 'one guarantee' means quality assurance."
Admittedly, engine weight reduction is not to follow the trend, not to mention searching for sex, cutting corners, and not guaranteeing quality. The product has no market at all, and in the end it just lifts a rock and hits its own feet.
In Yuchai, vermicular cast iron is just the tip of the iceberg for new materials. Although cast iron has good rigidity and low cost, its own specific gravity also restricts the application of this material in the field of engine weight reduction. In contrast, light-weight materials such as aluminum alloys and magnesium alloys have greater application space in the future.
In 2011, the manufacturing workshop for the Ministry of Manufacturing Technology was established, and one of its tasks was to test the application of new aluminum alloy materials. Not long ago, Yu Ping, chairman of Yuchai, went to the inspection workshop of the Manufacturing Technology Department. Chen Jinyuan demonstrated a technological achievement to Yu Ping, applying self-developed high-strength aluminum alloy materials, and optimizing the structure of the cylinder head, and successfully developed the high strength. Tough and lightweight a V-type machine aluminum alloy cylinder head. The finished product of this aluminum alloy cylinder head weighs 15.6 kilograms. Compared with the original cast iron cylinder head, it has a weight reduction of 17.7 kilograms, a drop of 53.2%. The aluminum alloy cylinder head blank has undergone 30 cold and heat cycle impact tests without cracks, and the tensile strength reaches HT250 level, to meet the needs of the engine. At present, the aluminum alloy cylinder head has entered the test and verification stage.
From the current domestic and international success stories of engine weight reduction, the application effect of new materials is the most obvious. With the mastery of new materials and new casting techniques, Yuchai's engine has taken a big step forward.
"Slimming" production is correct
Although engine weight is a major trend, engine manufacturers will not blindly implement lighter work without considering profitability.
Which model to choose for lightweighting requires rigorous argumentation and risk assessment. On the one hand, companies must consider the benefits of lightweighting. On the other hand, lightweighting itself also requires the discussion and verification of R&D design, manufacturing technology, technology, factories, and other related departments.
Chen Hongxing, the chief of the foundry's technical department, said that if we receive a task and we want to lightly weight a casting, then the first thing we need to do is to dissect the casting. This process is a bit like a doctor operating on a patient. Anatomy is to see the structure and see where there is room for improvement. The theoretical room for improvement still needs to undergo risk assessment and verification. This process is no problem, we can trial production, and then disassemble, analyze, and improve the trial castings until a satisfactory weight loss is achieved. To do more than 30 castings first, no problem, and then hundreds of small batch production.
Of course, this modification of the castings involved in the lightweighting of the engine, if it occurs regularly in the production of the factory, is bound to affect normal production activities.
"This problem can already be solved!" Chen Jinyuan told the author that Yuchai's die-free rapid manufacturing technology can overcome this difficulty. Using moldless rapid manufacturing technology, we can manufacture the castings we want without using molds. This saves costs and saves time. This technology is particularly beneficial to new product trials and will not hinder normal factory production. At present, this technology has been at the leading level in China.
"Slimming" production is correct, which makes the Yuchai Engine's lightweight road more comfortable.
The road to lightweighting engines such as YC6L, YC6MK, YC6J, and YC4D has already begun. For Yuchai, the road is long and long, and there are still many things that need to be explored in order to reduce the weight of the engine. This is just the beginning of a journey. In order to enhance the competitiveness of Yuchai's engines, there will be more lightweight Yuchai machines coming to the market in the future.
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