Excavating the "gold mine" Xichai made the "heart" of energy-saving and environmental protection cars

Wuxi Huishan clay figurines began in the Southern and Northern Dynasties and have a history of more than 1,000 years. Huishan clay figurines have long enjoyed a good reputation for their unique style of conciseness, colorfulness and ready-made style. They are also exported to more than 60 countries and regions in the world and have made great contributions to the cultural exchanges between China and foreign countries.

However, on February 23, 2012, in Huishan, a clay and clay production area famous in China and abroad, a new FAW-liberated Xichai heavy-duty diesel engine, which is a source of pride for the Chinese automobile industry and the internal combustion engine industry, was completed and put into operation here. This indicates that China's internal combustion engine industry has a competitive trump card in the international market, which indicates that FAW's independent strategy has strong support, indicating that the liberation of the brand's high-end heavy trucks has high-end power.

FAW Xichai New Base Modern Production Line

Take the initiative to shoulder the responsibility of state-owned enterprises

FAW was born in autonomy, grew up in autonomous, autonomous genes and born. Strong independence, strong business, strong country. It is the responsibility and mission of FAW to realize the dream of autonomy and power. In the commercial vehicle sector, heavy trucks are important weights for market development and competition. As the core component of the automobile, the engine is an important part of FAW's independent business. Today's heavy truck market in China, seizing market share and maintaining the advantages of heavy trucks are the eternal goals pursued by auto manufacturers.

As the eldest son of China's auto industry, FAW wants to “liberate” to sit first in China’s heavy trucks, rely on a long history and cannot adapt to the development of the times, and must fully build its own core strength. The total engine achievement is the most important one among core strengths. component. FAW invested 2.5 billion yuan to build a heavy-duty diesel engine production base in Wuxi. This is an important manifestation of FAW's commitment to state-owned enterprises, and it is also a strategic layout for FAW to accelerate the development of autonomous vehicles.

On July 12, 2010, the new base of heavy-duty diesel engines of FAW Jiexie Diesel was laid in Huishan. After 17 months of hard work, the world's leading independent research and development heavy-duty diesel engine base was successfully completed and put into operation. The completion of the production of the heavy-duty diesel engine production base in Xichai has enabled FAW independent brands to reach an annual production and sales volume of 2 million vehicles.

The new base will create "leading design, leading equipment, and leading management"

Xichai heavy-duty diesel engine production base is designed with a high starting point, high standards, high-quality management, and has a world-leading heavy-duty diesel engine production base. In the aspect of design leadership: the design of the new base of Xichai has a modern atmosphere, and the unique “four-valve” architectural mark of the joint factory is unique in the surrounding area.

The scientific layout of the new base is scientific, and the machine-made offline point and the assembly line point achieve zero-distance butt joint. The assembly line is finally installed on the line to the school bus, painting, and oil seal off-line to achieve seamless connection, effectively reducing the inefficient transportation of the process. The cutting fluid adopts a centralized circulation processing system, the mechanical processing equipment adopts a centralized suction mist dust removal device, and the canteen and shower hot water use a solar heating system to save energy and effectively reduce the pollution to the environment.

The combined workshop air-conditioning system adopts a highly efficient and energy-saving centralized soil heat pump system, which is a typical clean and environmentally friendly renewable energy source. The electricity consumption is 40% lower than that of a conventional centralized air-conditioning system. This is the first of its kind in Wuxi City. The school car cradle adopts electric dynamometer instead of traditional hydraulic dynamometer. It converts more than 90% of the output power of the diesel engine into electric energy during the trial run, and is used directly on the grid to the 110KV electricity grid. This not only reduces sewage discharge, but also reduces the number of factories. energy used.

In terms of equipment leadership, the new base process equipment is equipped with the latest foreign development equipment with CNC, high efficiency, energy saving, durability, and stable quality. The entire line is under construction by the world's highest level German GROB company, and the overall equipment level has reached the world's leading level. The assembly line is equipped with 15 tightening machines, 35 electric screwing guns, 100 hydraulic pressure pulse guns, and 45 fixed torque wrenches to achieve full torque control of the bolts. Equipped with 16 automatic and semi-automatic detection equipments to improve the quality monitoring capability in the assembly process.

The school bus line adopts an automatic dynamometer dynamometer automatic cradle to achieve automatic running-in, vehicle inspection, implementation of check-up; equipped with South Korea ADT cold test bench, diesel engine cold test research and promotion, can save a lot of diesel consumption and exhaust emissions To achieve green manufacturing. The paint line adopts two robots for automatic paint spraying of diesel engines, which can effectively improve the quality of paint surfaces while protecting personnel and improving efficiency.

In terms of management leadership: Xichai is building a new base with advanced management ideas, emphasizing system capabilities, grasping the essence of TPS, and highlighting the lean manufacturing organization model of “planning body”, “retrieve system” and “just-in-time”; The load rate is the target. It is necessary to strengthen the training of multi-energy workers, push the walking operation, and strengthen the lean human resource allocation for quality construction.

Strengthen error prevention and self-inspection during production, implement stringent quality control methods for full-process control of product quality and all-round inspection of the production process; use “on-site” and “style” as the starting point to cultivate rigorous behavior standards for heavy machine behavior culture. We will deepen trust, exemption, and self-administered “three-level Jinsheng” teams; we will implement “three-self management” of employees who are autonomously formulating plans, independently implementing controls, and achieving their own goals. The factory will match the new base’s system construction and management priorities, and formulate 55 internal management documents covering the management content and control processes of production organization, process discipline, quality management, equipment management, employee training, employee attendance, and performance assessment. Xichai's distinctive management system.

At the same time, in terms of quality assurance, we use first-rate product design, first-rate manufacturing equipment, and first-rate procurement resources to ensure quality. The new base production line will be designed around three leading “manufacturing level leadership, process assembly leadership, and quality control leadership.” It will be agile, efficient, automated, and information-based, and the manufacturing level will be comparable to that of world-renowned companies.

Low carbon environmental protection is a major feature of the new base

Said that the new base of the heavy duty diesel engine is a “low-carbon factory”. It is based on the principle of low-carbon and environmental protection in the initial stage of the plan for the new diesel base, from the aspects of factory planning and design, architectural design and ancillary engineering, manufacturing technology and process equipment. Start with a variety of energy-saving and environmental protection measures, such as the use of a ground source heat pump compound system in the central air-conditioning system of the joint plant; the production line adopts a concentrated cutting fluid processing system, a centralized suction system, MQL trace lubrication technology, and high equipment mobility. , Roller conveyor PZR area control, efficient and environmentally friendly media, high standards of noise requirements and more.

The ground source heat pump combined system uses 1,821 heat exchange wells deep underground and 120 meters deep underground. The circulating water in a 211,000-meter-long U-shaped heat exchanger extracts cold heat from the shallow surface of the earth to provide air conditioning systems. use. The system itself has no combustion and emission process, neither destroys groundwater resources nor requires a large amount of water as a cooling tower. It is a clean and environmentally friendly renewable energy source. When the system is heating in winter, it can store cold at the same time to prepare for summer use; in summer air conditioning, it can also store heat in the ground for winter use.

The operating efficiency is much higher than that of the traditional air-conditioning system. When the heat is supplied, it can save more than 70% of the energy of the oil-fired boiler, and when it is cooled, it can be 35%-40% more than the ordinary air-conditioning. It is estimated that the system can reduce the emission of carbon dioxide by 2638 tons, reduce the emission of sulfur dioxide by 15 tons, reduce the emission of NOx by 8.5 tons, reduce the emission of CnHm by 0.08 tons, reduce the emission of carbon monoxide by 0.21 tons, and reduce the emission of smoke dust by 9.7 tons.

The centralized cutting fluid processing system means that several pieces of equipment or the entire production line use the same cutting fluid, and the used cutting fluid flows into the special equipment through the trench or pipeline for centralized filtration and processing, waste chips are collected collectively, and the clean cutting fluid is unified again. Supply each processing equipment for use. It can save 40% of the total consumption of cutting fluid, prolong the service life of the machine tool and the service life of the tool up to 10%-20%.

The temperature of the cutting fluid can be kept constant to avoid influence of the cutting fluid temperature on the processing quality. The cutting fluid of the machine tool is used for the upper row, through the air pipeline into the cutting fluid centralized processing system for cooling, filtration and other processing processes. Under normal circumstances, the cutting fluid is replaced every 2 years. Compared to a single cutting fluid system that needs to be replaced once a year, it can save about 1.5 million yuan in cost.

The new production line of the new base adopts high-end processing equipment. The equipment mobility rate is maintained at more than 99%, which effectively controls the number of units of the equipment and avoids unnecessary equipment consumption. Most press-fitting equipments use servo electric cylinders for press-fitting. Traditional press-fitting is generally driven by oil cylinders. Hydraulic oils consume large quantities and leak easily, causing environmental pollution. Servo-electric cylinders are driven by direct electric energy and are more environmentally friendly.

"Hotel style" workshop, robot display

Entering the new base of Xichai Huishan, the bright and transparent factory building and the white and green colors make it impossible to imagine that this is a factory for the production of heavy-duty diesel engines. The immersive experience is shocking. Saying that the hotel is not too much; saying that the hospital is really spotless. Quiet and warm. According to reports, the new base of heavy-duty diesel engines of Xichai successfully used the green factory design concepts and low-carbon manufacturing production experience of domestic and foreign advanced manufacturing companies. Indeed, people can feel the details of this modern factory's practice of low-carbon concepts from architectural design and ancillary engineering, manufacturing technology and process equipment.

Entering the workshop, we found that the biggest difference between the entire workshop and the ordinary workshop in the layout of the production line is that, with the joint workshop as the center, the parts warehouse and the whole warehouse are scientifically integrated according to the production process, and the machine is added with the cylinder and the cylinder head. The line is at the upper line of the assembly area and the delivery distance is very short. According to the staff, after straightening out the process flow, the logistics distance can be shortened as much as possible, and it can also effectively reduce the consumption of long-distance transportation and scratch damage, and can ensure continuous, rapid and convenient production.

Two 90-degree flips and two 180-degree flips send the cylinder parts to the assembly station and then to the outer assembly line via the truss handler. On the assembly line, an installation robot drew the attention of the reporter. Looking around the workshop, there were a total of five robots with different assignments. They were assigned to various processes in the workshop. They were glued, assembled, transported, and changed in attitude. With the help of these robots, the entire line automation rate has been greatly improved. On the one hand, robot work can reduce the labor intensity. It is said that the efficiency of a robot can reach 4 workers.

“Enjoy our hotel-style workshop? The energy for central air-conditioning is provided by our ground-source heat pump, which is the first one in Wuxi industrial enterprises. Although the low-carbon environmental protection system is more expensive than traditional air-conditioning More than 10 million yuan, but can save more than 2.8 million yuan in operating costs each year, which can be recovered in about 5 years after normal use. Calculating accounts is still very cost-effective." The operator said with pride.

The start-up of the new base is the pride of China's internal combustion engine industry

In the interview, Xing Min, executive vice chairman and secretary-general of China Internal Combustion Engine Industry Association, said with emotion that the success of Aowei Engine in the past eight years has brought three impacts to the industry. The first is to actively participate in international cooperation. The development of the Xichai CA6DL “Aowei” engine takes the path of independent development and international cooperation. After unremitting efforts, China’s first four-valve diesel engine with five patented independent intellectual property rights was developed and manufactured. It has created a brand-name power for the national automotive industry.

This type of service focuses on me, proposes a new product system concept, faces global resources, carries out system development and integration, and creates a development model for products with independent intellectual property rights, which is a great reference for the industry. The second is the development of independent products. The development of Aowei's products has changed the status of China's engine research and development. From reverse development to positive development. The so-called positive development starts with a concept and then realizes this idea step by step. This development concept greatly enhances the confidence of independent research and development. The third is to drive system capacity. Through the successful development of Aowei Engine, it has boosted the capability of domestic parts and components, and allowed many foreign-funded enterprises to establish wholly-owned enterprises or joint ventures in China, raising the level of the entire internal combustion engine industry in China. This is Aowei's biggest contribution to the Chinese internal combustion engine industry. Therefore, the commissioning of the new base is the pride of the industry and the pride of the Chinese auto industry.

Xichai heavy-duty diesel engine has the "six heart" advantage

Dr. Li Jun, director of the Technical Center, commented on the heavy-duty diesel engine of Xiechai. From the perspective of current industry development, the competition in the heavy-duty diesel industry is more inclined to lead the design concept of low carbon and environmental protection. Xichai Aowei heavy-duty diesel engine CA6DM integrates four valves and top. Advanced technologies such as camshafts and high-pressure common rails are integrated, and key technologies such as engine braking are integrated at the beginning of development and design. They are compact in structure and have the "six-center" advantage. They are both "powered" and have a maximum torque of 1900N. m, 800r/min torque ≥ 1100N.m, in line with market development needs, is at the leading domestic level.

"The heart of fuel economy", using AVL's Cruise calculation software to optimize vehicle matching, under the premise of satisfying the power to obtain the best fuel consumption, full load minimum fuel consumption ≤ 193g/kW.h; saving 5-10% than similar products. The “heart of love” adopts electronically controlled high-pressure common rail + SCR exhaust gas after-treatment technology to meet emission requirements and reduce gas emissions. "Eternal Heart" adopts patented cross-flow double water jacket design, cylinder head cooling is more uniform, and overall rigidity is higher. At the same time, the wet cylinder liner design adopts high strength and small deformation of the cylinder liner, which makes the piston operation more reliable and meets the explosive pressure in the cylinder above 200bar, which makes the diesel engine longer. After eight years, a total of 8 21 durable tests were completed. The cumulative test run time was 37,750 hours. B10 has a life span of 1 million kilometers and has reached the international advanced level.

"Confidence", the superior performance and matching design of Aowei 11-liter (6DM) diesel engine enables the diesel engine to easily deal with various road conditions and various environments. It is more convenient to operate and operate, and the compact structure design and large torque PTO output make the diesel engine Has a strong supporting adaptability.

"The heart of safety", through the precise design and matching of the engine brake, at 2100 rpm, the braking power of more than 200kW, is at the leading level in the country. In particular, under 1500 engine operating conditions, brake efficiency is even higher. Long-distance downhill vehicles do not need to step on the brakes, which significantly reduces the wear of the brake pads and ensures that the brake pads operate at a relatively low temperature, thereby improving the safety of the entire vehicle and the reliability of the braking system.

Li Jun explained that from the design point of view, the 11-liter engine is an engine designed using modern methods. It started research and development in 2006 and benchmarked the most advanced engines in the world. It was designed using modern design methods and was published at the European annual meeting. It is the first time for our country to publish at the European annual meeting. In terms of structure, it has adopted an overhead camshaft, four valves, and full electric control. From the perspective of indicators, fuel economy, strong power, long life, safety, low cost, and low noise have more features and selling points. With its own core technology, the feedback from users is powerful, fuel-efficient, lean, and cost-effective.

Wuxi Huishan is not only famous for clay figurines, but also coincidentally, on February 23, 2012, it was the February 2nd "Dragon Heads Up" day. The Chinese auto industry will remember that FAW Jiefang Xixihai Huishan New Base is the industry leader and world leader. The first-class heavy-duty diesel engine production base, the “gold mine”, will provide strong support for the development of FAW’s independent business and provide high-quality core power for the competitiveness of trucks.