The "Automobile Lightweight Innovation Strategic Alliance" led by the China Automotive Engineering Society (herein referred to as the "Lightweight Alliance") has been working hard for seven years. Under the light weight alliance organization, the alliance member continues to break through the lightweight key technology, and realizes the technical result to transfer within the alliance, simultaneously established a series of industry standard and the alliance member database, promoted our country automobile lightweight level enhancement.
The significance of lightweight coalition is not to solve a company's technological development problems, but to solve the problems of an industry's development. It solves the problem of the inability of enterprises to "hug together" and jointly develop, solves the problem of difficult sharing of technology and data among enterprises, and solves the problem that the results of production, study, and research collaboration technology are difficult to reach. Under the impetus of the lightweight alliance, we can also feel the fruitful achievements of the alliance member companies. At the "2014 China Lightweight Body Conference" recently held, seven vehicle manufacturers focused on the lightweight body of their main models. The reporter interviewed several members of the major vehicle companies of the Lightweight Alliance and reported on their work on lightweight technology.
Changan Automobile "enters the stage of technology transformation and application"
"As long as the development and application of lightweight technology is carried out step by step, it will surely achieve good results." Liu Bo, director of the body technology department of the Technical Center of Chongqing Chang'an Automotive Research Institute, told reporters. This is also true.
The research and development and application of lightweight technology in Changan Automobile can be divided into three phases. First of all, during the "11th Five-Year Plan" period, Chang'an mainly relied on national science and technology projects to engage in single research and development, focusing on lightweight technology research and reserves, such as the application of magnesium alloy new materials to auto parts.
Secondly, after 2010, Changan entered the integrated research stage of lightweight technology and relied on the lightweight alliance project “Lightweight design of vehicle body parameters and integrated application in the target vehicle†to further understand the lightweight product structure design. Parametric design, accumulation of research and development data, creating Changan lightweight R & D system and process, while gradually trying to use aluminum parts, castings, high-strength steel, plastic and other lightweight parts of steel applications, improve the new material connection process.
Now, Changan has entered the stage of lighter technology transformation and application, aiming at an average goal of reducing the weight of the main model by 50kg by 2020, and using this as the overall goal to drive the subdivision of the body, chassis, electric equipment, power system and other departments. Field lightening programs and systems.
Under the guidance of the Lightweight Alliance, Chang'an has obtained the support of parts suppliers and raw material suppliers, gathered industry forces, and jointly promoted the development of lightweight products. The self-developed aluminum alloy engine cover is one of the major achievements of Changan after joining the lightweight alliance.
Liu Bo said that everything starts from scratch. Beginning with the research on the selection of aluminum materials and the technical specifications, the joint raw material suppliers and mold makers explored viable industry-acceptable material standards, continuously improved aluminum sheet joining and stamping techniques, production line equipment, and coating of steel and aluminum components. The assembly process, after numerous optimizations of the structure, stiffness and fatigue tests, was able to create a qualified aluminum alloy engine cover.
The aluminum cover plate was applied to the Chang'an Yat-Iron hybrid car. Its weight was reduced to 10.98 kg compared to 18.9 kg of steel parts, and the weight loss rate was 41.9%. Relying on this project, Changan participated in the compilation of the “Damage Performance Test Specification for Automotive Cover Sheets†and “Design Specification for Aluminum Front Cover Assembly†to guide the development of enterprises and industries.
FAW Group "Previous Person of Lightweight Technology Development Plan"
One of the decisive factors is whether the lightweight technology can be transformed into productivity. Whether the company has developed a detailed lightweight technology development route. At this point, FAW Group has been at the forefront of domestic companies.
Wang Yan, Senior Engineer of FAW Car Technology Division, stated that FAW has established a lightweight development strategy plan, which determines the lightweight target according to the requirements of the vehicle body stiffness and the lightweighting factor of the vehicle, clearly clarifies the direction and topics of lightweight research, and masters lightweight design and manufacturing. And material technology, to reduce the vehicle weight, to achieve the reduction of the entire vehicle fuel consumption. FAW mainly promotes the development of lightweight technologies from the following five aspects: design theory and methods, research on new light-weight materials application technology, lightweight manufacturing technology for load bearing components, lightweight manufacturing technology for safety components, and research on application technology of high-strength steels.
By 2020, FAW will form a systemization capability for the research and application of lightweight technologies, establish a normal lightening mechanism for advancement, promote the horizontal application of the Group's lightweight technology, and build a professional team for lightweight products, processes, and materials. “Before 2007, vehicle manufacturers designed their products almost without regard to light weight factors, and in recent years, most companies have made lightweighting an important reference for product planning. The light weight strategy of FAW Group is to solve the problem of lightweight development. The problem of the route is an important sign of the development of China's lightweight technology at this stage. Each vehicle company should develop a lightweight technology development plan and a specific work path as soon as possible, which is more important than breaking through a single lightweight technology. The director of the first expert committee of the League, Chen Yilong, commented.
According to Wang Yan, under the impetus of the Lightweight Alliance, FAW established an automotive lightweight and advanced forming technology innovation base, and developed three-dimensional roll pressing, 1800 MPa hot forming, semi-solid aluminum alloy machining, and aluminum alloy extrusion molding for molding technology. Research on lightweight technologies such as high-vacuum die casting, most of the technology is in the mass production phase. In terms of materials, the second-generation and third-generation advanced high-strength steels, hypereutectic aluminum-silicon alloys, heat-resistant magnesium alloys, carbon fiber composite materials, PC, GMT, and other light-weight materials were applied in automotive applications. Some of the materials were transferred. Production stage. In terms of design, finite element analysis, partial reinforcement design, topology optimization and other technologies are used to reduce the number of components from the structure; under the premise of satisfying strength, material consumption can be reduced and product weight can be reduced.
It is reported that the investment of FAW Car in the research and development of lightweight technology has exceeded 100 million yuan. Lightweight technology has a large number of application results in passenger cars and commercial vehicles. FAW's Pentium X80, under the combined effects of various lightweight technologies, has lost 90kg of weight compared to the benchmark model of a joint venture, while the C-NCAP crash test has achieved a high score of 58.9.
Great Wall Motor's "Project is Fastest in Execution"
“At this stage, we have integrated the lightweighting target as an important indicator into product engineering design. In the past, the Great Wall once separated lightweight technology research and development into a single department to carry out specific operations. With the advancement of lightweighting, we have The lightweight concept is integrated into every aspect of vehicle design and manufacturing to ensure the implementation of the technology." From the few words of Yang Jie, executive vice president of the Great Wall Automotive Technology Center Materials Institute, we can feel that Great Wall Motor has plans to The pragmatic spirit to implement.
Great Wall Motor Co., Ltd. applied for joining the Lightweight Alliance in 2010, and it officially became a member of the alliance in 2011. Zhang Ning, deputy secretary-general of the China Association of Automotive Engineers and secretary-general of the Lightweight Union, said: "While Great Wall Motor is a late-entry company, it is the fastest-growing company with the strongest execution ability and has always been the development of the alliance. , industry progress plans."
Yang Jie believes that: "Lightweight alliance is to solve the common problems in the development of enterprises, is for the progress and application of lightweight technology, so senior leaders and technical R & D personnel of Great Wall Motor hope to support the development of lightweight alliances."
It is reported that high-strength steel is one of the most widely used lightweight materials in the current phase of Great Wall Motor's mass production. For this purpose, Great Wall has invested heavily in setting up a production line and applying hot forming technology to produce high-strength steel components. It is used on H6 models. . Among the models being developed by the Great Wall, there are at least 8 major components applied with high-strength steel, and the overall weight loss exceeds 10%. With the help of the coalition, Great Wall and Baosteel set up laboratories to jointly undertake several lightweight research projects. “The platformization between the models allows the Great Wall to share lightweight technologies and parts with various models, and the cost will gradually decline,†said Yang Jie.
Carbon fiber material is one of the major directions of Great Wall lightweight technology. Yang Jie said that many domestic vehicle and component companies are engaged in research and development of carbon fiber components, but there is still a considerable distance from the industrialization target of acceptable costs. According to sources, BMW is planning to invest 80 million euros in the carbon fiber industry to reduce production costs by 90%. In China, if the production cost of carbon fiber parts can be reduced by half, the possibility of mass production is very high. It is reported that, under the requirements of the lightweight coalition, Great Wall is leading the organization of a number of vehicle companies, want to jointly tackle carbon fiber technology, and promote the development of domestic carbon fiber industry.
Beijing Auto "Pick personally"
"Future automotive technology innovation will create more possibilities on the basis of intelligence, electrification, and lightweight. These three major trends will drive innovation and development of the industry, and lightweighting will also become one of the important trends in the development of automotive technology in the future." On September 10, 2014, Beihe Group Chairman Xu Heyi stated at the Davos Forum held in Tianjin.
It is reported that Xu Heyi has already incorporated the development of lightweight technology into the strategic layout of BAIC Group and created a "top leader project." In June of this year, Xu Heyi made an important directive to BAIC Group. "We must step up the deployment and application of lightweight technology for self-owned brand vehicles. The models that are listed must reflect specific lightweight technologies and new material applications."
At the Automotive Lightweighted Alliance Media Communication Conference held recently, Lu Xia, an engineer at the Beijing Automotive Research Institute's New Technology and Materials Department, said that in recent years, the BAIC Group’s research and development and industrialization of automotive lightweight technologies have been outstanding, mainly due to the leadership of the group. It attaches great importance to the rigorous management and control processes promoted by lightweight technologies. In addition, BAIC strongly supports the work of lightweight alliances, strengthens cooperation with alliance members, and provides venues and construction support for the national key laboratories for vehicle lightening.
The BAIC Group has always emphasized the awareness of engineers to develop lighter products, and invited light weighted experts, senior experts from Baosteel, Hunan University professors, and Jilin University professors to hold light weight training to promote lightweight knowledge. Improve the lightweight technology of engineers, and actively participate in lightweight academic conferences at home and abroad. Lv Xiafu said: "The Beijing Automobile Group is compiling a "lightweight technical manual," and plans to have a full-scale engineer's manual for the institute's institutes. It will also regularly compile and publish light weight briefings to introduce the progress of lightweight technology at home and abroad."
In order to promote Beiqi's own brand's lightweighting, the Beiqi Research Institute's engineers carried out lightweight technology research and application in three aspects: lightweight materials, lightweight technology, and lightweight design. Strengthen the application of high-strength steel plate on the vehicle body, expand the application scope of aluminum alloy materials in automobile chassis and power system components, and carry out special work such as plastic substitute steel. Increase the application of thermoforming, roll forming, hydroforming, laser welding and other technologies to independent brands. Every new model launched by BAIC will have a detailed lightweighting plan and put it into practice. “The research and development achievements of BAQ's lightweight technology will be promoted in various models of the Group, while the application of lightweight new technologies will enable the mature technologies and models of Saab and Beijing Hyundai. The BAIC Group’s own brands and joint venture brands have always had The close technical exchanges will help improve the technical level of independent brands.†Lv Xiajun also stated that “automotive lightweight technology is one of the key technologies to boost product sales. We hope that lightweight technology applications can form an ecological chain. Implement green manufacturing, control the production of harmful substances, and improve product recovery."
Chery Automobile "Introduces Weight Management Concept"
Tiggo 5 is another result of Chery’s positive R&D efforts. It is also a vehicle that uses a lot of lightweight materials and technologies. Three-quarters of the material used in the body frame is made of a variety of high-strength steels, which are used in connection processes and laser welding. Roll forming, thermoforming technology has also greatly improved. A key step for Chery to promote the application of lightweight technology is to establish a weight engineering system and set product weight targets. "After Chery took a positive approach to R&D and promoted its own design, the goal of lightweighting was fully integrated into the development system of new products," said Li Yuyi, director of core technology management at the Chery Automobile Research Institute. In the early stages of new product development, Chery introduced the concept of weight management. It needs to establish a weight engineering system for new models and set product weight targets to determine the technical process, material selection, and structural development design of each assembly component.
The design of the new car weight target is not so easy. “The Chery team collected a large amount of vehicle operating data to simulate the relationship between vehicle dynamics, economics, and light weight requirements to analyze and determine a reasonable weight target for new vehicles. Lightweight technology import requires consideration of manufacturing requirements, assembly design, and cost control. ,Quality improvement in four aspects, and to establish a detailed lightweight technology R & D application road map." Li Yiyi explained.
In addition, promotion of lightweighting will increase manufacturing costs to a certain extent, but only lightweight technology with low cost can be promoted to the market as soon as possible. Li Yuyi said that the goal of Chery’s lightweighting is to make lightweight products that are easy to maintain and acceptable to consumers in line with international safety standards, and to accurately select lightweight technologies according to the model market's positioning.
Shanghai Automotive has invested tens of millions of yuan for lightweight technology
“Innovative green energy drives the futureâ€, SAIC Roewe E50 has received great attention from the market since its launch. The body of the car is heavily used in high-strength steel, light metal and non-metal materials such as aluminum alloy frames, bumpers and battery boxes using composite materials. , Front-end modules, etc., through the car body cover thinning, structural optimization, application of thermoforming technology and other measures, so that the body weight loss 37kg. This body integrates SAW's achievements in light weight research. “Shangqi's own brand started the research and development of lightweight technology and parts since 2007, which ensures that SAIC meets the national requirements for average fuel consumption of passenger vehicles in 2015.†Feng Qi, SAIC's new energy and technology management department said.
It is reported that before 2008, SAIC was engaged in the development of scattered lightweight components on its existing platform. By 2013, SAIC had invested several tens of millions of yuan in the research and development of lightweight materials and technologies such as aluminum alloy bodywork. Feng Qi said that at present, SAIC’s lightweight target has risen to the strategic level of the Group, and under the leadership of the Group’s leadership, a forward-looking technology research department has been established to conduct in-depth research on advanced technologies in areas such as new energy and lightweight and establish technology Product conversion model.
Feng Qi said: "Lighter coalition cooperation model promotes technological exchanges between enterprises. We also look forward to working with more companies to strengthen cooperation and technology sharing, data sharing, SAIC Forward-looking Technology Research Department will also strongly support the lightweight alliance development of."
Dongfeng Motor's "lightweight commercial vehicle is significant"
Dongfeng Motor Co., Ltd. actively develops lightweight automotive technology under the guidance of the Lightweight Alliance. The subject “Development of Applied Technology for Deformed Aluminum Alloys and Its Integrated Application to Target Vehicle Models†has successfully achieved various targets and achieved expected results. The aluminum body of the Dongfeng aluminum alloy hybrid bus has a weight reduction of 40.9%. The vehicle also uses high-light frame, high-stress leaf springs, aluminum alloy wheels, magnesium alloy seat frames, resin glass and other lightweight non-metallic bodywork. The built-in parts make the car lose 1615kg overall and the weight loss rate is 14.2%.
Liu Chenghu, head of the Dongfeng Motor Commercial Vehicle Technology Center, said: “Dongfeng Motor has been working hard to promote the application of lightweight technology in various models. It is understood that Dongfeng applies magnesium and aluminum alloy materials in the development of key auto parts. Parts have reached 81 species. In addition, there are a large number of plastic steel parts have been applied in batches. It is reported that Dongfeng is developing a two-seater electric vehicle, whose main body is aluminum alloy material. The cover parts are made of steel plate and non-metal materials, and the weight reduction of the car body is more than 25%.
Commercial vehicles are the key areas for the application of Dongfeng lightweight technology in recent years. As early as 2008, Dongfeng started the research and development work on the application of lightweight technology for heavy commercial vehicles. Taking Dongfeng Tianlong's new tractor as an example, after adopting a series of measures such as the optimization of aluminum alloy fuel tanks, plastic air filter housings, high-strength steel frames, high-strength steel wheels, and component brackets, the vehicle's weight loss has reached 9.3%. Liu Chenghu said that in the future, Dongfeng will also launch high-end heavy trucks that are equipped with lightweight components such as all-aluminum alloy wheels to meet the market demand for high-quality commercial vehicles.
For Dongfeng’s best-selling “Jinba†light trucks, Dongfeng uses fuel tank assemblies made of plastic steel, high-strength steel frames and wheels, aluminum alloy cylinder heads and transmission boxes, and aluminum alloy goods. The optimized design of the box body, shaft shaft tube and battery of the drive shaft will reduce the weight of the vehicle by 10%.
Chen Yilong, director of the first lightening coalition's expert committee, believes that Dongfeng Motor’s significance in the research and development of lightweight technology for commercial vehicles is significant. The cost of fuel consumption per year for a heavy commercial vehicle is about 20 times that of an ordinary passenger car. Therefore, the application of lightweight technology for commercial vehicles is the key to controlling the growth rate of total fuel consumption in the automotive industry.
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