New energy vehicles are the general trend. According to the automobile production and sales data just released by the China Association of Automobile Manufacturers, in November 2022, the production and sales of new energy vehicles in my country will be 768,000 and 786,000 respectively, a year-on-year increase of 65.6% and 72.3% respectively. From January to November, the production and sales of new energy vehicles were 6.253 million and 6.067 million respectively, a year-on-year increase of 1 times, and the market share reached 25%. Since 2020, the production and sales of new energy vehicles have achieved rapid growth. Among them, in 2020 and 2021, the sales volume of new energy vehicles in my country will exceed 1.36 million and 3.5 million respectively. It is estimated that the sales of new energy vehicles in 2022 will exceed 6.7 million, an increase of 90.3%.
The rapid development of the new energy vehicle market has brought new opportunities for the die casting industry. New energy vehicle “shifting system” housings, “three electric system” housings, body structural parts, etc., require a large number of aluminum alloy die-casting parts. Therefore, this has created a new demand market for upstream and downstream enterprises in the die-casting industry chain. For example, the high cleanliness requirements for the “transmission system” shell (aluminum alloy die-casting parts) at the core of new energy vehicles involve high-cleanliness cleaning technology and equipment solutions.
The reasons for the abnormal sound of the gearbox when the “speed change system” of the new energy vehicle is working:
From the first item in the above table, it can be analyzed that the second-tier supplier of the vehicle factory, that is, the gearbox factory is responsible for assembling a qualified gearbox, and the gearbox factory provides multiple parts from several parts factories. Whether there are foreign objects left, and how to control these foreign objects before assembly is one of the key points in building a gearbox. Today, I will analyze the ins and outs of this technology for you!
1. A gearbox is mainly composed of intermediate housing, left and right housing covers, driven gear, differential shaft, differential housing and other small parts.
The transmission factory of these products entrusts several parts to produce these parts, and proposes cleanliness standards for the cleanliness required in the production process of these products. The detailed analysis is as follows:
It can be seen that the control of metal foreign objects is quite strict, and it is not easy to achieve the above standards.
Second, the method of cleanliness:
Usually after the parts are finished, the cleanliness sampling inspection is carried out. Generally, the foreign matter on the surface of the part and in the hole is extracted by extraction method for weight detection, analyzed by professional analysis equipment, and then the corresponding test report is obtained. Here is only a brief description, not Introduce them one by one.
3. How to meet the above cleanliness standard:
Comprehensive analysis, it is also a comprehensive process problem that affects our cleanliness. It is not just a cleaning machine that can achieve a relatively high cleanliness. Each link has an inseparable relationship, which makes us unable to achieve a certain degree of cleanliness. Only through long-term accumulation of experience in die-casting and machining, cleaning industry, and back-end assembly process, and analyzing each of the above-mentioned standards, can we prescribe the right medicine and finally meet the cleanliness standard. Of course, the cleaning link is a very critical link, and effective cleaning is also the only way and means to improve the cleanliness by 90%.
Fourth, how to improve the cleanliness of the washing machine more efficiently:
Cleaning equipment in the die casting industry is generally non -standard. Guangdong Saihong Precision Cleaning Equipment Co., Ltd. (abbreviation: Guangdong Saihong) is a professional cleaning equipment manufacturer in the die-casting industry. The non-standard has become the standard, and several standard cleaning equipment suitable for the new Tongyuan vehicle gearbox casing and the three-electric system casing have been developed and introduced to the market. For different application scenarios, there are mainly three types of equipment: fully automatic through-type cleaning machine drying, fully automatic rotary cleaning and drying system, and fully automatic tank cleaning and drying system.
According to the technical director of Guangdong Saihong, for a high-standard cleaning equipment in the die-casting industry, it is necessary to fully evaluate the customer’s cleanliness standards and testing methods, production capacity, automation requirements, product protection requirements, and maintenance when selecting models. Then formulate a suitable plan, and the above details need to guide customers and understand them clearly.
The technical director of Guangdong Saihong analyzed the cleanliness of the transmission housing. Due to the abnormal shape of the “speed transmission system” housing die-casting products, the inner cavity is curved, complex, and there are many holes, how to effectively clean each position of the housing is a complex problem. the process of. Metal foreign matter particles can basically be controlled within 400-600um to meet the requirements of die-casting manufacturers, but this requirement is also a very complicated process. Generally, it needs three stages of deburring, pre-cleaning and final cleaning. And solve the technical bottleneck and pain point of the industry. Burrs and burrs are an important factor affecting the cleanliness of the rear section. The generation of burrs and burrs can be reduced by improving the precision of CNC machining in the front section. Secondly, manual removal and automatic robot removal after CNC processing are used; pre-cleaning is generally simpler. Cleaning equipment is used to remove 90% of the grease, dirt, and particles on the surface of the product; then some water inspection and press-fitting processes are carried out; and then the final cleaning before shipment is carried out to remove 10% of the surface and the stains in the hole and dry. Generally, five processes are required, including: pressure spray degreasing, pure water spray rinsing, water removal, drying, and cooling. Of course, this process requires special tooling (positioning accuracy ±0.1mm) to focus on the transmission housing hole and oil passage, the filtration accuracy of the cleaning section, the dust-proof treatment of the drying section, etc., and the factory environment before packaging is clearly defined. requirements. Only when these points are guaranteed one by one can the cleanliness be up to standard.
However, in order to meet these high standards, die-casting manufacturers need to pay high manufacturing costs and invest a lot of high-end fixed assets. The cost of each transmission case will be very high. Comprehensive planning and process evaluation are required. Evaluate, do big things with little money, and reach a balance point of investment.
In the manufacturing environment, after rounds of industry reshuffles, many manufacturers have begun to pursue changes from quantity to quality improvement, and use ingenuity and meticulous craftsmanship to make every product a high-quality product. Established in a complex economic environment.