80 Years of Liberation Power Storm

Always at the forefront of the powertrain industry internationally

December 27th

Liberation Power Changchun Super Factory put into operation

The grand ceremony for the production of the lightweight 440 bridge in the G power domain replacement was held

Marking the liberation of power, accumulating momentum and reaching new heights

Crossed a new milestone

Follow the perspective ahead

Approaching the Super Factory and Interpreting the Super Axle

Understanding the Navigation Path of Liberating Power

FAW Jiefang Commercial Vehicle Development Institute

Wang Linguo, Chief Engineer of Transmission System Development

FAW Jiefang Powertrain Division

Li Hongjian, Deputy Director of Changchun Factory

Yang Xiaoguang, Assistant Director of Changchun Factory

Li Haiming, Senior Chief Engineer of Manufacturing Engineering Technology at Changchun Factory

Accept interviews from multiple industry media outlets

Interpret from a professional perspective what 'super' means!

CHINA AUTOMOTIVE NEWS

On August 26th of this year, Liberation Power released the G power domain product GD300-3.0 in the intelligent power domain. What is the relationship between the upgraded lightweight 440 bridge and the G power domain?

The "Liberation Intelligent Power Domain" product brand includes four major power domains: "G, H, E, and F." The G power domain is a green and low-carbon power domain product with diesel, natural gas, hydrogen engines, AMT transmissions, drive axles, and domain controllers as its core. The newly released upgraded lightweight 440 bridge is part of the G power domain, which will be matched with CA6DV1 engines and CA12TA300A integrated AMT to meet the high horsepower market demand of trunk logistics, express delivery, and other industries, providing users with high intelligence, high reliability, and low TCO green intelligent power solutions.

Jilin Daily

Which models will the upgraded lightweight 440 bridge be mainly used in the future? What are the benefits for users?

The upgraded lightweight 440 bridge is designed for the highway traction, high-end cargo, and specialized vehicle markets, while also catering to the target markets of the 435 bridge and 457 bridge. It is a new product with high reliability, lightweight, high efficiency, and long oil change cycles, suitable for standard load vehicles such as express delivery, express delivery, and dangerous goods. It also has good adaptability to composite working conditions and can be matched with a maximum engine of 660 horsepower. In the future, it will mainly be matched with J6, JH6, and J7. For users, the B10 bridge has a lifespan of up to 2 million kilometers and is more durable. In addition, the bridge also has a long oil change cycle for lubricating oil and a long oil tanker end, which can effectively reduce maintenance frequency and lower vehicle maintenance costs. Users can save about 7000 yuan in maintenance costs.

Jilin TV

How to ensure the quality of product development for the upgraded lightweight 440 bridge?

Design: Based on the application scenario of the whole vehicle, collect the load spectrum of the whole vehicle, perform design calculations and bench verification.

Bench validation: Conduct fatigue reliability validation on torque transmission components such as gears and bearings at a distance of 2 million kilometers; To address the failure modes of market driven axle bolts, additional torsional fatigue tests will be conducted on fasteners to verify the strength of the main gear nut, differential housing, and half shaft connecting bolts; The bearing shall be subjected to fatigue test verification according to 3 times L10 (standard version) and 4 times L10 life (high-end version); The durability test requirement for oil seals has been increased from 240 hours to 1880 hours, and extreme eccentricity and acceleration strengthening tests have been added.

Road verification: The first full condition vehicle road test verification of the drive axle has been completed, including subjective evaluation, water immersion test, differential lock life test, enhanced road test, high environmental reliability test, mountain reliability test, low temperature adaptability test, and dry heat adaptability test.

User testing: 20 vehicles were deployed for user testing in different regions. Currently, the average mileage of the 20 vehicles is 385800 kilometers, with a maximum mileage of 551300 kilometers.

China News Agency

How is the production capacity and layout planned for the liberation and replacement of vehicle axles?

11 new production lines will be built and 9 production lines will be renovated, covering the processing of key components such as assembly, painting, axle housing, gears, reduction housing, and differential housing. The production capacity of replacement axles is 100000 units, mainly used for Jiefang J7, Yingtu cars, and some J6 models. At present, the replacement bridge has been put into production, and the CA6DV1 engine will be put into operation at the Dalian Super Factory in March next year. The transmission manufacturing factory is currently installing and debugging, and is expected to start production on June 30th next year.

CHINA AUTOMOTIVE NEWS

What are the key manufacturing technologies for replacing the lightweight 440 bridge? What are the advantages?

Manufacturing technology: equipped with 18 innovative technologies with technical difficulties and 44 technological upgrades in manufacturing; Such as automatic detection technology for gear contact area, cold stamping technology, AGV assembly carrier technology, dry spray booth technology, rapid scanning inspection technology for welding bridge housing, visual tracking of weld seams, etc.

Advantages: We have achieved industry-leading levels in axle housing processing, gear processing, axle assembly, and painting processes. Specifically, as follows:

① In terms of assembly, the bridge assembly adopts AGV load volume positioning and pallet changing method. It is the first domestically developed automatic assembly of the drive axle wheel end, with an automation rate of 30%. With the support of digital systems, it achieves ultimate error prevention and ensures product assembly quality.

② In terms of coating: adopting the two spray and two baking process+high salt spray water-based paint to achieve improved coating quality; The salt spray resistance has been improved from 240 to 504.

③ In terms of bridge shell, high-strength cold stamping technology is adopted to achieve green manufacturing; Innovative mold design to achieve favorable distribution of half shell stress. Fully automatic welding line, utilizing visual inspection, visual tracking, friction welding, double wire welding and other technologies to achieve stable and reliable welding quality of bridge shells. Fully automatic bridge shell machine with integrated processing using imported horizontal machining center and online comprehensive measuring instrument technology; Ensure the dimensional accuracy of the bridge shell bracket. The automation rate in the field of bridge shells is over 90%.

China Daily

What are the characteristics of a new factory?

Lean and efficient: achieve consistent logistics flow from reduced assembly to vertical storage, post assembly, and painting; High production efficiency, with a 30% increase in output compared to the industry for the same area.

Safe and green: The coating adopts a dry paint booth+RTO exhaust gas treatment, and the VOC emissions are collected by more than 99%.

Intelligence: Through the linkage of MOM, LES and other systems with hardware, achieve unmanned factory logistics and intelligent scheduling.

Reliability: The production line quality stability is industry-leading, ensuring the reliability of the assembly process and parts manufacturing process from multiple dimensions.

Commercial Vehicle Home

What are the highlights of the upgraded lightweight 440 bridge product?

Lightweight: 101kg lighter than competing products of the same level and currently produced products of the same level, making it the lightest in the industry.

High efficiency: Adopting drive axle high-efficiency technology and low friction high-efficiency bearings, the overall efficiency is 3% higher than competitors.

Long lifespan and oil change: reliability improvement, B10 lifespan reaches 2 million kilometers, with 800000 kilometers of oil change, both of which are the highest in the industry; Long term replacement of oil tankers can effectively reduce maintenance frequency and lower vehicle maintenance costs.

Low noise: Improve the accuracy of the gearbox gears, while using high-precision low-noise bearings. The noise test of the drive axle assembly shows that within the range of 100 km/h, the maximum radiated sound power is 3-5dB (A) lower than that of competitors.

Bangning Studio

What are the difficulties in developing the upgraded lightweight 440 bridge?

Firstly, after the service life of the drive axle B10 is extended to 2 million kilometers and the oil change cycle is 800000 kilometers, ensuring that the oil seal does not leak oil is a difficult point. For the oil seal, we have increased the durability test requirement from 240 hours to 1880 hours, and added extreme eccentricity and acceleration strengthening tests to ensure the sealing performance of the oil seal.

Secondly, while ensuring the performance of the drive axle, we adopt various lightweight technologies to achieve a weight reduction of 101kg compared to competing products of the same level and current production products of the same level

Finally, long-term maintenance should fully meet the current demand for high efficiency and high attendance in road transportation. The application of long-life oil seals and long replacement oil tanker ends/maintenance free wheel ends can effectively reduce maintenance frequency and lower vehicle maintenance costs.

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Where there are liberation trucks, there is liberation power

From the power manufacturing of commercial vehicles

From 'big brand' to 'high-end brand'

Liberate the power of the road to simplicity, and persistently strive for progress

Progress has no end, innovation is endless

Leading China's power towards the world stage

The goal of liberating power is the stars and the sea

Article source: Reprinted from Liberation Power