Lightweightness and environmental protection will be the trend for heavy truck development in the future. In particular, lightweighting of heavy trucks has a significant effect on reducing transportation costs and improving operational efficiency.
The automobile body accounts for about 30% of the total weight of the car. Under no-load conditions, about 70% of the fuel consumption is spent on the body weight. For every 100 kilograms of vehicle weight, 0.6 liters per 100 kilometers can be saved. If the vehicle weight is reduced by 10%, the fuel efficiency can be increased by 6%-8%; if the rolling resistance is reduced by 10%, the fuel efficiency can be increased by 3%; if the transmission efficiency of the axle, transmission and other devices is increased by 10%, the fuel efficiency can be improved. Increase by 7%. Therefore, the lightweight design is not only to save materials, reduce self-weight, and increase the load quality; more importantly, it aims to reduce energy consumption, reduce emissions, improve operational efficiency, and drive safety.
Lightweight vehicles mainly have the following methods.
1, using a single frame frame beam
Compared with leaf springs, the weight of the frame is greater, and the weight of the frame is effectively reduced, which will greatly reduce the overall quality of the vehicle. With the improvement of design level, manufacturing process, and improvement of material properties, single-layer frames are fully qualified under standard load conditions. Due to the severe overloading of heavy trucks in China, it was almost unimaginable to use monolayers for heavy trucks before 2008. After 2008, domestic manufacturers began to launch their lightweight products one after another. The frame uses a single-layer beam structure.
2, using composite materials
The cab is the assembly with the most composite materials, especially the outer cover: the front panel, angled panels, fenders, bumpers, and even the top cover, all using a large number of composite materials. On the one hand, this effectively reduces the weight of the entire vehicle. On the other hand, due to the good formability of the composite material, the molding structure can be more complex, more beautiful, and more accurate in size than the metal stamping. At present, domestic heavy trucks still prefer the cab structure of an all-steel structure, which is mainly related to the harsh working environment of heavy trucks in China: heavy trucks are faced with too many tests and injuries, and it is difficult to repair composite materials after they are damaged, which improves the maintenance of the entire vehicle. cost. However, from the perspective of new products introduced by heavy truck manufacturers in recent years, the proportion of composite materials used in vehicles is gradually increasing, and the use of a large amount of composite materials is an inevitable trend.
3, with aluminum alloy material
Aluminum alloys have a lower density than steel and are durable. Therefore, in places where some composite materials cannot be replaced, aluminum alloy materials, including sheet metal parts and castings, can be used. Aluminum alloy sheet metal parts are the most representative of the Fuel Tank, aluminum alloy tank material, not only reduce the weight, and the oil tank is not easy to rust, eliminating the trouble of regular cleaning. The body can also use aluminum alloy instead of cold rolled steel. In order to reduce its own weight, American heavy trucks use aluminum alloys to make cars. Due to the poor welding performance of aluminum alloys, they can only be riveted. Therefore, the US long heavy trucks we see are all rivets.
4, with a variable cross section less leaf spring structure leaf spring
Because the leaf springs are all metal parts, the weight is very large, and the weight of the leaf springs is reduced, which is also an important measure for reducing the quality of the rigging. The variable cross-section leaf spring is composed of several leaf springs of variable cross-section in the longitudinal direction. Variable leaf springs not only reduce weight, but also improve ride comfort and service life by reducing friction between leaf springs. In addition, the use of rubber suspension or air suspension can also reduce the weight of the suspension system.
5, using vacuum tires and ultra-wide tires
To reduce the weight of the vehicle, the tire can not be underestimated. The use of vacuum tires and extra-wide tires can also reduce the weight to some extent.
Compared with conventional tires, vacuum tires not only reduce the number of inner tires, but also reduce the structure of the rims. The entire vehicle is replaced with a vacuum tire, and the reduced weight is very objective. In addition, vacuum tires have a small resistance to travel and can reduce fuel consumption to some extent.
The driving wheels of heavy trucks generally use double tires. If they are replaced with ultra-wide single tires, not only can the number of tires be reduced, but the number of rims can also be reduced, and the weight loss effect is very significant. In addition, the ground area of ​​an ultra-wide single tire is not smaller than that of a double tire. Besides reducing its own weight, it can also improve running stability and avoid the phenomenon of “gesture†of the dual tires.
6ã€Integrate part functions and reduce the number of parts
In addition, integrating the functions of parts, integrating multiple parts and components, achieving multi-functional parts, reducing the number of parts, and making the structure more compact, it can also reduce the weight of the vehicle to some extent. Such as: the tank and the table pedal combination, the tank and SCR urea tank combination.
7, the use of high-strength steel
The high quality of steel will affect the lightweighting of vehicles, but the use of high-strength steel plates in places where other materials cannot be replaced and steel can only be used can reduce the thickness of steel plates and reduce the weight. High-strength steels can be used for cold-rolled steel sheets used to make bodywork and hot-rolled steel sheets for frame construction. In European and American heavy trucks, almost 100% of steel used in heavy trucks is high-strength steel. In the past, the proportion of high-strength steel plates used in domestic heavy trucks was relatively small, and they have been widely used in recent years. Even the cars of dump trucks have begun to use high-strength steel plates to increase the strength of the car and reduce its own weight.
The above is a common method for vehicle weight reduction. The reader can consider it according to the situation of the vehicle.
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