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In order to add a "green" to the Shanghai World Expo Park and its travels, SAIC Motor will provide nearly a thousand new energy Expo vehicles, of which, the proportion of World Expo new energy buses exceeds 50%, including fuel cell buses, hybrid buses, and pure electric vehicles. Coaches, pure electric stadium cars, fuel cell sightseeing cars and other vehicles. With tight schedules and heavy tasks, in the face of this unprecedented challenge, a group of SAIC “Expo People†with high combat effectiveness, superior execution capability and abandoning personal gains and losses began to fight under the call of SAIC Union “Pioneer in Actionâ€. "Sword"'s fighting spirit and determination to win are carrying out a special "battle" for the Expo.
Shanghai Auto Commercial Vehicle Technology Center:
R & D pioneer "sword" backing
Here, there are no daytime or no nights, and some are the telephone connections, the sound of the engine on the bench of the lab, and the project progress map that has been updated; here, not the troops, but the brave warriors who dare to fight and dare to shine their swords...
Entering the new energy technology department of SAIC Commercial Vehicle Technology Center, the busy and tense atmosphere is solidified in the air. In March of last year, the Technology Center undertook the World Expo New Energy Bus project, which is only 500 days away from the opening of the Expo.
Only one fifth of the time completes the design development
The rapid rotation of the countdown hands, the general vehicle development takes 18 months, the fastest to go through the development process also takes more than 1 year, 8 months of research and development time to complete such a major project design, it is easier said than done. As the new energy technology covers many aspects such as machinery, electronics, control, simulation, testing and testing, this comes from a number of designers including the SAIC Commercial Vehicle Technology Center, the Shanghai Internal Combustion Engine Research Institute, Shanghai Huizhong, and the Nanjing Automobile Research Institute. The newly formed team of new energy technology departments began to work together.
Everyone carries forward the "additional awareness," "awareness of mutual assistance," and "a sense of integration," and is fully committed to the design and development of the Expo. On the team, everyone has undertaken the task of developing more than two models, and the electrical group has also assumed the electrical work of all models, including pure electric, hybrid, and fuel cells. For these electrical engineers, the electrical work of all models must be completed within 3 months, and the electrical drawings of a single vehicle model amount to 50 to 60 sheets. In the face of large and complicated work, we are constantly telling ourselves to “chong, rush, rush!â€. In order to ensure the timely supply of new energy components, the staff of the project management department, ignoring the cold weather, risked a low temperature of minus 20 degrees, went deep into the suppliers' factories, and inspected more than a dozen places in Beijing, Chongqing, Xi’an and Xiangfan. supplier. During the project's development, many people asked for leave from their families. How many times did he go home when the child fell asleep, and when he left home, the child still fell asleep.
In late July last year, eight kinds of new energy models for the World Expo were completed. One of the purely electric passenger car's technical solutions was completed in just over three months. Compared to the average vehicle development, it took 18 months. They shortened the time by four-fifths and the work efficiency was surprising.
Never miss a detail
In August 2009, the Ministry of Industry and Information Technology reviewed and obtained qualifications for the entry of pure electric and hybrid buses. How to turn technology into engineering is to really test the team's actual combat capabilities.
In the test and verification of the prototype process, the most important problem faced by the team is that the technical standards of the component suppliers of the new energy power system are not high, and the quality of some key components cannot always be stable. For this purpose, the research team quickly attacked and entered the production line of the supplier at the first time, checking the causes of the quality fluctuation one by one, and the technical quality improvement and control were extended to the final supplier.
Every morning at 6 o'clock in the morning when other people are still asleep, team members have been carrying cold winds to go to remote bases. Because this is a batch of new energy vehicles that have never been tried before, the demanding nature of the installation process and the complexity of the electrics are unmatched by traditional cars, and repetitive rework often occurs. Everyone is constantly communicating patiently with the workers in the workshop. The female engineers do not cry or cry. They are like all male colleagues: the next workshop, the climbing roof, and the bottom of the drill!
"Fighting the boat, rushing to the eve of the day," the bright swords of ability one after another, a sample car to eliminate the fault, we all feel that all the hard work has paid off.
Shanghai Shenwo Bus Co., Ltd.:
Riveting efforts for the expo bus
Shenwo Bus is mainly responsible for the new energy bus at the World Expo and the manufacturing of buses during the Expo. For the company’s employees, this is not only an honor but also a responsibility. In order to round up the dream of a World Expo new energy bus, the company’s trade unions launched an activity to “welcome the Expo, guarantee quality, and safeguard operationsâ€â€”Shanwo’s “Pioneerâ€. All employees responded to the call and riveted their efforts.
Body shop: Repeatedly improved "skeleton"
The new energy bus operates for a long period of time during the Shanghai World Expo. It has a large passenger capacity and requires a higher body structure than a normal passenger car. Therefore, the square tube density must be increased to ensure the safety of the original body structure. According to this requirement, we must first create a new tire frame. However, for the employees of the auto body shop, the new model is not familiar with the new model, and a new tire frame with a relatively high technical difficulty is also a challenge. As a result, the workshop deployed elite troops and was led by Du Jianzhong. Through precise calculation, trial production, and continuous improvement, a new "skeleton" for supporting the tires was completed in compliance with the above-mentioned indexes.
Chassis workshop: Pacing out "blood vessels"
Hybrid bus, which integrates motor and engine. The chassis is long, and there are 8 sets of electrical lines, which is twice as much as a normal passenger car and the operation process is complicated. This intricate electrical circuit is like the "blood vessel" of the whole vehicle. Where there is a slight difference in installation, it will hinder the normal operation of the vehicle. However, due to the immature assembly process, the operation space is very small, labor intensity is high, and physical exertion is heavy. It is difficult to make mistakes without making mistakes.
"It is to meet difficulties." During the assembly process, employee Zhu Furong found that due to a defective design of the electronic throttle support plate, it could not be assembled. After careful observation, the rational proposal for pre-embedded nuts on the bracket plate was put forward and the problems in the assembly were solved. The employees of the chassis workshop drilled and drilled in the narrow working space, taking care to line up every "blood vessel" of the Expo vehicle.
Paint Workshop: Excellence in "New Clothes"
The painting project is the most intuitive appearance of the bus, and it can’t tolerate the slightest skepticism. The paint shop staff can be said to be perfect.
In the production of pure electric and super-capacitor models, the pattern has changed from the original bus pattern. Therefore, the team responsible for the pattern shielding and the painting group each have to pay nearly half an hour for each vehicle. After more than 60 vehicles were produced in this model, the customer proposed changes to the front wall pattern. Although only a few changes were made, the painters immediately spent a great deal of effort to achieve the desired results. This was achieved with hard work and sweat. The user's request.
After busy with the pattern change, the huge volume of the roof attachment of the hybrid bus has brought everyone no trouble. There are 6 roof attachments, and the largest one needs 4 people to move at the same time. The spray booth of the shop spare parts group did not have such a large space to complete the spraying, and the daily spare parts painting had already made the group open enough horsepower, and there was no extra manpower and time to paint large parts. At this moment, the staff of the paint shop carried forward the spirit of “one game at the whole workshopâ€. No one was preoccupied with the work of this team. For the purpose of exposing the Expo cars to the users in the best possible coating effect, they “exempt themâ€...
Nanjing Nanqi Special Vehicle Co., Ltd.:
Heartbeat with the Expo
Nanjing Nanqi Special Purpose Vehicle Co., Ltd. is a SAIC-owned enterprise. Although its factory building is separated from Shanghai by 300 kilometers, the hearts of all employees of the company are all bouncing with the Expo.
At the end of 2008, the company received a special task: to develop electric vehicles for the Expo venues. In order to race against time, within two months, the R&D team that was immediately established completed the feasibility study report for the “Electric Electric Vehicles and Fuel Cell Sightseeing Vehicles†project. After the project was established, it immediately developed the trial system and began "walking on two legs" to grab time with the Expo countdown.
Considering that during the opening of the Shanghai World Expo, which coincides with the rainy season and the high temperature season, R&D personnel insist on stringent tests for stereotyped products under harsh conditions and test various test data at high temperatures... August 2009 During the high-temperature suitability test period, Yang Lin, Shen Ningyi, the engineer in charge of the test, experienced symptoms of heatstroke such as vomiting due to high temperatures. He only washed with water, drank a few cool drinks from the leader, and continued to complete the test on schedule.
During the entire vehicle inspection process, Jiang Tao, senior manager of the manufacturing project, and Zhou Jie, a senior engineer, discovered that air bubbles appeared on the surface of the purchased glass fiber reinforced plastic parts at high temperatures of 70°C. However, these potential air bubbles are difficult to find at normal temperatures. The staff worked with the on-site staff to carry out technical research, first baking with a high-temperature light gun, but found that the effect is not good and time-consuming. At this time, Li Xiaofeng, a paint technical support personnel, identified various methods to find ways to rapidly find bubbles by hot air blowing, solved these problems in one go and ensured the assembly progress.
Solve the bubble problem and there are new problems, the appearance of the body paint gradient color is always not satisfactory, there are always more or less color difference sprayed out of each car, in order to solve this problem, paint project leader Fu Yong Li Zhengdong launched a post contest contest at the Shanghai Base in due course. He selected two master painters who were skillful in their technique and natural color transition. When the crowd praised Li Yuping, a young man from Yunnan, he wiped out a near-perfect gradient color spray. Said: “This is my job. I can tell my relatives in the future that these Expo electric cars will be sprayed by me...â€
Shanghai World Expo countdown card on the "ticking ... ...", a vehicle Expo new energy venues car ready to go.