Analysis of the latest viewpoints and trends of materials for new energy vehicles

In recent years, the development of new energy vehicles has entered a rapid development path, especially in the overall slowdown of China’s auto market sales last year, the sales of new energy vehicles still show a sharp increase, and the annual sales of new energy vehicles reached 800,000. Vehicles. According to data from the China Automobile Association, China's new energy vehicle sales have reached 412,000 in the first half of this year, an increase of 112% year-on-year. With this growth rate, it is expected that the cumulative sales for the whole year of this year will be the first million vehicles.

According to industry forecasts, the number of traditional fuel vehicles will reach a peak in 2025, and the total volume will gradually decline thereafter. New energy vehicles will gradually increase. By 2030, the output of new energy vehicles is expected to exceed that of traditional vehicles.

In fact, under the current global energy crisis and the pressure of environmental protection, with the transformation of traditional fuel to electric drive, the automotive power revolution is becoming more and more intense, and the automotive material revolution of lightweight body is also gaining momentum. Walk side by side. Different from traditional fuel vehicles, new energy vehicles use batteries as power to drive the car. Limited by the weight of the power battery and the range of the power battery, under strict energy saving and consumption reduction regulations, the lightweight body has become a new energy vehicle company. The first consideration.

Analysis of the latest viewpoints and trends of materials for new energy vehicles

A few days ago at the 2018 China Automotive Lightweight Industry Summit Forum hosted by Gasgoo, many industry leaders expressed their latest views on the application of materials for new energy vehicles. Combining these points, Gasgoo once published a report in "New Energy Vehicles Are So Hot. How will it affect future steel? "In the article, the focus has been analyzed on the types and demand of new energy vehicle steel materials in the future. Today we will look at the latest views and trends of new energy vehicle materials in combination with other materials.

Future automotive material trends: increasing the proportion of non-metallic materials

At present, from the perspective of body materials, steel accounts for 65%-70% of the vehicle weight, non-ferrous metals 10%-15%, and non-metallic materials 20%. At the China Automotive Lightweight Industry Summit Forum, BAIC Cao Du, deputy dean and chief engineer of the Joint Stock Research Institute, pointed out: "In the next 10-15 years, the various materials and consumption of automobiles will be evenly divided, and ordinary steel, high-strength steel, polymers, aluminum alloys, and magnesium alloys will reach 20% application, this is a revolution in the automotive materials industry."

It is understood that this data forecast comes from a report on the lightweight inventory of automobiles commissioned by the German Association of Engineers, which shows that the application of aluminum alloy and composite materials will increase significantly in 2025, and various materials will increase by 2035. have equal shares.

In fact, aluminum alloys and magnesium alloys are currently the best choice for lightweight vehicles. As the most common lightweight material for automobiles, it is predicted that aluminum alloy can be used in automobiles up to 540kg, which can reduce automobile weight by 40%. It is widely used in structural parts and stamping parts such as engines and bodies. Among them, Audi and other car companies have seen The all-aluminum body is put into reality.

For new energy vehicles, take the power battery tray as an example. In the past, steel was used to make the power battery tray, but now it is mostly made of aluminum alloy profiles. The density of aluminum alloy profile is 2.7g/cm3, and aluminum alloy has obvious advantages in terms of shrinking or welding. The density of magnesium alloy is 1.8g/cm3 and that of carbon fiber is 1.5g/cm3. The use of these materials to make battery trays can achieve substantial weight reduction.

"Magnesium or magnesium alloys will also be used in some invisible structural parts, such as steering supports, seat frames, etc.; they will gradually be used in high-end cars in terms of engine covers, transmission shells, and body structures. New energy The car body will also increase the application of carbon fiber materials, which will first be applied to the car body, covering reinforcement and rigid structural parts (such as castellated beams)." Cao Du said.

Although data shows that in 2025, the proportion of steel applications in automobiles will still reach more than 50%, but according to industry forecasts, non-metallic materials will account for a large part of the future increase in automobile materials. At the China Automotive Lightweight Industry Summit Forum, FAW Gaogong Tian Hongfu also pointed out that in addition to non-ferrous metals to replace some steel, the remaining part is key non-metals. But on the one hand, there are many good lightweight technologies that are not quickly applied and not popularized. At most, it is due to the cost. If the cost of the best technology is too high, it will affect the entire product.

At present, there are many types of materials for power battery shells of new energy vehicles, including metal materials such as steel, iron, and aluminum alloys as well as non-metallic materials such as plastics and carbon fiber. Tian Hongfu pointed out that this piece is not fully mature now, but in the future this part, as well as charging piles, sockets, etc. are important parts of new energy vehicles, and the amount will be very large. Non-metallic materials have very good application advantages in this field. .

In addition to batteries, non-metallic materials are also widely used in motors. For example, polyphenylene sulfide has high strength, high temperature resistance, high flame retardancy, and corrosion resistance. It can replace some metals to manufacture key components of new energy vehicles. At the same time, in the field of intelligent networking, it can also be used for sensors, controllers, and actuators, including cameras, radars, etc. With the development of the new four modernizations of automobiles in the future, the extension of application fields will also put forward higher requirements for non-metallic materials.

Lightweight landing mode: It is too superficial to reduce the weight of parts

How to ensure the strength of the car body while achieving light weight to meet the stringent vehicle crash test and safety requirements has become the most important consideration for the OEM. In general, OEM engineers mainly optimize the configuration from three aspects: lightweight materials, vehicle structure design and manufacturing processes to achieve safe and lightweight vehicles. In this regard, Cao Du pointed out, “Car lightweighting now only stays at the low-level level of component weight reduction, which is wrong and too superficial.”

Cao Du gave a clear definition of automobile lightweight. He pointed out that lightweighting means using the lightest materials in the most suitable places at the least cost. He said that for technical personnel who do target design, the specific content of lightweight can be clarified based on this definition. This usually includes material lightweight, structural optimization, and process lightweight. Most people pay attention to lightweight this point.

But in fact, according to the definition of lightweight is not enough. "Modular design is also a kind of lightweight, which is in line with the definition of lightweight. There are also lightweight assembly designs, such as laser tailored welding, which combines different density steels to make lightweight designs." Cao Du pointed out that, in fact, the worst thing currently done is lightweight performance goals. He took the chassis as an example and pointed out that the independent brands are actually still at a reverse and semi-reverse level. "Who would dare to say that if you want to reduce the weight by 150 kilograms and dare to change the longitudinal beam of the chassis at will, there is currently no problem. There is no problem with changing the body and interior and exterior decorations. The safety parts of the chassis are not at this level. The reason is because we are right. The formulation of performance targets is reversed, restricting the level of lightweight vehicle."

Therefore, on the whole, the weight reduction of the whole vehicle research and development is definitely not a simple part weight reduction, but the development of the overall positive design. The lightweight of the whole vehicle is a positive design that moves the whole body at one start. It is the overall weight reduction of each system rather than the weight reduction of certain parts. This is the key to the problem.

Cao Du further explained that the weight reduction of the whole vehicle is not a simple part weight reduction. "What are the advantages of the weight reduction of the whole vehicle? After the weight reduction, the overall fuel consumption has been reduced by 1.2L. Everyone It’s hard to imagine that the fuel consumption of 130 kg reduced by 0.3L and 0.4L will be reduced to 1.2L? In fact, the engine displacement is reduced after the weight loss, and a better optimized 1.5DGI is used. After changing the engine displacement, the engine vehicle power system is re-matched. This matching has been reduced by 0.4L, so the combined effect can achieve the overall effect of reducing the fuel consumption of the vehicle by 1.2L."

In fact, the current lightweight technology route formulated by my country is still stagnating at the level of the component lightweight technology route. There is no complete lightweight technology route to talk about the lightweight of the entire vehicle. There is no overall lightweight technology developed. of. Cao Du was worried about this, "I hope relevant departments of the Chinese government can make some improvements in this regard."

summary:

With the introduction of stricter environmental protection and fuel consumption regulations and policies, lightweight vehicle manufacturing has become the only way to achieve energy saving and consumption reduction. Driven by the wave of new energy and lightweight, all kinds of materials continue to introduce new ones, and the replacement of traditional metals with high-quality and lightweight non-metals will also become a major trend in the future. And as Cao Du said, how to use the lightest materials in the most suitable places at the least cost, avoid the weight reduction of the whole vehicle into the misunderstanding of the weight reduction of pure parts, and guide it into the overall forward design and development track, and introduce the corresponding To help OEMs cope with the challenges, the lightweight technology route of OEMs should attract the attention of relevant departments. It is also a subject and direction for OEMs to think about.

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