Technological Achievement Brilliantly Decrypts Shangchai's Technical Quality Improvement

From the previous page of New China

Shangchai has always been committed to the research and development and production of internal combustion engines. It has been at the forefront of the national industry in terms of technological progress, product innovation, improvement of process quality, and scale of the company. Especially in the field of construction machinery, it has been designed and manufactured by China since 1958. The first 6135 diesel engine, which pioneered China's medium-bore diesel engine, has laid a foundational position in the engineering industry. Shangchai is still one of the most important suppliers of domestic construction machinery power.

Shanghai Diesel Co., Ltd. was established in 1947, formerly known as China Agricultural Machinery Corporation Shanghai Wusong Agricultural Machinery Repair Factory. At that time, it was also affiliated with four family factories, mainly engaged in the repair of agricultural machinery and equipment. After the founding of the People's Republic of China, it was renamed Wuye Machine Factory. In August 1953, it was officially named Shanghai Diesel Engine Factory. In 1993, it was restructured into a joint stock limited company and was renamed Shanghai Diesel Engine Co., Ltd.

Today, the company already owns three series diesel engines, including D114, C121, and 135 (G128), and its full power coverage is 60 to 420HP. The products are mainly used for commercial vehicles, construction machinery, ships, and self-powered power stations. Based on existing products, the company has also developed new products such as LPG, natural gas, dimethyl ether, and dual-fuel engines to enhance the company's ability to cope with energy shortages and sustainable development. Shangchai has grown from an old agricultural machinery repair factory in China to one of the most important internal combustion engine manufacturers in China. After more than 60 years of hardships, Shangchai has written on their long-standing technical quality development history page about their constant pursuit of quality.

Brilliant course

After the founding of the People's Republic of China, it was renamed as Wuchai Machinery Factory's Shangchai Company, which revived a new vitality. It had produced a single-cylinder horizontal 750 rev/min 12HP diesel engine. In 1951, the FM110 series marine diesel engine was successfully manufactured. After officially establishing its name as the Shanghai Diesel Engine Factory in August 1953, it began to design and manufacture diesel engines on its own under the guidance of the principle of "independent, self-reliance". In September 1958, China's first self-designed, fully domestically-produced 6135 diesel engine was born in Shanghai, creating a precedent for the manufacture of medium-power high-speed diesel engines in China, and the first 50 loaders, large bulldozers, and heavy-duty trucks in China. Large-scale construction machinery is equipped with diesel engine 6135, which lays the foundational status of Shangchai in the construction machinery industry. From then on, China’s diesel engine has made every major step forward in the diesel industry. For quite some time, every technological progress and product innovation of Shanghai Diesel Engine Factory is almost equivalent to a progress made by China in the field of diesel engines. Those classic products familiar to the field of construction machinery are still unforgettable.

Table 1 The pace of upgrading of important product innovations and technologies

The first generation of domestic power - 135 series diesel engine

In July 1957, the Ministry of Agriculture's Power Bureau established the "Central Diesel Engine Design Office," established at the Shanghai Diesel Engine Factory, and organized a number of technical backbones responsible for designing its own 135 diesel engine. By May 1958, the design of the first-generation 6135 120HP diesel engine was completed and the prototype was immediately put into trial production. By 1965, the design and trial production of the upright 2, 4, 6 and 12V cylinder 135 series diesel engines were completed. Has become China's first series of diesel engine products.

135 series diesel engine technology structure and various performance indicators, standardization, generalization level, combined crankshaft, camshaft and transmission gear and other major components are made of ductile iron. The level of technical quality has reached the advanced level of similar international products at that time. The successful trial production of the 135 series diesel engine has made a significant contribution to the development of the internal combustion engine power in China.

In 1961, there were large-scale bulldozers at Wuxi Air Compressor Plant, Shanghai Construction Machinery Factory, and Luoyang Tractor Factory. Xuzhou, Luoyang, Liuzhou, Xiamen, and other construction machinery factories all equipped with 135 diesel engines for supporting. The 135 series diesel engines have been successively equipped with equipment in ships and other fields and have made great contributions to the development of China's national economy.

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Heart of crane - D114 diesel engine

In February 1985, Shangchai Plant completed the design of the first prototype of the D6114ZQ supercharged diesel engine. At the same time, it completed the thermal process calculation of the supercharged diesel engine as well as various kinematic calculations and strength checks. The D6114ZQ diesel engine was developed and included in the Ministry of Machinery Industry and the Ministry of Electronics read the 1990 Mechanical Industry Technology Development Plan. In March 1992, experts from the Ministry of Machinery and Electronics Industry identified the main performance indicators of the international diesel engine in the early 1980s. It also has a wide range of application prospects in construction machinery, industrial, agricultural machinery, diesel generating sets, marine main and auxiliary power. In September 1996, the D6114ZLQA supercharged and intercooled diesel engine was identified by experts from the Ministry of Machinery and Electronics. This type of diesel engine has gradually entered the supporting fields of construction machinery and other various market segments. Among them, the market share in the crane exceeds 80%, and the market share of graders, rollers, and pavers exceeds 70%. The quality of D6114A diesel engine has been widely recognized and praised by users. In the second half of 1994, the company cooperated with the internationally renowned AVL company to jointly improve the D6114 diesel engine series and develop a new generation of D6114 series B diesel engines. In 1999, the D6114B diesel engine passed the expert appraisal organized by the Ministry of Machinery and Electronics. The D6114ZQ2B diesel engine was awarded the National Key New Product Award by the State Economic and Trade Commission in 2001. This type of diesel engine has been widely used in domestic passenger cars, trucks, construction machinery, marine main and auxiliary engines, and generator sets, and has been consistently approved and praised by users.

Loader Ace Power - Series 121 Diesel Engine

The Shangchai 121 diesel engine is a product that has been imported from Caterpillar for diesel engine technology and has been manufactured for 20 years. It is widely used in construction machinery and is particularly suitable for high-efficiency ZL50 loaders. At the same time, the company also introduced caterpillar main processing equipment and product testing equipment. Through the use of advanced technology from the United States, special attention is paid to the reliability of parts and components in design and manufacturing, making 121 diesel engines become construction machinery with high quality and reliability. Recognized ace power. The Shangchai 121 diesel engine has been designed with full consideration of the characteristics of the use of construction machinery and the harsh working environment, the design of the complete machine and its components, and the implementation of high reliability and long life. The design concept of the main components and the machine with the same life span The important friction pair is very reliable and durable. Strong engine power, large displacement, high torque reserve coefficient, extraordinary dynamic performance and good responsiveness make this type of diesel engine able to support 50, 60 loaders; 160-230 type bulldozers, 165-type and 220-type levelers, etc. Machinery is also the dominant driving force for the industry's export-oriented 50 loaders.

Technical upgrade - electronic control products

The use of mature products in the market and the successful transformation of Shangchai Electric Controlled State III diesel engine has outstanding advantages. Shangchai uses the ECD-U2 high-pressure common-rail injection system of Japan Denso, which is considered to be superior in performance and stable and reliable. At the same time, the electronically-controlled diesel engine body of Shanghai Diesel Engine Co., Ltd. is a D-series diesel engine with an annual production and sales volume of 80,000 units. Both electronically controlled diesel engines and electronically controlled fuel systems are mature, reliable, and stable guarantees for electronically controlled diesel engines. In addition, other components of electronically controlled diesel engines, such as superchargers, pistons, and starter motors, have also adopted internationally renowned brands, providing favorable protection for the reliability of diesel engines. In addition to meeting the national III standard for emissions, the diesel fuel economy and supporting adaptability of Shanghai Diesel Engine are also very good.

The SC9DF engine is another upgrade after the SC9DK. Shangchai relies on the company's accumulated experience in diesel engine R&D and its technical strength. It has been jointly developed with the Southwest Research Institute of the United States to conduct comprehensive performance testing and development of diesel engines; and a new generation of four-valve heavy-duty diesel engines has been designed and tested according to the North American heavy-duty diesel engine process. Power up to 420HP. This series of engines adopts DENSO electronically controlled high pressure common rail system, advanced technology such as selective catalytic reduction technology (SCR) with improved control strategy, and internationally-available CAN bus communication technology to optimize combustion systems, fuel systems, and The matching of the exhaust system, more sophisticated ECU and DCU control and other advanced means to build a green, environmentally friendly diesel engine that meets the country V emission. The engine has excellent performance, good economy, high reliability, long service life and wide application range. It is suitable for products such as heavy-duty trucks with 270-375HP and car cranes with 20-75t. Immediately afterwards, Sangchai was born with the SC9DFQ5 engine with a National 5 emission standard.

In recent years, Shangchai’s pursuit of environmental protection engines has never stopped. From country 2 to country 5, the upgrade rate of Shangchai’s electronically controlled engines is accelerating, and the upgrade time is shortening.

Power Innovation - New Energy Engine

In order to adapt to the environmental protection trend in China and even the world, Shangchai has also actively developed natural gas engines and dimethyl ether engines on the basis of the technical quality level of traditional internal combustion engines. Although it is mainly used in passenger cars, the technical strength of Shangchai is evident.

Perseverance in quality improvement

In the course of more than 60 years, Shangchai has always regarded quality as the life of a company and always valued the quality of its products. Shangchai has always been committed to the research and development and production of internal combustion engines, and has taken the lead in the country in terms of technological progress, product innovation, improvement of process quality, and enterprise scale. For the community to provide a large number of high-quality products. Since the founding of the People's Republic of China, "Shangchai Manufacturing" has always been synonymous with high quality products in the domestic internal combustion engine field.

Perhaps a series of quality certifications passed by Shangchao can explain the problem: In 1994, Shangchai passed the ISO9001 quality system certification in the first Chinese internal combustion engine industry; in 2002, the company passed the QS9000 quality system certification of the Rhine company; in 2005, the company passed the Rhine company. ISO/TS16949 certification for the automotive industry quality system; in 2007 the company passed the ISO14001 environmental system of Huaxin Corporation and the GB/T28001 occupational safety and health system certification. The emphasis on quality coupled with a strict quality management system creates high-quality products. High-quality products bring practical value to users.

In 2008, after Shangchai entered a new enterprise platform, quality work was placed at the top priority. In 2008-2010, the company was rated as a quality year for three consecutive years. The quality of the department leaders and top leaders attended each month was personally attended. Regular meetings, commenting on quality performance, promoting quality improvement, and forming a good atmosphere for everyone to value quality. Through quality "hundred-day integration" activities, the company further improved the company's quality information system, built up four major quality information platforms for end-users, OEM customers, internal quality, and supplier quality to ensure that quality problems are resolved at the first time.

To this end, Shangchai adopted a series of practical management and technical measures to further enhance the company's product quality.

(1) Improve product development process and improve product quality from the source: Shangchai introduced and digested the global automotive development process GVDP in 2008, improved design standards for vehicles, improved new product quality management processes, and significantly improved the quality of new product development. Improve quality accreditation standards, strengthen selection, process and product review.

(2) Preparation and implementation of a series of management processes: Shanghai Diesel developed and implemented Q/SC 1854-2008 "Quality Evaluation Guidelines for Potential Supplier" to improve the criteria for potential supplier access; implementation of Q/SC 933-2005 "Process Audit Control" Procedures to improve the quality assurance ability of the production process; implement Q/SC934-2005 "Product Audit Control Procedures" and conduct quality assessment of the products.

(3) To carry out assessment and management of reliability tests: Shangchai Company initiated the three-year reliability lift plan for the years 08-10 to promote product reliability. The company has a "Reliability Management Office" within the Quality Assurance Department responsible for product reliability management. Rolling tests were carried out for 95 hours, 500 hours, and 1000 hours of reliability growth bench tests. The test simulated the operating conditions of the supporting host and continuously improved product reliability. Proactively conduct follow-up surveys on users' reliability and continuously improve the level of reliability of use.

(4) Continuous improvement of product quality: The company formulates the “Continual Improvement Plan for Product Quality” every year: adopting the 8D method and project system form, conducting expert review of key nodes to ensure product quality improvement efficiency and continuously improve product quality level.

Strict management processes and management systems bring high-quality products. High-quality products bring practical benefits to users. Users have won the fortune and Shangchai has earned a reputation and reputation. In 2001, Shangchai became one of the five quality gold award companies in Shanghai. In 2005, Dongfeng Diesel Engine Co., Ltd. of Shangchai Company was rated as China Top Brand Product. In June 2005, the Shanghai Quality Gold Award was re-evaluated. Shangchai company is constantly providing users with more excellent power products through its own efforts.

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