◆ Research and development of Dongfeng 130-160 horsepower series tractors
Based on the needs of supporting large agricultural machinery and compound operation machinery, the company has successively developed Dongfeng 130-160 horsepower series wheeled tractors, which passed the new product appraisal organized by Jiangsu Provincial Economic and Information Commission in April 2015 (Su Jingxin Appraisal [2015] No. 122). The gearbox of this series of products adopts a 4×(3+1) structure, which has a wide working speed range, compact structure, high transmission efficiency, and can meet various operation needs; the tractor adopts a power output cut-off protection device and a lifting device linkage safety protection device when driving in reverse gear, and has obtained 2 invention patents; in order to adapt to various agronomic requirements, especially to meet the requirements of compound operations, a variety of power output speeds are designed for selection, and multi-way hydraulic output is set; a full hydraulic steering system is designed. At present, it has achieved batch sales and has been widely praised by users. In 2016, 2,530 units were produced and sold, with sales revenue of 318.32 million yuan and profits of 50 million yuan.
◆ Development of Dongfeng DF504G3 series wheeled tractors
This series of products uses the newly developed 4G33T direct injection engine of Changchai, which has low fuel consumption and emissions; the main clutch adopts a diaphragm spring structure, and the auxiliary clutch adopts an electronically controlled hydraulic clutch, which is controlled by buttons and easy to operate; the gearbox adopts a multi-axis system and a movable support partition wall structure, which is easy to assemble and repair. Synchronous shifting, with shuttle gear and crawling gear, multiple gears, high operating efficiency; equipped with a mid-mounted power output to expand the scope of use; fully optimize ergonomics. This product has an advanced structure, and many advanced technologies are first adopted in China. The overall technical level of the product is at the advanced level in China. In 2016, it achieved sales of 496 units and sales revenue of 22.52 million yuan, becoming a new economic growth point for the company.
◆ Research and development of Dongfeng DF2204 heavy-duty tractor
Dongfeng brand DF1604-2204 series heavy-duty wheeled tractors are new products independently developed by the company. They use electronically controlled high-pressure common rail engines, multi-axis assembled gearbox structure, hydraulically assisted single-acting dry main clutch, electronically controlled hydraulic auxiliary clutch, electronically controlled wet hydraulic differential lock, full hydraulic steering mechanism, imported electronically controlled hydraulic lifting system, and optional automatic navigation driving system. They have advanced structure, comfortable operation, and convenient maintenance, and their technical level has reached the advanced level of the domestic industry. The CAN bus technology is used to realize the communication, display and monitoring functions of the whole machine such as the engine, gearbox and lifting system; the new ergonomic design adopts a six-column cab, an electronically controlled power output (PTO) clutch, a hydraulic power steering system, a full hydraulic steering system, a steering wheel adjustment device, etc., to achieve the whole machine control effect of light operation, comfort and good vision; the electronically controlled force position comprehensive adjustment hoist is adopted, and the operation state of the machine is automatically adjusted through a set of execution and feedback systems; the differential lock adopts the electro-hydraulic controlled wet multi-plate clutch technology, which can realize automatic engagement and separation according to the changes in parameters such as tire slip rate, steering angle and vehicle speed during operation, and the driver can also decide the engagement and separation of the differential lock by judgment; the four-wheel drive transfer mechanism also adopts the electro-hydraulic controlled wet multi-plate clutch technology to realize the one-button function to select four-wheel drive or two-wheel drive mode; when driving, the four-wheel drive can be automatically engaged to realize the four-wheel braking function according to the driver’s braking needs; it is equipped with an automatic navigation driving system, compatible with Beidou, GPS and other positioning systems, to meet the development needs of precision agriculture. At present, small-scale production and sales have been achieved.
◆ Combine harvester
Based on extensive absorption of advanced technologies at home and abroad, combined with my country’s crops and harvesting conditions, the 4LBZ-150 series semi-feed combine harvester was designed and developed. This product has high horsepower, fast harvesting speed and high productivity. In terms of structural design, it adopts a static night pressure continuously variable transmission (HST) plus a mechanical control valve, which is easy and reliable to operate. It adopts a double drum structure, an extra-long main drum, and a cleaning system that increases the vibrating screen area, making threshing cleaner and reducing losses. The vertical header is equipped with multiple adjustment mechanisms and is suitable for lodging crops. It is equipped with a grass cutter as standard, which can simultaneously chop crop stems. It has the characteristics of advanced structure and excellent performance, and has strong market competitiveness.
The 4LZ series of full-feed combine harvesters have been developed, with a cutting width of 2 to 2.2 meters and a feed volume of 2.5 to 5 kg/s. The Korean large-displacement HST (40 ml) is used, which is powerful and easy to operate. The optional lower cutter can greatly reduce the load on the drum and improve the harvesting efficiency. The optional grass cutter can chop the stems and return them to the field. The working range is wide. In addition to adapting to the harvesting of similar crops such as rice and wheat, it can also harvest economic crops such as soybeans, astragalus, and rapeseed.
Currently, mass production and sales have been achieved. In 2016, 908 units were produced and sold, with sales revenue of 56.47 million yuan.
◆ Donghua brand 3WZ-600 self-propelled grape sprayer
The company’s independently developed 3WZ-600 self-propelled grape sprayer is specially used for grape spraying, with a planting row spacing of 1.2 to 3 meters. The whole machine is equipped with a fully enclosed cab as standard, and air conditioning is optional. High efficiency, low dosage, up to 10-16 mu of work per hour, only 50 kg of medicine per mu of land. Air-supplied spray, uniform atomization of medicine, strong penetration, good diffusion. Gantry-type spray boom structure can surround the whole grape, and the front and back of the leaves are evenly sprayed. HST hydrostatic continuously variable transmission is adopted, which is flexible in forward, backward and turning. The motor controls the extension and retraction of the spray arm, the height of the spray, and the extension and retraction of the spray mechanism, which is convenient and simple. This model has multiple uses. The medicine barrel and spray support frame can be removed to realize the use of flatbed trailers. 42 units were sold in 2016, with sales revenue of 2.89 million yuan.
◆ Development of high-horsepower tractors equipped with CVT continuously variable transmission
The company has carried out the development of high-horsepower tractors equipped with CVT mechanical continuously variable transmission. There is still a blank in the domestic high-horsepower tractors using CVT continuously variable transmission. Our company is developing a high-horsepower tractor with a non-power interruption CVT automatic control continuously variable transmission. This transmission breaks the limitation that foreign CVT continuously variable transmissions can only be used for low-power tractors, abandons the traditional CVT hydraulic pressurization and speed change mode, and has the characteristics of high efficiency, energy saving, environmental protection, and low cost. The product technology is at the international advanced level and has very high international and domestic competitive advantages. The prototype trial production and testing have been completed. Entering the small batch trial production stage.
◆ Cold core core making line mold automatic exchange stereoscopic warehouse
The casting cold core core making line consists of 3-5 core shooting machines, which are used for casting cold core production. The traditional core making line mold changing method is manual crane hoisting. Due to the large variety, frequent mold changes, high labor intensity, and low efficiency. The company designed and manufactured an automatic exchange stereoscopic warehouse on its own, which is matched with the core making line to realize the automatic exchange and storage of multiple varieties of molds, greatly improving production efficiency and reducing the labor intensity of operators. At present, there is no similar equipment in China, which is a domestic innovation.
◆ Casting static pressure molding line
Adopting international advanced static pressure molding technology, a complete automatic production line for casting molding is formed. The sand box size is 1000×800×370, which can meet the production of gray iron and ductile iron castings such as tractor gearbox, rear and front box, half-axle sleeve, and lifter housing of our company. It adopts the original imported host of HWS in Germany and the casting grabbing manipulator of Claysman in the UK, and is composed of domestic molding lines and semi-automatic pouring machines, sand processing equipment, medium frequency induction furnaces, etc. The production line.
The company designed and manufactured a CNC fully automatic core setting machine by itself, which is matched with the host. It has the characteristics of high core setting precision and good automation effect, which greatly reduces the labor intensity of workers and improves production efficiency, so that the production of static pressure molding line reaches the design requirement of 90 boxes/hour.
◆ Half-axle truss manipulator processing production line
The production line consists of 6 machine tools and a truss manipulator, covering the rough turning, fine turning, milling spline, drilling flange holes and grinding processes of various half-axles. All processes are completed by the manipulator to automatically load and unload materials and fully automatic serial processing. The single-shift production quantity is 150 pieces, which only requires 2 people to operate. After the line is put into use, it greatly reduces the labor intensity of employees and improves the labor productivity of employees. The efficiency is increased by 300% compared with the original decentralized processing, and the production volume of work-in-progress is greatly reduced, which truly realizes one-piece flow processing.
◆ Fully automatic planetary gear production line
The production line consists of 4 machine tools and two sets of manipulators, which realizes the fully automatic production of planetary gears from turning, gear hobbing, chamfering, and gear shaving. The operation cycle is 2 minutes, and one person can operate two production lines, which increases the production efficiency by 5 times. At the same time, it reduces the labor intensity of employees. The “one-piece flow” production method greatly reduces the work-in-progress in the workshop and improves the effective production efficiency.
◆ Application of joint robots
The domestic industrial robots are used for automatic loading and unloading of lathes, and robots can replace manual operations. They can automatically complete the entire processing process, such as front bin material grabbing, OP1 loading and unloading, workpiece transfer, OP2 loading and unloading, and rear bin unloading, etc., realizing single-machine automated production, greatly reducing the labor intensity of employees. Operators are converted into equipment maintenance personnel, saving labor costs, and the robots have stable repeated positioning accuracy, which effectively guarantees the processing accuracy. It has opened up a development path for the company to achieve single-machine automation of lathe processing.
