I. Material and Structural Innovation: Lightweighting and Functional Integration
1. Die-Cast Aluminum Alloy Oil Sump
● Lightweight Benchmark: Utilizing aluminum alloys such as A380 and A356-T6, this system achieves a 30%–40% weight reduction compared to traditional steel Oil Sumps, helping to reduce vehicle fuel consumption by 5%–8%. For example, the rough stock of a 1.5T engine Oil Sump weighs only 10.74kg yet meets high-pressure sealing requirements of 300kPa in the internal cavity and 600kPa in the oil passages.
● Highly Integrated Structure: The balance shaft, oil passages, and Oil Sump are integrated into the design, reducing engine size and assembly steps. For example, one integrated Oil Sump utilizes a "three-sided casting + high-vacuum exhaust" process, enabling mass production of complex structures (annual production of 400,000 units, with a ≥97% pass rate).
2. Composite Oil Sump
● Extreme Weight Reduction: Nylon + Fiberglass material reduces weight by 60% compared to metal oil pans (e.g., 30kg for steel vs. 10kg for composite), meeting the stringent range requirements of new energy vehicles.
● Outstanding Weather Resistance: Maintains sealing reliability under temperature cycles from -40°C to 150°C, with extended service intervals up to 200,000 kilometers, suitable for long-term commercial vehicle operation.
3. Forged Aluminum Alloy Oil Sump
● High-Performance Track-Grade: Machined from a single block of 6061-T6 aircraft aluminum alloy, featuring a built-in O-ring groove for glue-free sealing. This increases oil capacity by 15% and heat dissipation by 25%, making it suitable for high-revving engines like those found in racing cars like the GTR R35.
II. Die-Casting Technology Features: Process Innovation and Quality Assurance
1. Core High-Pressure Die-Casting Process
● Clamping Force and Filling Control: Utilizing an 800–1650T cold-chamber die-casting machine (such as the ZDC-800T with 800T clamping force), coupled with "three-side pouring + high vacuum exhaust (vacuum ≤ 4kPa)" technology, this technology addresses porosity and shrinkage defects in complex structures.
● Super-spot Cooling and Intermittent Water Supply: Super-spot cooling pins (Ø4mm diameter) are designed for hot spots (such as threaded holes and intersections of wall thickness). The mold temperature is precisely controlled at 220°C ± 20°C. Intermittent water supply with a "5s delay, 13s cooling" pattern prevents shrinkage cracking.
2. Efficient Production and Intelligent Control
● Single-Mold, Multi-Cavity Design: For example, the balancing bearing cover utilizes a "1-cavity, 8-mold" layout, reducing unit production costs by 40% compared to sand casting and making it suitable for large-scale production (annual output ≥ 50,000 pieces).
● Real-time Parameter Monitoring: The MES system links the die-casting machine with auxiliary equipment, enabling real-time comparison of 18 parameters, including injection speed (high speed ±3m/s), molten aluminum temperature (675±10°C), and vacuum (≤4kPa). Any deviations are automatically scrapped, ensuring batch stability.
3. Exhaust and Sealing Technology Breakthroughs
● Three-Dimensional Chilled Exhaust Valve: The traditional "I"-shaped exhaust channel is replaced with a "W"-shaped curved structure, increasing the exhaust area by 1–3 times and improving extraction efficiency by 2–4 times. This solves the problem of oil pan high-pressure oil channel leakage (for example, a Guangdong Hongtu Oil Sump leaks ≤2.7mL/min at 700kPa).
III. Market and Application Adaptation
● Passenger Vehicle Sector: Die-cast aluminum alloy Oil Sumps are the mainstream, suitable for 1.5T–2.0T engines, meeting the lightweighting and thermal management requirements of the China VI emission standards.
● Commercial Vehicle Industry: Our composite oil pans have been certified by Cummins, Sinotruk, and other companies, with an annual production capacity of 1.5 million units, achieving the dual advantages of "weight reduction and long life."
● Racing Industry: Our forged aluminum alloy Oil Sumps are CNC-machined from a single piece to support continuous high-speed operation, such as the VR38DETT engine in the GTR R35.
