Zhengheng Power and Seres Jointly Build Intelligent Production Line for New Energy Vehicle Engine Blocks
The HG15T(S919) project is a fully automated engine cylinder block production line designed and constructed by Zhengheng Power for Seres, now officially operational. This line focuses on the precision machining needs of core components in new energy vehicle powertrains, integrating intelligent equipment with digital management systems to deliver efficient and reliable manufacturing solutions.
Intelligent Production Line Empowers Efficient Manufacturing
To address the complex structural characteristics of the HG15T(S919) split-type upper and lower cylinder blocks, Zhengheng Power built the line around automation and digitization:
- Robot-Assisted Collaboration: Industrial robots handle machining, assembly, and disassembly of upper and lower cylinder blocks, reducing manual labor and ensuring consistent production rhythm.
- Stability Control in Precision Machining: Automatic feeding systems, combined with tool-setting modules and automatic tool compensation technology, guarantee precision consistency in critical machining surfaces.
- Full-Process Quality Traceability: By interconnecting MES (Manufacturing Execution System) and automated equipment, the line achieves traceability across the entire product lifecycle—from raw material intake to finished product delivery. SPC (Statistical Process Control) sampling and PPK (Process Performance Index) analysis enable closed-loop quality risk management and process optimization.
- High-Precision Process Assurance: Line boring technology ensures crankshaft bore coaxiality (PPK ≥1.33), while a four-stage honing process (rough grinding, semi-finish grinding, finish grinding, polishing) meets stringent requirements for cylinder bore diameter and surface roughness.
Key Technological Breakthroughs Enhance Product Reliability
The line achieves multiple upgrades in core processes:
- Dual Assurance of Assembly Accuracy: Fully automated pin press-fitting and 4-axis synchronous tightening technology for bearing cap bolts ensure torque consistency at critical joints.
- Precision Sealing Control: Glue application detection and pressure curve monitoring in automated water nozzle press-fitting equipment prevent leakage risks through real-time data feedback.
- Online Inspection & Closed-Loop Management: Real-time automated inspection of crankshaft and cylinder bore diameters, paired with SPC analysis, enables instant quality judgment and traceability.
- Anomaly Prevention Mechanisms: Tool breakage detection and spindle servo torque alarms preempt machining anomalies, minimizing downtime.
- Automated Pressure Testing: Upper and lower cylinder blocks undergo automated pressure testing, with qualified products seamlessly moving to subsequent processes.
The HG15T(S919) line not only showcases technological prowess but also reflects an upgrade in manufacturing philosophy. Zhengheng and Seres have jointly validated the feasibility of intelligent production lines in reducing costs, improving quality, and boosting efficiency—laying the foundation for future collaborative development of new energy core components.
Deepening Collaborative Innovation in New Energy
“The successful launch of the HG15T(S919) line demonstrates Zhengheng Power’s capabilities in precision machining and smart manufacturing,” stated a company representative. “Through modular line design and flexible production strategies, we delivered a cylinder block solution that balances lightweighting and high reliability, supporting Seres in optimizing new energy powertrain efficiency.”
As a core supplier in automotive powertrain components, Zhengheng Power has developed expertise spanning traditional engine parts and new energy three-electric (battery, motor, electronic control) system housings. This collaboration with Seres marks a deep exploration of synergistic innovation in the new energy industrial chain.
Zhengheng Power will continue advancing process innovation and digital factory development, aligning with trends toward lightweight and high-efficiency new energy vehicles. By partnering with industry leaders, the company aims to drive technological upgrades in core components and accelerate the rapid growth of China’s automotive sector.
Post time: Feb-26-2025
