Investigation of Diesel Engine Crankshaft Industry
Regional distribution of the crankshaft industry
The crankshaft is an important part of the engine and the working environment is harsh. Especially for automotive diesel engines, the machining accuracy, toughness and strength of the crankshaft are higher than those of general parts. It is precisely because the quality of the crankshaft has a direct impact on the performance of the diesel engine, China's diesel engine companies are basically homemade crankshaft. Only under the market economy conditions, the engine plant to seize the market share in order to expand production, to adapt to the general trend of cooperation in the division of labor, only procurement of accessories manufacturers of products supporting. The crankshaft manufacturers discussed in this article do not include diesel engine OEMs.
According to statistics, there are about 108 crankshaft manufacturers for automotive diesel engines above designated size in China, mainly located in Shandong, Liaoning, Jiangsu, Zhejiang, Anhui and Hunan. Compared with other accessories, the characteristics of regional accumulation of crankshaft enterprises are more obvious, and the regional concentration is relatively high.
The reason why such a pattern is formed as shown in Figure 1 is that these regions have strong industrial bases and strong metal processing capabilities; second, these provinces distribute important crankshaft supporting enterprises - diesel engine plants (Shandong Province: Weichai, China Heavy Truck, Shi Feng, Shi Feng Yanmar, Zibo Diesel Engine Factory, Lai Dong; Jiangsu Province: Xichai, Sida, Changchai, Yangchai, Yuejin, Yangdong, Jianghuai Power, Rugao Diesel Engine Factory, Nantong Diesel Engine Factory; Liaoning Province: Dachai, Dongfeng Chaochai; Zhejiang Province: Hangfa, Xinchai, Sanhuan, and Geo.
Judging from the distribution of crankshaft companies in major provinces, Shandong Province has the largest engine crankshaft enterprise Tianrun Crankshaft Co., Ltd., and Haid crankshaft, Laiyang crankshaft and other crankshaft factories with strong strength. These enterprises are characterized by large scale, complete series and high technical content. The number of crankshaft enterprises in Liaoning Province is second only to Jiangsu. The most important enterprises are Liaoning 518, Liaoning North Crankshaft Co., Ltd., Shenyang Crankshaft Factory, and Lingyuan Hongfa. The remaining more than 10 crankshaft plants are relatively small, mainly based on light diesel engine crankshafts. And some manufacturers are non-supporting companies. Jiangsu is a major producer of crankshafts. The representative crankshaft companies include Jiangsu Songlin, Jiangsu Wanli, Jiangsu Bolette, and Jiangdong crankshaft. However, except for the Jiangsu pine forest, most crankshaft companies only produce light products, which are Yangchai and Sida. Changchai and other supporting facilities. There are also a large number of crankshaft manufacturers in Jiangsu Province that are equipped with single-cylinder and twin-cylinder diesel engines.
Analysis of the supporting pattern of the crankshaft market
From the perspective of crankshafts in the matching market, before 2005, the overall demand for four-cylinder crankshafts was relatively stable, and the total amount of supporting crankshafts was less than that of six-cylinder diesel engines. Since 2005, the increase in the commercial vehicle market has increased and the demand for crankshafts for four-cylinder diesel engines has been significantly higher than that for six-cylinder diesel engines (see Figure 2). In 2009, the state issued a series of supporting policies for light trucks, and the output of four-cylinder machines was further ahead of the six-cylinder machine. It is expected that this pattern will not fundamentally change in the next two years. Due to the irreplaceability of agricultural transport vehicles and low-speed trucks, they still show very stable and rigid demand in the context of the subsidy for light trucks. Therefore, small-displacement four-cylinder engines and diesel engines with two or more cylinders will be longer. During the time, the trend is strong, while the single-cylinder machine will continue to linger in the depressed zone. This is also one of the reasons why a large number of small crankshaft factories supporting single-cylinder agricultural vehicle diesel engines can survive and are difficult to develop and break through.
From the perspective of supporting enterprises (see Table 1), the heavy-duty crankshaft production company is mainly Tianrun Crankshaft Co., Ltd., which had a share of approximately 38.22% of the heavy-duty diesel engine crankshaft market in 2008. It completed listing in 2009 and expanded Xichai in part. , Weichai, Cummins, after the heavy machinery production capacity, the market share will be close to 40%, in 2010 is expected to reach 45%, it is expected that by 2013, Tianrun crankshaft company heavy-duty diesel engine crankshaft market share will reach the highest peak 50%, after The proportion will be around this point (the crankshaft made by the diesel engine manufacturer, the multinational crankshaft company and other heavy-duty crankshaft manufacturers with relatively strong strength will still occupy a certain percentage). Tianrun's major competitors in heavy-duty crankshafts are Liaoning No. 18 and Jiangsu Songlin, Lingyuan Hongfa, etc. However, these companies are relatively small compared to Tianrun. The medium-sized diesel engine has little market space, which makes the market capacity of medium-sized engine crankshafts have limited growth. The market share of Tianrun Company is about 16.8%. The rest of the companies are Haide crankshaft, Guilin Fuda and Jiangsu Songlin. Lightweight crankshaft lining has low capacity and has nearly one hundred crankshaft manufacturers. However, the high-end light crankshaft products are basically provided by diesel engine manufacturers and Tianrun crankshafts, Haide crankshafts, Guilin Fuda, Hangzhou Jiangnan, and Shenyang crankshaft mills.
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Crankshaft industry concentration will slowly increase
After years of rapid development, the output value of the crankshaft crankshaft companies in our country varies greatly. At present, with the implementation of State III emission standards and a new round of foreign investment, commercial vehicles have been fully upgraded, and fuel economy and noise reduction have become important performance indicators. Therefore, the supporting market for crankshafts will increasingly be concentrated in large and technologically advanced factories. Giant companies with an annual output value of over 500 million yuan are welcoming more development space and opportunities.
As shown in Figure 3, China's crankshaft companies only account for 3.71% of their annual output value of more than 500 million yuan. Even if companies count more than 300 million yuan as the first echelon, there are only a few, only Tianrun crankshaft, Liaoning May 18th. , Guilin Fuda, Jiangsu Songlin, Jiangsu Wanli and more than a dozen. It is these small companies that account for the vast majority of the heavy and medium-sized crankshaft market. In recent years, the capacity expansion of the diesel engine crankshaft industry has mainly concentrated on these enterprises. Among them, Tianrun crankshaft has grown into an international, modern, and open crankshaft leader and has become China's largest manufacturer of high-end crankshaft engines. From 2006 to 2008, the company’s operating income reached 488 million yuan, 749 million yuan, and 819 million yuan, respectively, an increase of 23%, 54%, and 9.5% year-on-year, respectively, achieving a net profit of 0.32 billion yuan, 0.94 billion yuan, 1.13 respectively. Billion yuan, a year-on-year increase of 106%, 194%, and 20% respectively. In 2009, 60 million A-shares will be listed and issued, and the production capacity of the crankshaft production line that has been funded will reach a substantial increase after production. It is expected that a series of corporate restructurings and acquisitions will be launched. As early as 2005, Fuda invested together with Dongfeng Cummins to establish Xiangfan Fuda Dongkang Crankshaft Co., Ltd., becoming the company's global procurement supplier. In 2007, the foundation of Fuda Guilin Automobile Parts Industrial Park was laid. In 2008, Fuda's low-speed vehicles and special-purpose vehicles were put into operation, filling a gap in the production of low-speed cars and special-purpose vehicles in Guangxi. On December 18, Fudan Group's Forging Center construction project was started. It is estimated that the first-phase construction investment will be 5.1 billion yuan, and 3 fully automatic hot die forging production lines with international advanced level will be built to form an annual output of 57,000 tons of precision forgings. The annual production and sales amounted to 820 million yuan, profits and taxes 150 million yuan. In 2009, Haiden crankshaft also launched a new crankshaft rough normalizing and tempering heat treatment production line.
In recent years, the total production and sales volume of cars has grown much faster than that of commercial vehicles. Many diesel engine crankshaft companies have invested in the production line of crankshafts for gasoline engines. It is much more cautious for the expansion of diesel engine crankshafts.
In addition, an annual output value of 30 million yuan to 100 million yuan concentrated a number of large-scale enterprises, most of them mainly light diesel engine crankshaft enterprises. With the implementation of policies such as the implementation of light vehicles to the countryside, these enterprises have ushered in a more relaxed period of development. And more than 60% of the crankshaft factory annual output value is below 30 million yuan, this part of the company mainly produces single-cylinder diesel engine crankshaft. The survey found that companies in this segment did not have large-scale improvements in equipment and products for more than three consecutive years. Since 2003, more than a dozen companies have gone bankrupt, auctioned or changed.
Figure 4 shows the average sales value of several companies in the diesel engine crankshaft industry with large scale and good operating performance. The figure shows that per capita sales of Jiangsu Wanli, Tianrun crankshaft and Guilin Fuda are relatively high. More than 350,000 yuan per capita. This value is among the best in the entire auto parts industry. Explain that these enterprises have high technological content, advanced equipment, and high quality employees. Most of the rest are about 11.2 million yuan per capita. In fact, there are about 50% of the diesel engine crankshaft industry, the per capita sales of less than 80,000 yuan, the lower only about 60,000 yuan. Most of these companies are outdated equipment, aging products, a considerable proportion of employees engaged in migrant workers, most of the production of diesel crankshaft less than four cylinders. The survey found that some of them only started production seasonally during periods of high demand.
In summary, the difference in the competitiveness of diesel engine crankshaft companies is increasing. It is expected that the industrial concentration of heavy-duty diesel engines and high-end light diesel engines will be greatly enhanced in the future. The medium-sized diesel engine crankshaft market is narrow, and the current pattern is basically maintained. The low-end light diesel engine crankshaft has a large number of users due to the large market demand, and the pace of industrial concentration will be relatively slow.
Technology R&D Helps Enterprises Improve Their Competitiveness
Perhaps due to the difficulty of crankshaft processing and its special importance in diesel engines, compared with other types of parts and components industry, crankshaft companies generally pay attention to the role of R&D and technical personnel, even for smaller factories. A considerable proportion of technicians.
From figures 5 and 6, it can be seen that some of the major diesel engine crankshaft manufacturers such as Tianrun and Liaoning Wuyi have a higher percentage of technical personnel. The Shenyang crankshaft factory also has a large proportion of passenger vehicles and the proportion of technical R&D personnel. Higher. As the largest manufacturer in the industry, Tianrun Crankshaft Co., Ltd. has more than 2,000 employees and over 400 professionals. The company also has the nation's first crankshaft engineering and technology research center, national post-doctoral research station, and national-level technology center.
In April 2009, Tianrun's "Development of High-strength and High-toughness QT900-5 New Material and Application Development on High-Power High-Speed ​​Supercharged Diesel Engines" and "Research and Development of Heavy-Duty Full-Electronic Engine Cummins ISM11 Crankshaft" passed the Chinese Academy of Sciences. The appraisal that the technology is a domestic and foreign first, ranking the international advanced level. Guilin Fuda and Tsinghua University jointly established the Tsinghua-Fudan Automotive System Technology Development Institute, which created a precedent for China's private enterprises and the establishment of the Institute of Tsinghua University.
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In recent years, most of the high-end models use steel crankshafts, but the price of steel crankshafts is high, and companies have made arduous explorations on iron-based steel technology. Binzhou Haide Company adopts a round rolling process and ion nitriding technology to reinforce the nodular cast iron crankshaft. The anti-fatigue performance is significantly improved. The strength is close to the steel crankshaft, but the price is only 70% of the steel crankshaft. It is reported that hundreds of thousands of engines have benefited from this technology. After Dongfeng Chaochao’s selection of the company's products after a series of assessments and tests, it has been used in the market with excellent performance and reliable quality. Experts said that forged steel crankshaft has become the future direction of development. However, this does not mean that the cast iron crankshaft is going to be wood, and the ductile iron crankshaft reinforced by the fillet rolling surface has taken an important step in the direction of replacing the steel crankshaft.
At present, the multi-knife turning process and manual grinding process that have been used for more than half a century are quitting the stage of history. High-speed and high-efficiency composite processing technology and equipment rapidly enter the automobile and parts manufacturing industry. High-speed and high-efficiency composite machining technologies have been used to a considerable degree in crankshaft machining. Some major crankshaft companies have also introduced a large number of German KW casting lines and Germany. BECHE forging production line, Austrian gas nitrocarburizing crankshaft production line and other advanced equipment processes.
It is the crankshaft companies that generally value the quality of the products. The crankshafts sold in the market are of better quality and are relatively stable. The qualification rate is higher than that of other parts of the diesel engine. In 2008, the General Administration of Quality Supervision, Inspection and Quarantine carried out state supervision and spot checks on the quality of crankshaft products. A total of 40 products produced by 40 companies in 9 provinces and municipalities including Hebei, Shanghai, Jiangsu, Zhejiang, Anhui, Shandong, Henan, Hubei and Hunan were spot-checked. The qualified rate of product physical quality sampling was 97.1% (see Table 2).
The spot checks are based on the requirements of the national standards and related product standards such as JB/T6727-2000 "Technical Conditions for Crankshafts of Internal Combustion Engines" and QC/T481-2005 "Crank Specifications for Automotive Engine Crankshaft", the flaw detection of crankshaft products, and the surface hardness of spindle necks. Twelve items such as connecting rod journal surface hardness, metallurgical microstructure, quenching and tempering hardness, and mechanical properties were examined. The spot check results showed that the spot check, the hardness of the main journal surface, the surface hardness of the connecting rod journal, and the surface roughness of the journal fillet surface were 100%. Moreover, the large-scale production enterprises with higher market share have better product quality, and all the items they have examined meet the requirements set by national standards. The main quality problem in spot inspection is that some products such as hardness, metallographic structure, and tensile strength are unqualified.
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