From single point breakthrough to gradual expansion, Donghua Machinery's advanced path in the field of new energy vehicles

Lightweight, intelligent, and electrified. These three keywords not only define the product strength of new energy vehicles, but also the complete manufacturing chain behind the vehicle. The transmission path of change is not complicated: OEMs demand higher standards, component suppliers are forced to follow suit, and ultimately it is transmitted without reservation to the core of equipment manufacturing: injection molding machines.

Once regarded as a "supporting role", plastic parts are now evolving into a complex carrier carrying functional integration and appearance differences.From continuous light strips to intelligent cabin interiors, from precision components of three electric systems to large integrated structural componentsThe challenge faced by injection molding technology is no longer whether it can be done, but how to make it more precise, faster, and more stable.

01.

Device positioning is being restructured

The development of intelligent connected vehicles has raised higher standards for the appearance quality, weather resistance, and functional integration of plastic components, and these changes are deeply transmitted to the upstream equipment manufacturing industry.

Need to push the equipment from a simple molding tool to a collectionPrecision manufacturing, functional integration, and data intelligenceA complex system that integrates cost-effectiveness and stability. Only by making it affordable for more enterprises can more innovation be fostered.

From the bidding documents of top enterprises, digital and intelligent transformation has become a mandatory question. For auto parts factories, this means that the equipment must truly support higher yield, more stable mass production, and more controllable overall costs.

02.

Donghua's pragmatic approach:

Balance efficiency, accuracy, and stability

Donghua Machinery does not blindly pursue larger tonnage, nor does it mythologize the short-term effects of AI, but adheres to the strategy of "single point breakthrough, gradual expansion".

For small and medium-sized injection molding machines (under 500 tons), elbow bar typeAll electric injection molding machineIt is the first choice. The accuracy and stability of the entire motor have become industry consensus and are increasingly accepted by the market.

For large injection molding machines, two plate electric injection molding machines are a cost-effective choice. Taking the Donghua JHB series as an example:

　　machine characteristics

　　Adopting a two plate locking and electric shooting platform scheme, significant efficiency improvement has been achieved through multi axis linkage technology

　　The firing rate is 1.5-1.8 times that of a regular aircraft

　　The screw speed is 1.2-1.5 times that of a regular machine

　　On the premise of ensuring the inherent accuracy and stability of electric injection molding machines, the molding efficiency is greatly improved, especially suitable for mass production of large automotive components such as bumpers and door panels.

In terms of core technology, the JHB series also reflects independent exploration: adopting IPM convex poleservo motorCooperate with MTPAAlgorithm (maximum torque current ratio algorithm) and PLC injection torque algorithm control. In the same 150MPa injection pressure test, the average current of JHB injection motor was only 95A, while the other one reached 160A, significantly reducing heat generation and energy consumption.

1600JHB Two Plate Electric Motor

　　These practical technological optimizations mean more stable production status and lower long-term operating costs for factories.

03.

Real delivery verification

With the expansion of the new energy vehicle industry chain and the deepening of domestic substitution, domestic injection molding machines have moved from the "usable" stage to a new stage of "precision, good use, and high efficiency".

A typical case is Donghua andGreat Wall MotorCollaboration: Transforming the injection platform of a hydraulic press into an electric injection platform, and after the transformationThe repeatability accuracy of product weight reaches 0.9 ‰And the main components are all made of domestic parts.

This case directly proves that the domestic supply chain has a solid foundation and provides reliable localization references for other auto parts factories - higher precision, consistent batch performance, and more stable supply chain support.

Great Wall Motors Customer Workshop (Part 1)

04.

Clear industry judgment

Objectively speaking, apart from the thin-walled light guide plate field still dominated by high-speed machines imported from JapanCar lamp manufacturing, precision electronic component molding, etcIn most high-end scenarios, domestically produced full motors can already meet production needs.

Although servo hydraulic presses still have certain cost advantages in some special fields (such as thick walled optical component production), overall, domestically produced all electric injection molding machines have strong competitiveness.

But we must face a core bottleneck: the domestic high-end all electric injection molding machineCore components such as ball screws and high-speed controllers (PLC)Still relying on imports. Under the premise of hardware gap, intelligent algorithm compensation can be used to achieve "overtaking on curves".

Donghua Machinery continues to promote the development of intelligent functions and is also aware that algorithms have their boundaries. Intelligent algorithms can play an important role in precision compensation, process optimization, data warning, etc. However, in the face of the hardware gap at the purely mechanical level, hardware and software collaborative iteration is still needed.

For example, when developing an electric high-speed packaging machine, the domestically produced ball screw can experience a temperature rise of over 30 degrees Celsius (close to the critical value) after running for half an hour under rapid mold opening and large load conditions, resulting in thermal expansion, contraction, and mechanical deformation; And the temperature rise of imported parts under the same working conditions is only about 10 degrees.

　　Donghua has been focusing on long glass fiber reinforced materials since 2006In response to the application needs in the fields of automotive parts (bumpers, door panels), household appliances (air conditioning fan blades), precision instrument packaging containers (toolboxes), etc., and in cooperation with South China University of Technology, we have developed the IMC1200 long glass fiber online mixing and injection molding machine.

In the past decade, with the deepening trend of automotive lightweighting, high-performance materials such as carbon fiber reinforced plastics and long glass fiber composite materials have been increasingly widely used. For injection molding machines, the key lies in the targeted structural design of the plasticizing part:

　　Low shear design: reduces mechanical damage to reinforcement materials while preserving fiber length.

　　High wear resistance configuration: The reinforced material has high hardness and significant wear, requiring the use of wear-resistant solutions such as fully hard alloy screw components.

　　
This type of long-term layout reminds us:Single point breakthrough, gradually expandingStill the real path. Admitting the gap is the key to down-to-earth and continuous iteration.

05.

The true turning point towards high-end

Full chain system collaboration

The three major bottlenecks of mold accuracy, process stability, and adaptability to new materials are essentially a manifestation of insufficient systematic capabilities.

Although a single breakthrough is important, the real turning point lies in establishing a full chain collaborative capability covering design, manufacturing, control, and process. Donghua looks forward to working together with host manufacturers, component suppliers, material and mold partners to promote.