On December 24th, the live broadcast challenge event of the Star Yue L Thunder God Hi·X One Tank of Fuel for 1,300 km with full transparency came to an end at the Geely Yiwu Powertrain Base. The final result of the challenge was the achievement of driving 1,426.1 km with only one tank of gas, with a fuel consumption rate of 3.9L per 100 km.
3 Top-notch Technologies Used in the DHT Pro Hybrid Drive System
The Thunder God Power’s DHT intelligent micrometer factory has adopted micrometer-level carving precision manufacturing and micrometer-level management systems, which are comparable to European automotive manufacturing standards, achieving two levels of precision higher than traditional AT transmission systems.
Vacuum Quenching Process
Thunder God Power has adopted the French ECM vacuum furnace for heat treatment in its vacuum quenching process. It uses 11 specially designed vacuum quenching furnaces and fully infiltrates carbon atoms at a high temperature of 960°C by combining high-purity 20 Bar helium gas quenching.
This process ensures a surface hardness of 60 HRC while simultaneously controlling the core hardness at 33 HRC, balancing the external wear resistance and the internal material toughness. The depth of the hardening layer can be controlled within ± 0.1 mm, while the tooth shape deformation of the gear is less than 8 microns, which is twice as good as the industry standard.
Intelligent Induction Heating and Subquenching Process
With DHT Pro, Geely has achieved the first large-diameter ring gear mass production using intelligent heating and pressure subquenching technology in Asia. The EMA automatic water-cooled pressure quenching machine prevents deformation, and the gear tooth deformation after heat treatment is controlled within ± 8 microns, allowing for the application of post-heat minimal margin hobbing process, breaking through the current industry practice of not processing ring gears after heat treatment.
Rolling and Grinding Hobs Process
Through specially designed cutters, DHT Pro can achieve three-dimensional “on-demand twisting” special tooth shapes and irregular surface textures that cannot be achieved by conventional processing methods, by machining gears from horizontal, vertical and circular directions. The surface roughness of the tooth surface is improved from Ra 0.4 of traditional gear grinding to Ra 0.25, and the depth of surface machining marks is less than 2 microns, which is better than the 3.2 microns of grinding technology commonly used in the industry, effectively reducing fixed-order noise generated during the meshing process and significantly improving the NVH of the meshing process.
In addition, DHT Pro maintains consistent quality through ultra-precision manufacturing and measurement processes, such as 1 micron shaft neck smoothness, 0-5 micron compensation accuracy, and 0.3 micron ultra-high precision three-coordinate measurement.
Advanced Management
Micron-level manufacturing excellence is not only reflected in carving precision but also in management systems. DHT Pro is the first Chinese brand to integrate a 60 bar high-pressure hydraulic system with a hybrid electric drive. Its hydraulic system valves are assembled in a “dedicated chamber” in a micron factory.
This chamber can circulate 25 times per hour and has a 99.9% particle capture rate for suspended particles of 0.3 microns or larger in the air, exceeding the level of N95 masks. It is truly an IC-grade dust-free assembly workshop. It is worth mentioning that DHT micron factory also uses a “0 error” intelligent matching system, precisely grouping and controlling the entire assembly process to the micron level, ensuring excellent quality throughout the product life cycle.
Every “magic machine” must pass the strictest “graduation exam” and establish a lifelong record before it can go offline. The two major testing systems of EOL testing and valve body testing, which cost hundreds of millions of yuan to build, can carefully inspect all functions and NVH performance. The inspection process involves more than 100 steps and up to 685 step parameters, achieving 100% fully automated testing and achieving a 100% pass rate.
🔗Source: Geely
This article is a translation by ChatGPT of a Chinese report from 42HOW. If you have any questions about it, please email bd@42how.com.