Competition in the new-energy vehicle sector is entering "deep waters."

Lightweighting and cost reduction of chassis components

Become the key to overcoming technological challenges.

A heavy responsibility from Brand B.

It has fallen on the shoulders of Wanxiang Intelligent Manufacturing—

Develop a new-generation suspension arm for the flagship model.

This is not just a technological upgrade.

It’s even more of a “materials revolution.”

From aluminum alloy to high-strength steel

While meeting the demands of ultimate performance,

Achieve cost reductions of over 50%.

In a field full of unknowns and challenges,

The project team has embarked on a journey.

A Race Against Time: A Tough Journey to Overcome Challenges

Technical Team for the Development of the H Rear Suspension Arm Project at Wanxiang Intelligent Manufacturing Co., Ltd.

Received the 2024 “Innovation” Honor Title from Wanxiang Group.

01. Break through from scratch and forge ahead with unwavering determination.

Switching from aluminum to steel was the first “roadblock.”
This is not a simple material substitution.
The project team is facing
A “no-man’s-land” in technology
Raw data provided by the user
It is a complex forged aluminum structure.
To transform it into
Steel structure formed by stamping and welding processes
It means all the designs must be scrapped and started over from scratch.

The photo shows the project team holding a meeting to discuss the technical solution.

“This is what we did,”
The first small suspension arm aluminum-to-steel conversion project,
Both individuals and companies lack relevant experience.
Project leader Kong Yangfan said:
At the beginning of the design
To meet performance specifications by optimizing the structure.
Until you find the right approach, you’ll just have to “work your tail off.”
The biggest challenge comes from the rear suspension upper arm.
It needs to precisely avoid surrounding components such as shock-absorbing springs.
The space is extremely small.
Meanwhile, the stabilizer bar is installed on the rear suspension upper arm.
Make its stress state exceptionally complex.
Thus, design, simulation analysis, rejection, and redesign.
Has become the daily routine of the project team.
To meet users’ high expectations
We’ve revised the data dozens of times.
In countless late nights
The 3D model on the computer screen is constantly being adjusted.
But their conviction never wavered:
We must conquer this technological fortress!
With the united efforts of everyone,
The project team has developed a complex forged aluminum rear suspension arm.
Design and development of modified steel (sheet metal stamping) structures
At the industry's leading level

02. Late-night call—urgent deployment

If we say the test during the design phase is “mind-bending,”
Then, the challenge during the validation phase is truly “agonizing.”
Due to the extremely tight project timeline on the user end,
Any issue requires a quick response.

The photo shows the project team reviewing the experimental data.

The most memorable for the project team
It was the time when I kept my phone with me 24 hours a day.
B brand’s road-testing facilities are located all over the country.
such as Shaanxi, Jiangsu, Hainan, and other regions
Whenever there’s a problem with the test vehicle on the road,
The user’s phone will immediately come back.
“Why does the product crack? How can this be resolved?”
What should we do about preparing the mass production line?
Behind a series of questions lies immense pressure.
“We often receive notice of an urgent meeting the night before.”
I have to go on a business trip immediately tomorrow.
To avoid delaying the valuable road test cycle.
The project team often flies overnight to the local area, carrying new components.
Replace the failed component at the road test site to complete the test.
Then, bring the problematic items back to the lab for detailed analysis.
Evenings when you can't get a taxi at the remote test site.
The moment of holding a video conference in the early morning to analyze the issue.
It has become the most profound footnote in these years of struggle.
It is precisely this “rapid response, never shirking responsibility” that...
Extreme sense of responsibility
Gained users’ trust and respect.
Paved the way for the project's ultimate success.

03. Craftsmanship Delivers Exceptional Performance

From design optimization to product delivery
Only a mere 4 months.
During this period, it went through countless times.
Data iteration and process parameter adjustment
During the prototype stage
The engineers and prototype technicians are keeping watch together in the workshop.
Operation and debugging—repeatedly working overtime late into the night.

The photo shows the project team discussing process design.

Under the guidance of the model worker spirit,
The project team has achieved several technological breakthroughs.
Far exceeds user requirements
They use integrated molding technology.
The number of suspension arm parts has been consolidated from multiple parts into a single part.
The welding process has been completely eliminated.
Fatigue performance improved by 90%.
In high-flexibility structural design
The bending performance of the guide arm has been improved by 329%.
The project team has also developed an intelligent production line.
Independently designed new-type press-fitting equipment and integrated tooling.
Production takt time improved by 33%.
And resolved the issue of surface damage to the parts.
The project successfully applied for 4 core invention patents.
"Lightweight, high performance, low cost" has been established.
A comprehensive technical solution for differentiated competitive advantage

After scaling the towering peaks of technological breakthroughs,
The company completed the ramp-up to mass production in just 3 months.
The yield rate far exceeded expectations.
As the first batch of products is loaded onto trucks and heads toward the market,
Wanxiang Intelligent Manufacturing, backed by strong capabilities and high-quality products.
Officially joined the ranks of B brand’s core suppliers.
Bring the company orders covering multiple vehicle models.
Standing at a new starting point
The project team is setting its sights on even farther horizons.
This team that excels at tough battles.
We will continuously enhance our R&D capabilities.
Let the light of Wanxiang’s intelligent manufacturing technology shine.
On the global stage of new energy vehicles
Bloom even more brilliantly.