柴油-天然气单燃料汽车改装方案

柴油-天然气单燃料汽车改装 柴油/天然气单燃料汽车改装方案 CONVERSION PROGRAM FOR DIESEL TO CNG SINGLE FUEL VEHICLES CONVERSION PROGRAM XX燃气设备(上海)有限公司 Technology Techforgas (Shanghai) Ltd. 二OO九年九月 September, 2009 目录Content 一、 序INTRODUCTION 1 二、 改装资质QUALIFICATION FOR THE CONVERSION 2 三、 人员要求、具体分工PERSONNEL AND DIVISIN OF DUTY 3 四、 发动机具体改造实施方案IMPLEMENTATION PLANS FOR CONVERTING THE ENGINE 4 五、 改装安排及场地设备要求Conversion arrangement and facility requirements 4 六、 改装技术CONVERSION TECHNICAL STANDARDS AND REQUIREMENTS 11 七、 经济效益及资金回收期ECONOMIC BENIFITS AND CAPITAL PAYBACK PERIOD (INCLUDING QUOTATIONS) 18 18 八、 改装成本演示(含报价)CONVERSION COST 九、 燃气汽车智能电控燃气系统优点:ADVANTAGES OF THE SMART ELECTRONIC GAS SYSTEM OF CNG VEHICLES: 18 附一:Annex I 19 一、 序I Introduction 现代汽车工业的发展给社会带来了巨大财富，但也同样带来了严重的废气排放污染。 Modern automobile industry has brought tremendous wealth, but also caused serious pollution. 汽车排放污染对大气污染的分担率达到了30%-60%(而被称为―绿色汽车‖的天然气汽车在 环保方面具有显著效益，汽车尾气中一氧化碳可减少97%，碳氢化合物减少72%，二氧 化硫减少90%，噪音减少40%，导致人体呼吸道疾病及癌症的苯、铅粉尘等减少100%)， 已成为城市污染的主要来源。Automobile polluting emissions account for 30% -60% of air pollution, having become a major source of urban pollution (however, "green cars" using clean natural gas have significant environmental benefits; carbon monoxide, hydrocarbons and sulfur dioxide in vehicle exhaust are reduced by 97%, 72%, and 90% respectively, in addition to noise reduction of 40%; benzene, lead dust which can lead to human respiratory disease and cancer are reduced by 100%). 天然气汽车发展从上世纪30年代起，已有70多年的历史，特别是近些年来，先进的电子 技术和机械制造技术使天然气汽车的安全性和控制性能得到保证，续驶里程由初始50, 70公里提高到300-400公里以上;天然气汽车气瓶重量和加气站的体积大为减少;给汽 车加注天然气同加注燃油一样方便，快速充气仅需5,15分钟，因此天然气汽车技术已趋 于成熟。Since its development in the 30s of the last century, CNG vehicles have developed for some 70 years. Especially in recent years, advanced electronics and mechanics have greatly enhanced the safety and performance of CNG vehicles. Continued driving distance has increased from the initial 50 ~ 70 kilometers to over 300-400 km, and cylinder weight and the size of filling stations have seen a significant drop. It is equally convenient to fill gas as oil fuel, and fast filling only takes 5 to 15 minutes; all this shows that CNG vehicle technology has matured. 目前世界上天然气汽车保有量已超过600万辆(其中货运和客运车中以柴油/天然气单燃料 车居多)，主要分布在富气贫油的意大利、新西兰、阿根廷、印尼等国家和环保法规严格的 美国、日本等。Currently, there is a CNG vehicle ownership of over 6 million (of which freight and passenger cars are mostly diesel / CNG single-fuel type), distributed predominantly in Italy, New Zealand, Argentina, Indonesia and other countries with rich reserves of gas and scanty oil resources, and in countries with strict environmental regulations like United States and Japan. 欧美的一些专家认为，从技术成熟度、经济性、易普及程度、资源等方面因素看，柴油/ 天然气单燃料汽车是最具发展潜力的汽车。Some European and American experts believe that, based on factors of technical maturity, economy, easy penetration and resource availability, diesel / CNG single-fuel vehicles have huge development potential. 从发展的眼光看，我国有可能进入天然气开发和应用领先的国家行列，因此，在现阶段大 力发展柴油/天然气单燃料车是解决油价节节升高，运输成本不断上涨，加油站布局不合理， 石油供需矛盾突出的有效途径和保障车辆正常运营的有效手段。From a development perspective, China may enter the ranks of the leading countries in exploration and application of natural gas. Therefore, diesel to CNG single-fuel conversion can be used effectively to address issues of escalating oil prices and transportation costs, irrational filling station distribution and the obvious contradiction between oil supply and demand, and to ensure the normal running of vehicles. XX燃气设备(上海)有限公司，采用国际先进改装技术，配备专业的技术服务团队，结合中 国实际情况，为您提供适合本土情况的解决方案。Technology Techforgas (Shanghai) Ltd., having internationally advanced conversion technology and professional service teams, will provide you with solutions suited to China local conditions. 1 现我公司针对西安柴油货运车提供如下解决方案:The solutions we provide for Xi'an diesel freight vehicles are as follows. 二、 改装资质II Qualification for the conversion 为合法改装CNG柴油/单燃料车，需要在省质量技术监督局申请一套压力容器安装维修许 可资质。(主要负责部门为省质监局特种设备处) In order for diesel to CNG single-fuel conversion to be legally viable, a license for pressure vessel installation and maintenance shall be available by applying to the Provincial Bureau for Quality and Technical Supervision. (The responsible department is the Special Equipment Branch of the Provincial Bureau for Quality and Technical Supervision) 五、 改装场地及设备要求V Conversion site and equipment requirements 改装场地要求Requirements for the conversion site 改装厂需设在具有二级维修资质及以上的修理厂，要求能独立大修各型柴油发动机。The conversion facility is required to have the secondary or above qualification for repair and maintenance, capable of independently overhauling various types of diesel engines. 改装场地要求两条以上地沟，地沟外作业面积不小于300平米，要求电、水、暖、焊机及 起重设备等配套。The facility shall have more than 2 trenches and no less than 300 square meters operating area around the trenches, as well as supporting equipment for electricity, water, heating, and welding and lifting devices, etc. 检测设备Testing Equipment 1、 手提电脑1台(带USB串口)，汽车电脑程序设定用One portable computer (with USB serial ports), for setting auto computer program 2、 柴油车缸压表1套，检测发动机各缸压力One set of cylinder pressure meter for diesel vehicles, used for checking engine cylinder pressure 3、 万用表1只，维修调试量电压用One multimeter for measuring voltage during maintenance 4、 点火正时枪1把，检测发动机点火时间One ignition timing gun for checking engine ignition time 5、 高精度电子秤1只(精度1克)，加工发动机活塞用One high-precision electronic scale (accuracy 1g) for use in machining the engine piston 6、 20MPa高压试压设备1套One set of 20 MPa high-pressure testing equipment 改装厂所需工具设备The necessary tools included: 2 1: 电焊机(大)1台 14: 工具车2台 Welding machine (large) 1 Tool Cart 2 2: 切割机1台Cutting machine 1 15: 工作灯6把Work Lights 6 3: 台虎钳1台 16: 插线板2套(轴式) Table vice 1 Plug-line board 2 (axis) 4: 台转1台Bench drill 1 17: 拉铆枪1把Riveter 1 5: 手电转(大)2把 18: 干电磁式手电转2把 Electric hand drill (big) 2 Dry electromagnetic flashlight switch 2 6: 手电转(小)2把 19: 丝锥柄1只(小，竖式) Electric hand drill (small) 2 Tap handle 1 (small, vertical) 7: ,2.2-16转头两套 20: 丝锥M6---M14, 1套 Taps M6 --- M14, 1 ,2.2-16 swivel 2 sets 8: 汽保工具3套 21: 起子各4把 Auto maintenance kit 3 sets Drivers, 4 pieces each 9: ,8-25套筒两套 22: 砂轮机1台 Grinding machine 1 ,8-25 sleeve 2 sets 10: 电烙铁1把Electric iron 1 23: 35毫米开孔器1个35 mm hole saw 1 11: 电工专用工具1套 24: 气焊设备一套 Special electrician tool 1 Gas welding equipment 1 12: 电动扳手一把Electric Wrench 1 25: 榔头1把Hammer 1 13: 钳子2把Pliers 2 三、 改装人员要求、具体分工III Personnel and division of duty 我公司配有专业技术改装人员，可提供上门指导服务，进行样车试改以及培训工作。Our company has skilled conversion technicians providing on-site services, sample conversion and training. 如何组织、管理改装(改装厂)人员:How to organize and manage personnel engaged in the conversion (in a conversion facility): (一) 安装人员要求分3组，每组5名。(i) The personnel are to be divided into 3 groups of 5. 每组人员要求有机修工三名，电工一名，焊工1名。Each group requires three mechanics, one electrician and one welder. 其作业内容为:2名负责气瓶及管路安装;1名负责燃气装置安装;1名负责电器安 装;1名负责发动机拆装(能大修各种发动机的机修人员)。The conversion involves the following operations: 2 people will be responsible for cylinders and pipeline installation; one for installation of the gas device; one in charge of electrical 3 installation; one in charge of dissembling and assembling the engine (a person capable of overhauling a variety of engines). (二) 焊接人员1名:具体负责改车过程中的各种支架制作，各种管接头的焊接及安装过 程中的配合支持。(ii) The one welder will be responsible for the production of a variety of stents, welding of connectors and support tasks. (三) 资料员1名:具体负责改车过程中各项档案资料收集、整理、保管。(iii) The one filer will be responsible for the collection, collation, storage of files during the conversion. (四) 外勤1名:具体负责改车过程中所需材料、对外联络、协调事宜、后勤保障等工作。 (iv) The one coordinator will be responsible for materials needed in the conversion process, external liaison, coordination and logistics, etc. (五) 外协加工1名:具体负责加工改车过程中所需的配件，要求与改装进度密切配合。(v) The one purveyor will be responsible for providing he needed parts, closely coordinating his work with the conversion progress. (六) 调试员1名:具体负责检验及调试单燃料车辆，要求熟悉各种电脑操作软件，并具 备专业的汽车维修知识。(vi) The one tester will be responsible for testing and commissioning of the single-fuel vehicle, who shall be familiar with various computer operating software and have professional knowledge of vehicle maintenance. (七) 试车员2名:要求对所改装车辆进行路试、载重试验等工作，并将发现的问题及时 给调试员。(vii) Two test drivers will carry out road tests and load tests for the converted vehicles, and timely reporting to the tester for any problems found. (八) 厂方技术员1-2名:负责改车过程中的技术指导工作和检验工作。(viii) One or two factory technicians will be responsible for giving guidance and inspection work in the conversion process. (九) 管理人员两名:负责改装厂的任务下达及日常管理工作。(ix) Two management staff will be responsible for task assignment and daily management. 四、 发动机具体改造实施方案:IV Implementation plans for converting the engine 在柴油车改装天然气过程中，需对原发动机进行改造，具体改造要求为:拆掉发动机缸盖、 进排气支管、取出活塞。The conversion from diesel to CNG vehicles requires changes to the original engine; specifically it requires removal of the engine cylinder head, intake and exhaust manifold and the piston. 对原活塞进行加工，作用是降低原发动机压缩比;在进气支管口加装节气门座和节气门体 及混合器;在主水道安装水温传感器;在排气管上安装氧传感器;拆掉原车的柴油总泵， 安装转速传感器;加工发动机缸盖(安装火花塞);对发动机水箱清洗。The piston shall be machined to reduce its compression ratio; install the throttle valve seat, throttle body and the mixer at the intake manifold port; install temperature sensors in the main waterway; install oxygen sensor on the exhaust pipe; remove the existing master cylinder and install speed sensor; machine the engine cylinder head (mounting the spark plug); clean the engine's water tank. 改造发动机时间排序:Schedule for converting the engine: 4 1、 拆发动机半天; half-day for removing the engine; 2、 同步加工活塞、缸盖、接头、焊接节气门底座、焊接氧传感器螺帽座、水温传感器 螺纹等半天; Half day for simultaneous machining of piston, cylinder head, connectors; welding throttle valve seat, oxygen sensor nut blocks, water temperature sensor threads etc.; 3、 装配发动机半天; Half day for assembling the engine; 4、 安装控制系统和供气系统1天; One day for installing the control system and gas supply system; 5、 调试检测半天。Half day for commissioning and test. 6、 样车安装大概需要7天时间。It takes about seven days for assembling the sample conversion vehicle. 方案一:加工缸盖Plan One: Machine the cylinder 加工发动机缸盖:原车的铜水套比较小，不能安装M14的火花塞，需把原车的铜水套拔 出来，需重新加工铜水套后再镶入，加工完后缸盖试压，更换排气门座圈和研磨，加工缸 盖要求精度高，精度达不到缸盖容易漏水，漏水会造成发动机工作不正常温度高。 Machining the engine cylinder head: The original copper water jacket is relatively small for the M14 spark plug and it needs to be removed for machining and then replaced. Then, the cylinder head shall undergo a pressure test and change of exhaust valve seat ring and grinding. When machining cylinder head, the precision requirement is high, failing which the cylinder head may leak, causing the engine to work abnormally and with high temperature. 方案二:换缸盖Plan Two: Change the cylinder head 找缸盖厂家直接订购燃气缸盖，这样能保证缸盖加工质量，同时改装时间能缩短一天。 Order directly from the manufacturer for gas cylinder head to ensure machining quality and the time used can be shortened by one day. 改装工艺流程图Conversion Flow Chart 5 安装前准备 加工及采购发动机和燃气系统 所用的部件及支架 气瓶固定架制作 拆发动机 加工缸盖、活塞、节气门座、磨气检验 检验 NO 门、换铜水套 检验 NO 气瓶吊装 OK 气瓶校正 装配发动机 NO 检验 安装燃气控制系 统 高压管线 安装减压器及混检验 NO 合器 OK 吹管、试压、检测 发动机缸压 NO 检验 OK 氮气置换 检验 NO OK 加气 检测点火正时、软件标定、调试 出厂检验 NO 6 Pre-installation preparation Production and procurement of parts and stents needed for converting engine and gas system Dissemble the Making cylinder holders Engine Machine the cylinder head, piston, throttle seat, grinding valves and Testing 检验 NO change the copper water jacket Cylinder installation Testing NO OK Cylinder correction Assemble the Engine Testing NO Install Gas Control High-pressure System pipeline Install pressure Testing NO reducer and mixer Blowpipe, pressure test OK and testing engine cylinder pressure NO Testing OK Nitrogen replacement Testing NO OK Filling gas Testing ignition timing, software calibration and commissioning Factory inspection NO 主要改动发动机零部件Major engine parts to be changed 1 更换或加工活塞降低压缩比，降低压缩比的计算方法，我公司有一套(活塞称重需 7 加工的量和增加缸垫的厚度两种方法)，只要输入原车压缩比、缸径、行程和需要降到的新 压缩比，就可得到需要加工的量。The reduction of compression ratio can be achieved by replacing or machining the piston. Our company has a set of formulas to calculate the compression ratio (two methods including weighing the amount for machining and increasing the thickness of cylinder gasket), which takes the input of the original compression ratio, bore, stroke and the new compression ratio to obtain the required amount for machining. 加工原车活塞 原车活塞 加工后活塞 加工后活塞 machining the original original piston machined piston piston after piston machining 2 更换进气门和排气门座圈:根据不同的发动机需采购不同的天然气专用进排气门座圈。 Replace the intake and exhaust valve seat rings: it will need to purchase the CNG specific intake / exhaust seat rings based on different engines. 火花塞孔 缸盖加工火花塞孔 cylinder head machining Spark plug hole spark plug hole 3 缸盖加工火花塞孔，拆掉原车喷油嘴，原车的铜水套比较小，不能安装M14的火花塞，需 把原车的铜水套拔出来后堂孔，需重新加工铜水套后再镶入，加工完后缸盖试压，加工缸盖 要求加工精度高，精度达不到缸盖就会漏水。To machine the spark plug hole of the cylinder head, remove the existing nozzle; the copper water jacket of the original vehicle is relatively small for the M14 spark plug, it shall be pulled out for boring, and the copper water jacket machined before replaced, and then the cylinder head shall undergo a pressure test. High precision is required for the machining of the cylinder head, otherwise it may cause leakage of water. 4 拆掉高压油泵，在原高压油泵处安装信号盘，安装转速传感器。Remove the high-pressure pump, in its place is installed a signal panel; install the speed sensor. 根据不同的发动机需加工不同的转速传感器支架及信号盘。Based on different engines, the speed sensor bracket and signal panel shall be machined. 8 如下面图片:Such as the following picture: 5 加装节气门体:原柴油机没有节气门，是靠控制喷油总泵的喷油量。Install the throttle body: The original diesel engine does not have a throttle valve, depending on controlling fuel charge by master cylinder. 改造过程中节气门与进气支管之间需加工接口盘。The conversion process will involve machining of the interface panel between the throttle and the intake manifold. 6 加装气瓶组Install the cylinder group 根据各种车型发动机的百公里油耗和单天行驶里程计算，设计安装多少只不同水容积(升) 的储气瓶。The number of gas cylinders of different water volume (liters) to be installed will be calculated based on engine specifications such as 100 kilometers fuel consumption and single-day mileage. 例如发动机百公里用柴油30升，一天行驶里程300公里，总用油量90升柴油，天然气与 柴油的替代率按1.3:1计算，90×1.3=117立方天然气，发动机改用液化天然气(LNG)时， 安装一只300升的液化气瓶就可以了。For example, if an engine consumes 30 liters diesel for 300 kilometers and its total fuel consumption will be 90 liters of diesel for a daily milage of 300 km; and if the replacement rate between natural gas and diesel is 1.3:1, the 3natural gas will be 117 N m by multiplying 90 by 1.3. If the engine is to use liquefied natural gas (LNG), it will be enough to install one gas cylinder with a capacity of 300 liters. 计算方法1升液化天然气是0.427公斤，一立方天然气是0.715公斤，液化天然气气瓶加 气量设计要求总容积的80%，实际300升的气瓶只能加240升液化天然气，把升换算公斤 再换算成立方，300×80%×0.427/0.715=143立方天然气。Calculation method: 1 liter of 3LNG is 0.427 kilogram; natural gas of 1 N m is 0.715 kilogram, liquefied natural gas cylinder plus content design requiring 80% of the total volume, so a 300 liters cylinder can only contain 240 liters of LNG; converting liter to kg and then to cubic meter as the equation shows: 300 × 80% × 0.427/0.715 = 143 cubic meters of natural gas. 7 加装电控系统和供气系统Install the electronic control unit and gas supply system 9 安装燃气ECU、逆变器24V—12V、转速传感器、水温传感器、氧传感器、节气门传感器、 增压步进电机、点火线圈、高压线、ECU线束等;安装减压器、燃气步进电机、混合器、 金属软管、低压气管、被压气管、循环水管等。It involves the installation of gas ECU, inverter 24V-12V, speed sensor, temperature sensor, oxygen sensor, throttle sensor, supercharger stepper motor, ignition coil, high voltage wire, ECU wiring harness, pressure reducer, gas stepper motor, mixer, metal hose, low pressure airway, compressed air pipe, circulation water mains etc. 五、 改装技术标准和技术要求 V Conversion technical standards and requirements 为确保天然气汽车改装的安全和可靠性，根据GB7258—1997、QC,T245—2003改装 CNGV的技术标准。In order to ensure the safety and reliability of CNG conversion vehicles, it will be conducted according to CNGV technical provisions of GB7258-1997 and QC/T245-2003. 10 一)、 改装前整车主要技术指标Pre-conversion technical indicators 1. 原车发动机符合GB3799，在各种速度下运行稳定，不得有异响，突然加 速或减速时，不得有突爆声;进气支管与消声器不得有―回火、放炮‖现象;机油 压力正常，电器系统良好;各缸压缩力和真空度应符合原设计规定，其压力差不 超过各缸平均压力的5,;发动机功率和最大扭矩不得低于原设计标定值的 90,。 The original engine shall be in line with the provisions of GB3799, stable in a variety of speeds, and without abnormal noise, sudden explosive sound under sudden acceleration or deceleration; the intake manifold and the muffler shall not emit explosive noise; oil pressure shall be normal and electronic system work well. The compression force and vacuity of each cylinder shall be consistent with the original design specifications, with pressure difference not exceeding 5% of the average pressure of each cylinder; engine power and maximum torque shall be no less than 90% of the calibrated value of original design. 怠速时进气管真空度，430mm汞柱(或，0.0567MPa);电瓶电压空载时，24V， 启动时电压，18V;起动机正常工作。When idling, the vacuity of intake manifold > 430mm Hg (or <0.0567MPa); battery voltage no-load> 24V, startup voltage > 18V; and the starter works properly. 2. 改装样车为天然气货运车，发动机厂家为:东风发动机公司生产，产品型号: EQ3208型,功率154KW:额定功率KW(PS)rpm:154/2200。Converting to CNG truck, the engine manufacturer is Dongfeng Engine Company, product type: EQ3208, power 154KW: Rated power KW (PS) rpm: 154/2200. 型式:直列六缸、回冲程、水冷、增压中冷柴油机，缸径×冲程(mm):，压缩比: 工作容程(L):，额定扭矩Nm/rpm:，气缸工作顺序:1—5—3—6—2--4，最低比 油耗(g/kmh):194。Type: Inline six-cylinders, back-stroke, water cooled, Turbocharged diesel engine, Bore × Stroke (mm): , compression ratio: cylinder capacity (L):, Rated torque Nm / rpm: , cylinder working order: 1—5—3—6—2--4, the lowest specific fuel consumption (g / kmh): 194. 3. 车架不得有变形、锈蚀、弯曲;螺栓、铆钉不得减少或松动。The chassis shall not have deformation, corrosion, bending; bolts and rivets shall not be reduced or loosened. 4. 前后桥不得有变形、裂纹。Front / rear axle shall not have deformation and cracks. 5. 安全性能应符合GB7258的规定。Safety features shall be consistent with the provisions of GB7258. 6. 对原车各性能不符合要求者，必须进行修理并达到以上要求后方可进行LNG汽 车改装。If the performance features of the original vehicle do not meet the requirements, repairs shall be carried out to meet the requirements for LNG conversion. 二)、 改装后发动机主要技术指标Main technical indicators of the engine after conversion 1. 发动机怠速(r/min)600?50 Engine Idle Speed (r / min) 600 ? 50 2. 排放标准:达到样车出厂年限标准(优于原柴油车的排放)。Emission standards: up to the standard specified for the vehicle (better than the original diesel 11 vehicle). 3. 动力性:改装后与改装前同车相比动力下降在10%以内。Dynamic property: compared to pre-conversion, the drop in transmission power will be within 10%. 4. 经济性:与原车柴油的能耗比为1:1.1--1.35内。(立方比，加气站的气质达到 国家标准的情况下)Economy: the energy consumption ratio as compared to the value pre-conversion is within 1:1.1 - 1.35. (in cubic volume, providing that the gas quality at filling stations is up to national standard) 5. 改装后发动机温度不超过原机的15%(在加大水箱容量40%的情况下)。 After the conversion, the engine temperature does not exceed 15% of the original machine (provided the water tank capacity increased by 40%). 6. 使用CNG燃气发动机机油或汽油机机油。Applying CNG engine oil or gasoline engine oil. 7. 采用顺序点火方式。Using sequential ignition mode. 三)、 改装后主要技术性能Main technical properties after conversion 1. 改装后LNG汽车总质量的增加量不得超过原车总质量的5,。After the LNG conversion, the increase in vehicle weight shall not exceed 5% of the original weight. 空载和满载状态下的轴荷分布应符合GB7258的规定。Axle load distribution under no-load and full load conditions shall be in line with the provisions of GB7258. 2. 设计天然气可行驶200KM以上(根据实际使用里程调整)。The natural gas is designed for driving 200KM or more (adjustable according to actual mileage). 3. 用天然气作燃料时，与用柴油作燃料时的同车相比最大功率不低于90,，扭矩 不得低于90,，最高车速不得低于90,，直接档最低稳定车速不得高于6,， 安全性能符合GB7258的规定。Compared to the original vehicle using diesel, the conversion to natural gas shall make the maximum power no less than 90%, torque no less than 90%, the maximum speed no less than 90%, direct gear with minimum stable speed no more than 6%; the safety features shall be in line with provisions of GB7258. 4. 发动机排放应符合相关标准。Engine emissions shall be in line with relevant standards. 5. 经检验合格后的LNG汽车，安全可靠，维修方便，安装外形美观。After the LNG conversion and passing the test, the vehicle will be safe, reliable, easy for maintenance and in beautiful shape. 单燃料车调试作业Single fuel vehicle commissioning 1、 充气Filling gas 1.1 使发动机熄火，关闭所有电气设备，断开电源总开关，将气瓶组内的天然气加入车上 气瓶，使气瓶内的天然气能将车开到加气站加气和调试用。 Stop the engine, turn off 12 all electrical equipment, switch off the power mains, fill the vehicle cylinder with natural gas from the cylinder group, so that it can be driven to the filling station to fill gas for commissioning. 2、 将手提电脑连接到ECU，检测系统是否正常。Connect the portable computer to the ECU and check if the system works normally. 2. 点火提前角调整:用天然气运行时,均应启动正常、怠速稳定、加速有力、发动机水温 正常。Spark advance adjustment: running on natural gas requires normal start, idle stability, forceful acceleration and normal water temperature with the engine. 3、 怠速和启动调试Idle and start-up tests 3.1 使发动机保持在1000r,min左右，待水温达到60度左右，调整减压器上的怠速调节 螺钉，直到获得稳定的怠速。Keep the engine speed at around 1000r/min; after the water temperature reaches 60 degree, adjust the idle speed adjustment screw on the pressure reducer until a stable idle is obtained. 其方法是:先将减压器旁通怠速调节螺针旋死，再松回1/4圈即可。The method involves fastening the idle speed adjustment screw to the maximum, and then loosening it for 1 / 4 of one circle. 调整用汽油然后用天然气燃料时的怠速，可反复调整减压器上的三级怠速调整螺栓， 若怠速还有提高，再调整节气门怠速螺栓，使发动机仍然稳定在原车规定的怠速转速。 Adjusting the idle from using gasoline to using natural gas involves repeatedly adjusting the third level idle adjustment screw on the pressure reducer. If the idle speed can be increased, then adjust the throttle idle screw, so that the engine remains at the stable idle speed provided for the original vehicle. 3.2 熄火后用天然气直接启动，看天然气启动是否容易、迅速，如启动性不良，应重新调 整。After switching off, use the natural gas to start the vehicle and if the start-up is not easy and quick, readjustment may be needed. 4、 将车开到加气站，使发动机熄火，关闭所有电气设备，断开电源总开关。Drive the vehicle to a filling station and after flaming out the engine, turn off all electrical equipment, and disconnect the master power switch. 5、 打开气瓶，在无泄漏情况下，充气至80%，将车开离充气站。Open the cylinder, and be sure there is no leakage, fill gas to 80%, and then drive away from the gas station. 6、 用检漏液进一步检查所有高、低压接头、管线和减压器总成，是否有泄漏，有泄漏及 时排除。Use leak detection fluid for further examination of all high and low pressure fittings, pipelines and pressure reducer assembly, checking to ensure there is no leak, otherwise immediately eliminate the problem. 检验技术要求Inspection technical requirements 1、 燃气汽车专用装置的安装应考虑车辆承载件的强度，对强度较弱的安装部位应有加强 措施，不允许采用导致车辆承载件强度和刚度降低的安装方法，不应将装置的部件作 为承载件使用。When installing dedicated gas vehicle equipment, consideration shall be given to the strength of the carrying pieces of the vehicle; take strengthening measures for the weaker parts of the installation. The installation shall not weaken the strength and stiffness of the vehicle’s bearing parts, and any part of the 13 equipment shall not be used in place of a bearing part. 2、 专用装置部件安装后应不得降低车架强度、刚度，气瓶无损伤、磨损;各部件应安装 牢固，不得因振动，颠簸而出现松动、脱落等现象。The installation of the conversion devices shall not weaken the strength and stiffness of the chassis; there shall be no damage or wear and tear to the gas cylinders; various components shall be installed firmly, there shall be no loosening or falling off due to vibration and bumping. 3、 专用装置及管线在使用过程中，不得与相邻的运动部件碰撞和磨擦。The installed parts and pipelines shall not collide with adjacent moving parts or causing friction between. 4、 专用装置应按产品设计要求安装，安装位置及方向应达到使用效果，要利于安装、操 作和维修，不能安装布置在妨碍发动机及其它零部件维修的地方。The special equipment shall be installed in accordance with product design requirements, installation location and direction shall have the desired results to facilitate installation, operation and maintenance; they shall not be installed in places impeding the maintenance of the engine and other parts. 5、 各部件与发动机排气管的距离不应小于75mm，距离在75mm~200mm之间时，应设 置固定牢固的隔热防护板;专用装置应远离热源和电源，特别是高压部件、电气元件、 管线及汽油管路等; The distance between any part and the engine exhaust pipe shall be no less than 75mm; if the distance is between 75mm ~ 200mm, a fixed solid insulation board shall be set up; the special purpose equipment shall be placed away from heat and power, especially high-voltage components, electrical components, pipings and gasoline pipelines, etc. 6、 各部支架、加工件应有足够的强度、规矩、光洁、尺寸合适、去尖角、作防锈处理。 All brackets and machined parts shall have sufficient strength and stick to the design, shall be clean and have appropriate sizes and have been subject to anti-rust treatment. 7、 燃气系统无泄漏，各装置部件、钢瓶、各改装部位必须保持不漏天然气、水、电等。 The gas system shall have no leakage; all parts, cylinders and converted parts shall be free of any possibility of leaking natural gas, water or electricity. 8、 LNG改装后，车辆最大总质量增加应不超过原车总质量的5,，车辆转向桥负荷不得 小于车辆总质量的20,。After LNG conversion, the maximum weight increase of the vehicle shall not exceed 5% of the total weight of the original vehicle; the steering axle load shall be no less than 20% of the total weight of the vehicle. 9、 天然气汽车安全性能要符合GB7258的规定;改装后应不影响原车行驶性和通过性能。 The safety features of the CNG vehicle shall comply with the provisions of GB7258; the conversion shall not affect the drivability of the vehicle. 道路试验Road Test 1、技术要求Technical requirements 1.1 用天然气起动良好;工作正常。After the conversion, the start-up shall be good and the running normal. 1.2 路试中加速性能正常，发动机在各种转速下都应运行平衡。In the road test it is required that the acceleration shall be normal and the engine shall be running 14 normal under a variety of speeds. 2、 作业内容Operation 2.1 汽车技术状况行驶检查里程不少于20Km,检查汽车的起步、加速、减速、匀速行驶状 况，如发现问题应停车检查，找出原因，排除问题后重新作行驶检查。The road test involves driving a distance of no less than 20Km, including checking the status in start-up, acceleration, deceleration, constant speed driving. In case of finding any problem, the vehicle shall be stopped to find out the cause and remove any uncertainties before renewing the driving test. 2.2 在车辆运行速度为30Km/h时急刹车，钢瓶不得发生位移。Conduct a sudden brake test when the vehicle is running at speed of 30Km / h, checking that there is no displacement of the cylinder. 2.3 在车辆运行后各紧固件不得因颠簸、振动而发生位移、脱落等现象;气密部件不得发 生渗漏;各仪表均应指示正确。There shall be no displacement or falling-off of the fasteners due to bumping and vibration when the vehicle is running; no leakage to the airtight components, and all the instrument shall work normally. 2.4 道路试验结束后，按改装厂要求复查紧固件和气密件。At the conclusion of the road test, re-check the fasteners and airtight components as required by the conversion factory. 车辆档案Vehicle File 1 改装中收集燃气装置(减压器)、气瓶等合格证、使用说明书，按车号分别装袋保管。 Collect certification and instruction manuals of gas device (pressure reducer) and gas cylinders during the conversion process, and keep them in separate bags according to vehicle ids. 2 由专职检验员签发LNG汽车改装竣工合格证，车辆检验表、原始资料、合格证、技 术文件全部整理归档。Full-time inspectors will sign and issue completion certificate for the LNG conversion; all vehicle inspection sheets, original data, certification and technical documents will be archived. 六、 经济效益及资金回收期(含报价)VI. Economic benefits and capital payback period (including quotations) 我公司柴油车改装技术成熟,已实现上万台车辆的改装,现运行良好。Our company possesses mature technology for diesel to gas conversion, and has converted thousands of vehicles that are running well today. 我公司生产、提供改装所需的整套系统，集中采购生产，节约客户采购成本和时间。We produce and provide complete sets of conversion equipment, have centralized purchasing and production capability, saving purchasing costs and time for customers. 15 表1各类柴油机用户车辆改装经济效益分析表 Table 1 Economic benefits analysis for all kinds of diesel vehicles conversion to CNG 车型 Vehicle Type 6缸机车型 四缸机车型 轿车系列 项目 Item 6 cylinder vehicle 4 cylinder vehicle Sedan series Diesel consumption 100 35 15 8 百公里耗柴油(升) kilometers (l) Gas consumption 100 340 19 10 百公里耗气(m) 3kilometers (m) 0 # diesel price (yuan / 5 5 5.26 0号柴油价(元/升) liter) 2.5(暂定) 2.5(暂定) 2.5(暂定) 33) CNG price (yuan / mCNG价格(元/ m) (Provisional) (Provisional) (Provisional) Average daily trip (km) 200-300 200-300 200-300 日均行程(公里) 100 kilometers diesel 175 75 42 百公里油价/元 cost / yuan 100 kilometers gas cost 100 47.5 25 百公里气价/元 / yuan Price difference 100 75 27.5 17 百公里油气差价/元 kilometers / yuan Daily cost savings 150-225 55-83 34-50 日节约燃料费(元) (yuan) 35800-41800/车 23000-28000/车 20000-24000/车 Conversion cost (yuan) 改车费(元) /per vehicle /per vehicle /per vehicle Recovery time for 7-9 8-10 16-22 改车费用回收期(月) conversion cost (month) 经济性估算:Estimated savings: 采用改装后的六缸单燃料汽车，从下面的计算可清楚地看出，每辆车每月可节省燃料费 4700元(与纯柴油相比):A converted 6-cylinder single-fuel vehicle can save a monthly fuel cost of 4700 RMB (compared to pure diesel): 公交公司车辆多数每天行驶约250公里左右，百公里油耗按35升柴油，按72.5%的柴油 替代率计算，每天可节省的费用:(0#柴油价格:5元/升;CNG价格:2.5元/标方) Most public transport vehicles daily travel about 250 kilometers, if the vehicle consumes 35 liters of diesel in a distance of 100 kilometers, based on a 72.5% diesel replacement rate, the 3daily saving will be: (price of 0 # diesel: 5 RMB / liter; CNG price: 2.5 RMB / N m) 2.5×35×72.5%×(5-2.5)=158元/天. 2.5 × 35 × 72.5% × (5-2.5) = 158 RMB / day. 合计每车每天可节省燃料费158元，月节省4700元，年共计可节省燃料费56400元，可 见柴油车改装后的经济性非常突出。The daily fuel saving is 158 RMB per vehicle per day, amounting to a monthly saving of 4700 RMB and an annual saving of 56,400 RMB, the economic benefits of conversion from diesel to CNG is great. 如改装100辆柴油车(每日行驶250公里为例)，每月节约的燃料费用为人民币56.4万元， 每年节约的燃料费用为人民币564万元。100 diesel vehicles converted (running 250 km per day for example) will save in monthly fuel costs of 564,000 RMB and the annual saving will be 5.64 million RMB. 16 七、 改装成本演示VII Conversion cost 柴油车:大车改车费用，Diesel vehicles: cost for large vehicles, 改装价:62000元/台The conversion price: 62,000 RMB / each 表3单车改装成本演示二:Table 3 The cost of conversion of a single vehicle: 单价(元) 序号 货物品或项目 规格型号 备注 Unit Unit Serial Products or Items specifications Remark price XX LNG单燃料装置(元) 套 电控 1 13000.00 Techforgas LNG single fuel device (yuan) set Electronic control 台 2 6000.00 安装费Installation fee set 400升钢瓶(大车用)(元) 400-liter 只 1只气瓶 3 38000.00 steel cylinder (large vehicle use) piece One cylinder (yuan) 角钢、扁钢 气瓶支架及耗材(元) Cylinder stent 每车 4 500.00 Angle steel, flat and consumables (yuan) per vehicle steel 四配套、气门座圈 每车 5 1500.00 发动机配件Engine Parts Four pieces set and per vehicle valve seat ring 每车 6 500.00 税费(元) Tax (yuan) per vehicle 加工费(元) Cost for machining 每车 7 500.00 (yuan) per vehicle 每车 8 60000.00 合计(元) Total (yuan) per vehicle 每车 9 2000.00 管理费(元) Management fee (yuan) per vehicle 八、 燃气汽车智能电控燃气系统优点:VIII Advantages of the smart electronic gas system of CNG vehicles: 先进—国际先进机电一体化独有技术，与原车动力相当，安装方便;Advanced technology– The proprietary mechanical and electrical integration technology, having the same transmission capability as the original vehicle, and easy to install; 安全—增压柴油车的燃料和空气在进气增压之后混合;Safety - Fuel and air of supercharged diesel vehicle mix after intake / supercharge; 经济—平均替代率100%以上，降低燃料费用45%左右;Economy – With an average replacement rate of 100% or more, it reduces fuel costs by about 45%; 环保—优化排放，减少黑烟，保护环境。Ecological benefits - Reduce emissions, soot and protect the environment. 17 附一:Annex 1: 我国预计从2005年到2020年的16年里，我国汽车保有量年均增长率在8%左右，远远 超过我国自产石油燃料供应量，降低石油燃料总消耗量成为当务之急。It is estimated that in the 16 years from 2005 to 2020, car ownership in China will have an average annual growth rate of about 8%, far exceeding the supply of self-produced petroleum-based fuels. It will be a top priority to reduce overall consumption of fossil fuels. 由此我国能源战略对汽车产业提出这样的近期目标:―十一五‖末在汽车保有量翻番的情况 下，汽车用燃油消耗增长不超过50%。Thus China's energy strategy includes a short-term goal for the automotive industry which states that at the end of the ―Eleventh Five-Year Plan‖ when vehicle ownership will be doubled, increase in vehicle fuel consumption shall not exceed 50%. 因此，在没有其他方法解决车用燃油消耗的情况下，必然将对部分车辆用油进行限制，天 然气作为替代能源也随之得到大力发展空间。Therefore, there is no other way to alleviate the situation of fuel consumption, and inevitably, a limit will be placed on it for some vehicles; and natural gas as an alternative energy for it will be vigorously promoted. 随着天然气加气站及柴油/天然气单燃料汽车改装的普及，这将是一个潜在的超大市场。届 时，他将促进与带动天然气、机加工、汽车维修、客货运输等几大产业～The growing number of the natural gas filling stations and the promotion of diesel to CNG single-fuel conversion will create a huge potential market. It will promote and stimulate the growth of a number of industries such as natural gas, machining, vehicle maintenance and passenger transport! 18