I. Introduction: The Industrial Cornerstone of Modern Livestock Transportation
With the large-scale development of my country's livestock industry, **cattle and sheep transport semi-trailers** (also known as livestock transport semi-trailers) have become a vital link connecting farms and consumer markets. Unlike ordinary cargo semi-trailers, these specialized vehicles require a balance of structural strength, biosecurity, and animal welfare. Their manufacturing process integrates technologies from multiple disciplines, including mechanical engineering, hydraulic control, and environmental control. This article will provide an in-depth analysis of the complete production process of cattle and sheep transport semi-trailers, showcasing the precision and rigor of modern specialized vehicle manufacturing.
II. Design and Development Phase: Engineering Design Centered on "Animal Welfare"
Before raw materials arrive at the factory, the R&D team must complete functional design and structural verification:
1. 3D Modeling and Simulation Analysis
- Use CAD/CAE software to build a 3D model of the vehicle body and simulate structural stress distribution under different road conditions.
- Design a detachable multi-layer fence system (usually 2-4 layers), enabling quick loading and unloading via hydraulic lifting.
- Calculate the ventilation system airflow to ensure the air exchange rate in the vehicle body meets live animal transport standards.
2. Process Route Planning
Determine the technical solution based on order requirements:
- Body Structure: Lightweight design using all-aluminum alloy (6061-T5 material) or fiberglass + stainless steel composite structure.
- Functional Configuration: Optional modules such as constant temperature air conditioning, spray cooling, automatic feeding, and sewage collection.
- Hydraulic System: Tailgate load capacity ≥ 2 tons, equipped with wireless remote control and manual dual operating systems.
III. Material Pre-treatment and Cutting Process
1. High-Strength Steel Processing (Chassis Part)
- Longitudinal Beam Cutting: High-precision cutting of the main beam web using a CNC plasma cutting machine, with an error control of ±0.5mm.
- Wing Plate Forming: Cold bending of the lower wing plate at the gooseneck section using a dedicated forming machine; side pressing process ensures consistent curvature.
- Crossbeam Pre-fabrication: Through-beams, end beams, and other components are cut using a CNC flame cutting machine, followed by end face milling.
2. Aluminum Alloy Body Material Preparation
- 2.2mm thick fiberglass is used as the base material for the inner and outer wall panels, with imported polyurethane insulation material (80-120mm thick) filled in between.
- Aluminum alloy edging strips use 2.5mm profiles, processed into specific cross-sectional shapes using a bending machine.
- Stainless steel door locks, hinges, and other hardware accessories are pre-treated for rust prevention and passivation.
IV. Chassis Frame Manufacturing: The Core Link for Load-Bearing Safety
1. Main Beam Assembly and Welding Process
Main beam assembly is completed on a dedicated assembly and welding platform:
- The upper and lower wing plates are assembled with the web plate, and clamping devices are used to ensure uniform weld gaps.
- Double-sided welding is performed using a submerged arc welding (SAW) machine. The inner weld is welded first, then the assembly is rotated 180° to weld the outer weld. The weld fillet height must meet design requirements.
- After welding, side bending correction is performed using a side-pressure straightening machine to eliminate welding deformation.
2. Frame Assembly
- Assembly Station: The main beams, crossbeams, end beams, and diagonal supports are fixed at designated points.
- Inclined Welding: Using a dedicated frame tilting machine, the assembly is tilted 90° to the left/right for boat-shaped position welding to ensure complete penetration.
- Suspension Bracket Welding: A rotating platform is used to weld the suspension brackets, ensuring a flatness of the mounting surface ≤1mm.
3. Floor Plate Laying
- Laying of patterned anti-slip steel plates (thickness ≥3mm), using clamping fixtures to eliminate gaps.
- Alternating welding on the front and back sides to control the flatness of the floor plate, providing a benchmark for subsequent body installation.
V. Special Body Manufacturing: Integration of Life Support Systems
1. Body Frame Welding
- A fully enclosed polyurethane panel bonding structure is constructed using a polyester wet-process panel manufacturing process.
- Layered installation of partitions: Each layer is approximately 825mm high, with a rotatable partition in the middle (hydraulically driven) for easy access and cleaning.
- Welding of feed trough brackets and drinking nozzle mounting seats to ensure load-bearing strength.
2. Environmental Control System Installation
- Ventilation System: Electronic ventilation fans are installed at the top of each layer (usually one per compartment), and adjustable louvers are installed on the side walls to create forced convection.
- Temperature Control System: A refrigeration unit (1200mm space at the front), a fuel heater, and temperature sensors are installed to achieve constant temperature control from -10℃ to 30℃.
- Sprinkler System: Atomizing nozzles are installed at the top of each partition, connected to a 220L stainless steel water tank, for emergency cooling in summer.
3. Biosecurity Facilities
- - Install slatted flooring with a slope of ≥3°, guiding urine towards the front drainage outlets (2 at the front and 2 at the rear, a total of 4 drainage outlets).
- Install UV disinfection lamps and air filtration devices (SP-level filter elements).
- The inner and outer surfaces of the compartment are treated with a special coating, making them corrosion-resistant and easy to clean and disinfect.
VI. Hydraulic and Electrical System Assembly
1. Hydraulic Tailgate Installation
- Install the hydraulic pump station, cylinders, and piping system, with an operating pressure of 16-20 MPa.
- The tailgate unfolds to form a loading and unloading ramp (level with the pig loading platform), with integrated guardrails to prevent animals from falling.
- Equipped with a wireless remote control handle and a manual emergency device, providing double safety assurance for operation.
2. Electrical System Integration
- Install an on-board miniature generator (Schneider/Siemens electrical components), with a power of ≥5 kW.
- Install a video surveillance system (2-3 cameras per layer), allowing real-time monitoring of animal conditions in the driver's cab.
- Install an LED lighting system and a temperature alarm device, providing audible and visual warnings.
VII. Final Assembly, Debugging, and Quality Inspection
1. Vehicle Assembly
- Assemble the compartment assembly with the chassis frame, using a torque wrench to tighten the U-bolts to the specified torque.
- Connect the brake lines and electrical wiring harnesses, and install accessories such as the toolbox and spare tire carrier.
2. Functional Testing
- Sealing Test: Close all doors and windows and conduct a rain test to ensure no leakage in the compartment.
- Hydraulic Test: Raise and lower the tailgate 10 times continuously, testing the system pressure stability and synchronization.
- Temperature Control Verification: Under both no-load and simulated load conditions, test the time and fluctuation range for the cooling/heating system to reach the set temperature.
3. Static and Dynamic Debugging
- Unloaded road test: Test braking performance, steering flexibility, and suspension system comfort.
- Full load test: Load with simulated counterweights (usually 1.1 times the rated load capacity), and conduct emergency braking and cornering tests.
4. Final Inspection
- Verification of welding quality (ultrasonic testing), coating thickness (≥80μm), and completeness of markings.
- Issuance of certificate of conformity, user manual, and warranty booklet.
VIII. Conclusion: Technology Empowers Livestock Transportation
From cold-rolled steel plates to intelligent "mobile ranches," the production process of cattle and sheep transport semi-trailers reflects the systematization and refinement of modern manufacturing. The strict control of every process – from the submerged arc welding of the main beam to the seamless bonding of the body, from the precise debugging of the hydraulic system to the intelligent integration of environmental control – embodies respect for life and responsibility for food safety. With the application of lightweight aluminum alloy technology and Internet of Things monitoring systems, future livestock transportation equipment will be more efficient, environmentally friendly, and humane, providing a solid equipment guarantee for the high-quality development of my country's livestock industry.