Dongfeng GX ECAS solenoid valve assembly 2939010-92100

The assembly features an integrated multi-way solenoid valve design (3-way or 4-way, based on Dongfeng GX ECAS configuration) optimized for precise air pressure control in the vehicle’s suspension airbags. It combines inlet, exhaust, and working ports into a single compact housing—eliminating the need for separate valves and reducing air line complexity. The valve core is driven by a high-response electromagnetic coil (12V/24V DC, matching GX’s electrical system) that switches between "fill," "hold," and "exhaust" modes in ≤ 50ms. Additionally, the housing incorporates internal pressure damping channels to reduce air flow turbulence, ensuring stable pressure regulation even during rapid suspension adjustments (e.g., load changes or road surface variations)

Valve Core & Seals: The valve core is made of high-precision brass (H62) with a mirror-polished surface (Ra ≤ 0.2μm) to minimize friction and ensure airtight sealing. Seals use fluororubber (FKM) with excellent resistance to high temperatures (up to 150°C), oil, and aging—maintaining leak-free performance for 100,000+ switching cycles.

Electromagnetic Coil: Wound with high-temperature copper wire (155°C class insulation) and encapsulated in epoxy resin for moisture and vibration resistance. The coil delivers a holding force of ≥ 8 N, ensuring the valve core remains in position even under low voltage (9V for 12V systems, 18V for 24V systems).

Housing: Constructed from die-cast aluminum alloy (ADC12) with a powder-coated finish (epoxy-polyester hybrid) to provide corrosion resistance (passing 500+ hours of salt spray testing) and mechanical strength to withstand underframe vibrations

As a core component of the Dongfeng GX’s ECAS system, this solenoid valve assembly fulfills three essential functions:

Airbag Pressure Regulation: It receives electrical signals from the ECAS ECU to control air flow into/out of the rear/front suspension airbags—adjusting pressure to maintain the GX’s target ride height (e.g., 350±5mm ground clearance) regardless of cargo load (from empty to full capacity).

Load Compensation: During load changes (e.g., loading/unloading cargo), the valve rapidly fills or exhausts airbags to balance the vehicle’s stance, preventing uneven tire wear, improving handling, and ensuring compliance with road height regulations.

Ride Comfort Optimization: By fine-tuning airbag pressure in real time (up to 10 adjustments per second) based on road surface inputs (detected via GX’s height sensors), the valve reduces vibration transmitted to the chassis—enhancing driver comfort during long-haul trips

This ECAS solenoid valve assembly meets global commercial vehicle standards, including China’s GB/T 13927 (Valves—Leakage test) and ISO 12100 (Safety of machinery), as well as IATF 16949 quality management requirements. Each unit undergoes comprehensive pre-shipment testing:

Pneumatic Performance Testing: Measuring air flow rate (≥ 80 L/min at 0.8 MPa) and leakage rate (≤ 1 mL/min at 0.8 MPa) to ensure efficient and airtight operation.

Electrical Testing: Verifying coil resistance (±5% of nominal value), insulation resistance (≥ 100 MΩ at 500V DC), and voltage tolerance (9-16V for 12V systems, 18-32V for 24V systems).

Durability Testing: Simulating 1 million+ switching cycles (equivalent to 300,000+ km of driving) under variable pressure and temperature conditions to confirm no valve sticking or seal degradation.

Environmental Testing: Exposing the assembly to -40°C to 85°C temperature cycles (200 cycles), high humidity (95% RH at 40°C for 500 hours), and vibration (10-2000 Hz, 20 g acceleration) to validate performance stability.

Backed by a 24-month manufacturer’s warranty, the assembly ensures reliable ECAS operation for Dongfeng GX’s heavy-duty applications (e.g., freight transport, passenger buses with air suspension)