When Sun Yu, the CTO of Great Wall Commercial Vehicles, stood under the spotlight at the press conference together with four truck drivers, it was destined to leave a profound mark in the history of domestic heavy trucks.
There were no experts in suits to bolster the scene, nor were there PowerPoint presentations to showcase a plethora of technologies. Instead, truck drivers complained that “it feels like being pulled backward during coasting” and “the brakes are ineffective when climbing mountains in mountainous areas.” and Sun Yu gave a bitter smile and told the true story of being caught between truck drivers and engineers.
The media said that this press conference took an “unconventional approach,” but it was also “the most down-to-earth and touching throughout.” Sun Yu, who had never appeared in front of the stage before, not only spoke well but also, with her simple and somewhat shy demeanor in front of the camera, particularly touched the hearts of netizens.
“Mr. Wei previously suggested that I do a live broadcast to promote heavy truck technologies. But I was a bit scared and even needed to inhale oxygen before the live broadcast,” Sun Yu worried that she couldn’t explain how Great Wall heavy trucks had developed over the past six years. After all, this story not only involved herself but also the efforts and hopes of many truck drivers.
01. “Deploying a large force to tackle tough challenges, Great Wall aims to produce high-end heavy trucks”
Everyone believes that a female CTO seemingly emerged suddenly at Great Wall Commercial Vehicles. In fact, no veteran at Great Wall is unaware of Sun Yu.
In 2005, Sun Yu joined the Technology Center of Great Wall Motor. Starting as a braking system engineer, she successively held key positions in chassis, power, complete vehicle design, and powertrain, and also took the lead in establishing a thermal management team.
It can be said that Sun Yu has accumulated rich technical experience in the work of manufacturing passenger vehicles. She is well-versed in the core technologies of manufacturing passenger vehicles, which is why she was appointed as the person in charge of heavy truck technologies.
When it comes to manufacturing high-end heavy trucks, Great Wall Commercial Vehicles doesn’t start from scratch. Besides strong talents like Sun Yu, there is also a group of elite personnel, such as Dr. Tang Ziwei, who is responsible for the development of the world’s first hybrid dedicated transmission, and Dr. Xiong Jian, an expert in domain control…
“Mr. Wei believes in deploying a large force to tackle tough challenges. Great Wall heavy trucks should benchmark against imported vehicles and create high-end heavy trucks.” After clarifying the direction, Sun Yu and her team investigated all heavy truck models at home and abroad. Almost every rest day, she immersed herself in heavy truck 4S stores to study the vehicles. She also went to Tianjin Port to thoroughly research heavy trucks of renowned brands such as Scania, Volvo, and Mercedes-Benz.
After figuring out the performance indicators of imported vehicles, they conducted user surveys across the country. The first batch of truck drivers surveyed were those from Great Wall Logistics Company. “While they were unloading goods, we chatted with them about how trucks are operated, what the vehicle usage scenarios are, and what their daily vehicle usage needs are.”
They also went to the vegetable wholesale market on the South Second Ring Road in Baoding. “We gave them cigarettes, bought them food, and said some kind words. Sometimes, we directly got on the truck and accompanied the drivers from Baoding to Laiyuan and Shijiazhuang, seizing every opportunity to have conversations.”
Later, Sun Yu and her team went to more distant places. They visited the No. 1 JD Logistics Warehouse in Guiyang, which is the largest freight station in Asia, and also went to the wholesale market in Nanjing to find Scania owners.
“There are numerous scenarios for commercial vehicles. Deciding which market to enter and what kind of vehicles to produce is not something that can be decided casually. Through in-depth user interviews, we found that the main concerns of everyone are sufficient vehicle power, safety, and comfort. Most importantly, the vehicle must be fuel-efficient.”
Sun Yu said that the heavy truck commercial vehicle industry is quite special. A truck involves three types of people: the truck owner, the fleet manager, and the driver. The fuel consumption per route and the timeliness are all predetermined, directly affecting the overall operation and profitability.
Sun Yu invited many truck drivers to test drive the Hi4-G hybrid heavy truck prototype. Lao Fan joined at that time. He runs a logistics company and manages hundreds of heavy trucks.
When they first met, Lao Fan asked Sun Yu to explain the technical route of Great Wall’s hybrid heavy trucks. Sun Yu said that their hybrid vehicles are definitely fuel-efficient, based on a specially developed hybrid platform, rather than simply transforming the traditional power system. Sun Yu was extremely busy at that time and spoke directly, “If you trust me, give it a try.”
Not long after, Lao Fan came to Xingtai and put forward a “rather excessive” request. He said that the fuel consumption per 100 kilometers should be reduced to less than 20 liters. At that time, the fuel consumption of the test vehicle was over 30 liters, and the fuel consumption of heavy-duty vehicles in the industry was generally over 30 liters. But Sun Yu said, “The request you put forward is a bit difficult for us at present, but we will definitely find a way to achieve it.”
Sun Yu’s promise moved Lao Fan. In this way, Lao Fan “officially joined” Great Wall heavy trucks. This boss with an asset of tens of millions became a free test driver for Great Wall heavy trucks.
Great Wall Motor adheres to the philosophy that mastering the core technologies of vehicle manufacturing is essential for survival. Similarly, manufacturing heavy trucks requires mastering core technologies, including the transmission, power domain control, and batteries. The fuel consumption must be firmly controlled.
02. Great Wall Heavy Trucks Have a “Special R&D Center”
The mountain is right at the entrance of the Xingtai factory. The mountain roads are full of ups and downs, providing an ideal route for hybrid vehicle testing. Heading north, there are flat roads, and further ahead is the Beijing-Hong Kong-Macao Expressway. “No other vehicle manufacturer has such a comprehensive natural terrain.”
But Lao Fan said, “It’s not enough to just test the vehicle with weights here. Drive the vehicle to my place and actually haul goods. Even if the goods are damaged, I won’t hold you accountable.”
During the first test drive, Lao Fan loaded the goods and set off on the night he received the vehicle. He took the engineer with him and drove from Linyi to Shanghai in the heavy rain overnight. After arriving at the destination and calculating the fuel consumption, it was 31 liters per 100 kilometers. He said, “Sister Yu, it’s not good. The fuel consumption is too high! We need to find a way to reduce it.” The R&D team optimized the vehicle control logic and data according to Lao Fan’s suggestions.
After the test drive, Lao Fan put forward suggestions, and Sun Yu made modifications. Such scenarios and conversations occurred repeatedly:
Lao Fan: “Can you reduce it further?”
Sun Yu: “Yes, we can.”
Every time the strategy was modified, Sun Yu told Lao Fan, “Come and test it again after I finish the adjustment in a few days.” As a result, Lao Fan arrived at the Xingtai factory gate at 8 o’clock the next day and waited.
Sun Yu remembered that once Lao Fan had a tender to participate in the next day, but he refused to leave and insisted on testing the vehicle that night. “That night, everyone in the team was busy adjusting the strategy. I was extremely tired and so sleepy that my eyelids were drooping. But in the end, the vehicle was extremely fuel-efficient. At one o’clock in the early morning, he left happily.”
After getting to know Lao Fan for two or three years, Sun Yu has hardly had a formal meal with him, nor has she reimbursed his tolls and fuel costs. Sun Yu asked Lao Fan why he was willing to spend his own money to collaborate with Great Wall to manufacture a heavy truck.
Lao Fan, born in 1987, has been working in the logistics and transportation industry for twenty years. He is well aware of the harshness of market competition. Whether using diesel or natural gas, the vehicle usage cost is high. After driving for two or three years, the vehicle is severely worn out, and the second-hand vehicle can’t fetch a good price. He doesn’t want to continue buying expensive imported vehicles, and domestic vehicles haven’t met his requirements. Lao Fan wants to find a breakthrough. Lao Fan said that when he first dealt with Sun Yu, she “didn’t take him too seriously,” unlike other vehicle manufacturers who engage in activities such as treating guests to meals.
On the contrary, this made Lao Fan feel that Sun Yu and her team are genuine technicians, “Great Wall is truly serious about manufacturing heavy truck products.” More importantly, Lao Fan believes that hybrid technology is a promising technical direction and the future development trend.
Gradually, the fuel consumption per 100 kilometers was reduced from 32 liters to 28 liters, and then to 26 liters. Finally, Lao Fan said, “There is hope.” His words of affirmation gave everyone confidence.
There are also about four or five bosses like Lao Fan who are willing to spend time, energy, and even their own money to manufacture vehicles together with us, such as Mr. Li from Yunnan and Mr. Lü from Shandong. “This circle is small. Lao Fan posts test drive videos in his WeChat moments every day, attracting them all.”
At the beginning, not everyone believed that the technical route of Great Wall heavy trucks would work. Mr. Li used traditional heavy trucks and was initially skeptical. Mr. Lü, who used electric heavy trucks, didn’t believe it at all. “But once these bosses personally test drove our vehicles, their attitudes immediately changed.” Later, they all joined and formed a team of heavy truck boss test drivers.
Many practical design ideas for this vehicle were proposed by truck drivers—they are the “first R&D center” of Great Wall heavy trucks. Sun Yu’s team precisely develops functions according to their real needs.
“For example, when a stone hits during driving, the fuel tank is prone to leaking. We made the fuel tank narrower and added an extra layer outside. Previously, the remote control for adjusting the suspension height was placed under the driver’s seat. They suggested moving this function to the mobile phone, allowing the driver to control the suspension lift outside the vehicle with the phone.”
Lao Fan witnessed Sun Yu and her team’s efforts every day. They listened to his suggestions and implemented them earnestly, unlike other companies that either ignored him or simply didn’t listen.
Lao Fan once told Sun Yu that every time he came to the Xingtai factory, he saw the words “Make progress little by little every day” written in front of the building. He felt that this enterprise is truly dedicated to its work and is thinking about products and problems from the user’s perspective. Despite the current difficulties, it will definitely succeed in the future.
03. The Vice President of Cummins’ Understanding of Heavy Trucks Has Been Subverted
The key to fuel efficiency is that hybrid heavy trucks need a “smart brain.” Reasonable and scientific strategies need to be comprehensively considered and precisely calculated so that the two motors, engine, and transmission can exert their best performance. Factors to be considered include different load capacities, various road conditions, and everyone’s driving style. Only by finding the most fuel-efficient and best-performing balance can truck drivers make money.
Sun Yu’s office in the Xingtai factory is extremely large, capable of accommodating 60 people for office work. There are three large tables around her, filled with colleagues in quality control, power domain control, programming, calibration, and strategy. Sun Yu specially placed a large TV on the table and led everyone to analyze data and curves every day.
Everyone was highly motivated. They bought many books for research. Two colleagues in strategy, one from Shenzhen and the other from Beijing, live in the dormitory next to the office building. As soon as they wake up in the morning, they come to work and often work overtime until late at night before returning to the dormitory. Sun Yu often has to urge them to get off work.
Sun Yu has many photos in her mobile phone, all taken casually during the work with everyone in the past two years. There are photos of swatting mosquitoes during evening meetings while looking at data, road testing in a large vehicle at midnight, and scenes of drivers refueling while squatting on the vehicle. There is also a photo of a red moon in the sky on a summer night in 2024, just like the confusion in Sun Yu’s heart at that time.
During that period, Sun Yu couldn’t bear to hear the words “fuel consumption.” Fuel consumption is related to the livelihood of truck drivers and is the most important thing for them. If the fuel consumption is not satisfactory, it means the development has failed. “Not only Lao Fan, but everyone is watching how the fuel consumption performs. If we can’t break through the industry limit, can Great Wall heavy trucks survive?” More than a year later, when Sun Yu thinks of that period, she can’t help but cry. It’s not because she feels sad but because she feels the pressure has finally been released.
Sun Yu believes that the support of her colleagues is crucial to the success of heavy trucks. The team worked day and night, conducting experiments, writing code, and test driving. After modifying a version during the day, they couldn’t wait to test the results at night. “Everyone was driven by a spirit of not admitting defeat, charging forward with single-minded determination, without even considering backing down.”
At that time, Sun Yu reported to Tang Haifeng, the Chairman of Great Wall Commercial Vehicles, every week. Mr. Tang also took the initiative to help her find solutions. “He has a high vantage point and a broad vision, and he can provide us with many specific suggestions, telling us how to adjust.”
On the night of July 31, 2024, Sun Yu drew the core strategy on a piece of paper. “That time, we truly understood it, which was a huge breakthrough. Everyone was extremely excited. Those in calibration, programming, and strategy worked overnight to develop software.”
Sun Yu was so happy that she couldn’t sleep all night. She was completely confident that the vehicle was sure to succeed!
There are many “second-generation truck drivers” in the team. Xiao Ya, a colleague in the Strategic Development Department, has a father who is a truck driver. Whenever she has time, Xiao Ya comes to Sun Yu and emphasizes that the sleeper must be more comfortable and it must be convenient to cook. Another colleague engaged in thermal management, who grew up in a truck, believes that the air conditioner must be good.
Later, Sun Yu realized that it was the heavy truck project itself that attracted these children who have an emotional connection with heavy trucks since childhood. This bond gives the team a greater sense of responsibility for manufacturing a good heavy truck.
During this process, the heavy truck team, relying on their strength, has gained a significant “fan” in the industry—Cummins, the world’s leading powertrain supplier.
Great Wall heavy trucks started as a novice, with a small engine purchase volume, similar to a retail buyer. At the beginning, Sun Yu and her team contacted the staff of Cummins’ engine sales department.
“Later, during the development process, Cummins discovered that our fuel consumption is very low. After learning about our innovation in heavy truck technology, it caught the attention of Cummins’ senior management.” Recently, Wang Kaijun, the Vice President of Cummins and General Manager of the Engine Division in China, signed a strategic cooperation agreement with Mr. Wei.
When Wang Kaijun came to test drive, Sun Yu originally only wanted him to drive one lap. However, it completely subverted his impression of heavy trucks. “I didn’t expect driving a large truck to be so easy, almost like driving a car.”
The engineers in charge of the engine couldn’t contain their joy and stood upright with pride.
04. Great Wall Hi4-G Hybrid Heavy Trucks Enable Truck Drivers to Make Money and Maintain Dignity
The Great Wall Hi4-G hybrid heavy truck represents a disruptive technological revolution for foreign high-end heavy trucks that have always held a leading position in the industry. It subverts the traditional power route with the most advanced hybrid technology route.
Over the past six years, Sun Yu’s team has accumulated hundreds of heavy truck technology patents. The Great Wall Hi4-G hybrid heavy truck they created is not only a newcomer in the industry but also an all-round warrior that leaves its competitors far behind.
The comprehensive power output of the Hi4-G heavy truck’s super intelligent hybrid system reaches an astonishing 1050 horsepower, which is a superpower that conventional industry models cannot match.
According to the CHTC-TT national working condition certification test, the comprehensive fuel consumption is only 29.7L/100km. It is the first heavy truck in China with a comprehensive fuel consumption of less than 30L/100km. The fuel consumption in the plain express working condition is 19.9L/100km, which is 15%-25% lower than that of traditional diesel heavy trucks. Calculated based on an annual operation of 250,000 kilometers, it can save truck drivers about 100,000 yuan in fuel costs per year.
From the very beginning, Great Wall’s view of high-end heavy trucks is to enable truck drivers to make money and maintain dignity.
After chatting with hundreds of truck drivers, the real problems they encounter while driving gradually became clear.
Truck drivers often complain that the steering wheel is heavy, and their arms and shoulders ache after driving for a day. Manual transmission vehicles are also tiring when pressing the accelerator and brake pedals. The seats are uncomfortable, and many people develop lumbar disc herniation in their 30s. The sound insulation of the cab is poor, and the wind noise is so loud during high-speed driving that it buzzes in their ears.
Sun Yu genuinely feels sorry for truck drivers. “They really have a tough time. To save money, many drivers eat and live in the vehicle. The cab is filled with clothes, quilts, pots, pans, and ashtrays, and there is a pungent smell of smoke as soon as you enter.”
A small table board is installed in the vehicle, along with a 220-volt socket. There is a refrigerator behind the driver’s seat, making it much more convenient for the driver to cook and eat. The steering wheel supports multi-angle adjustment, and electric power steering is added, making it much easier to hold for a long time. To prevent back pain after sitting for a long time, the seat is designed with lumbar support. The front of the vehicle is streamlined, not only reducing wind resistance but also making the interior of the vehicle extremely quiet. The windshield is particularly large, providing a broad view and improving the driver’s mood while driving. Moreover, the vehicle is equipped with an intelligent networking system that supports OTA upgrades, making the vehicle “smarter as it is driven”.
To enable drivers to sleep better, a sleeper made of coconut shell material is specially selected. It is moderately soft and hard, with good support and breathability. Even if male drivers sweat a lot or have a heavier body weight, they will not feel stuffy. The interior is made of easy-to-clean materials and designs. At the same time, the drivers who test drive the vehicle all say that the odor control in the vehicle is excellent, and there is no unpleasant smell at all.
Sun Yu said that in the future, when people see Great Wall heavy trucks on the road, they can feel more at ease regarding safety issues.
The Great Wall Hi4-G hybrid heavy truck is equipped with BSD radars on both sides of the vehicle, which can comprehensively cover the blind spots on both sides. To prevent the driver from failing to see pedestrians or small vehicles, a 360° panoramic image and emergency braking function are added. For high-speed scenarios in long-distance transportation, it has a lane-keeping function, saving a lot of effort for truck drivers. If the driver feels drowsy while driving, the fatigue monitoring system will beep an alarm and actively help the driver correct the steering wheel.
Conclusion
It takes six years to sharpen a sword. At the first debut, Mr. Wei told Sun Yu that they should hold a unique heavy truck launch conference.
Sun Yu thought that they should hold a “real” launch conference. “The heavy truck was developed together with the truck drivers. It’s like a child jointly created by us. We should let them come onto the stage to talk about their needs, lives, and stories. We also have the opportunity to solemnly express our gratitude to the truck drivers for their long-term support and companionship.”
At the launch conference, Sun Yu did not show off her skills. However, when it came to solving every user pain point, technology was always involved. On the large screen, there was a line of small text: running on pure electricity at low speeds, electric assistance during acceleration, fast charging and discharging, and stabilizing the instantaneous fuel consumption. This is the core of Great Wall heavy truck technology.
Whether it’s the truck drivers at the scene or those in front of the screen, they are all people who make a living with heavy trucks and understand this.
Before and after the technology launch conference, some truck drivers sent messages to Sun Yu: “Great Wall has truly created a different and excellent vehicle for us.”
Sun Yu felt that this sentence soothed all the hardships. “What we have most desired in these six years is the recognition of the truck drivers!”
