The structure of machine tool industry, enterprises and products is unbalanced, and the main machine is emphasized while the supporting equipment is neglected; Pay more attention to quantity than quality; Pay more attention to "face" than foundation; Pay more attention to hard power than soft power. Some homogenization is serious, and some are "blank"; These problems have not been solved, and it is difficult to solve them.

At present, government leaders and enterprises have no sense of urgency. In today's global economic integration, the supporting parts and functional parts used by the main engine factory can be purchased from the products produced by world-renowned enterprises in China. However, the number of domestic functional component enterprises is very small, and their competitiveness is weak, so it is difficult to feel the threat, which is a double-edged sword.

This also creates conditions for users to develop special CNC machine tools. Because users are familiar with the use process, the special CNC machine tools they developed are practical and cost-effective, and redundant functions are removed. For example, Shandong Binzhou Piston Factory has a professional manufacturing branch factory specializing in manufacturing CNC machine tools, with only 200 to 300 people and annual sales of 30 million yuan. One-third of the special CNC production line for producing pistons is for personal use, one-third is sold domestically and one-third is exported. Another example is Changshu Bearing Factory, which produces CNC lathes for rough and finish machining of bearing rings as needed. In order to remove chips conveniently, the spindle is turned upside down, and the effect is very good. Timkin's wholly-owned bearing factories in China and the United States all adopt this special CNC lathe. Other enterprises such as Dongfang Steam Turbine have also developed and produced special CNC lathes. The specialized production of functional parts provides convenience for users to manufacture machine tools, which may be a trend, and the machine tool industry has another competitive "opponent". Objectively, it fills a blank in the machine tool industry.

Among these functional components, the most important is the numerical control system and its servo drive device. In the long history of machine tool development in China, it has experienced ups and downs. Fifty or sixty years have passed, so far, most high-end CNC systems and driving devices rely on imports. Despite the strong support of "04 Special Project", the middle and high-grade systems are mainly provided by Fanuc and Siemens, and the middle and low-grade systems are provided by a few domestic manufacturers such as guangzhou cnc Equipment Co., Ltd., which still have certain competitiveness. Among them, guangzhou cnc Equipment Co., Ltd. has become a climate, and its sales volume and output value increased significantly last year compared with the previous year, which is really gratifying. However, there are only a few hundred sets of high-end CNC system manufacturers with multi-axis linkage, such as Huazhong CNC and Yangguang, while there are more than a thousand sets of mid-range CNC systems produced by Huazhong CNC. Domestic CNC system has made gratifying achievements, but it is also facing the problem of popularization. The main engine factory does not dare to use it, and the end users do not like it. Therefore, they cannot be industrialized. Without "quantity", there is no "quality" and the cost cannot be reduced. How to untie this "knot" is completely beyond the market mechanism. Under the situation of further deepening reform that "the market plays a decisive role in resource allocation", domestic high-grade CNC may be more marginalized, and the dream of machine tool power will be far away, which can only be solved by the wisdom and means of decision makers.

Thinking 4: Reliability, accuracy, consistency and retention are weaknesses.

Users report that there are not many major faults and many minor faults in CNC machine tools, and the maintenance service can't keep up, so high-end users dare not use them. According to the reliability research results supported by tuili Ningjiang Machine Tool Factory and Chongqing University, the initial failure frequency of small and medium-sized precision vertical and horizontal machining centers takes about three months, while foreign machine tools have little or no initial failure in use, and MTBF (Time to Failure) and MTTR (Maintenance Time) cannot compete with foreign machine tools. According to the 56-year research of Tuining Ningjiang Machine Tool Factory, the MTBF of small and medium-sized precision horizontal and vertical machining centers can reach 900 hours, with the target of 1500 hours. According to the research results, the factory formulated a set of management system to ensure reliability, and made more than 40 reliability test devices to eliminate unreliable factors in the factory. I think the goal must be achievable, which depends on silly efforts to endure loneliness and eliminate unreliable factors. The results are integrated into the design, technology and manufacturing process, and become norms and strictly implemented. Then get feedback from users to improve. This PDCA method with multiple internal and external feedback has accumulated a lot of valuable data, which will form a unique database in the future, providing a digital basis for "problem-oriented" innovation.

Looking at other enterprises, according to media reports, the MTBF of heavy CNC machine tools is only 200~300 hours. For users, downtime just can't create value, and it's strange that users have no opinions.

The numerical control system and servo device produced by Fanuc company in Japan have strict statistics and cause analysis. According to the company's statistics from 1 to 12 in 20 12, the total number of units needing maintenance services in China increased from 349,000 units in 10 to 385,000 units in 12, and the ownership covered all stages of the life cycle, with a failure rate of only 0.004. Mr. Laodaoye, the founder of Fanuc, is 90 years old. Every month, he will personally inquire and study the cause of the failure and take necessary measures to solve it. Can high-end CNC equipment enterprises in China produce this data?

The consistency of accuracy, that is, Cpk (Process Capability Index), is an index used by modern enterprises to express process capability, that is, the quantitative response of a certain project or process level, and it is also an index of engineering evaluation. The editor should reach 1.33 or above, which must be considered when purchasing machine tool products by large production enterprises such as automobile industry. At present, the accuracy of domestic machine tools is not high, so these big users dare not use domestic machine tools and their production lines. Of course, there are other reasons. German, Japanese, American, French and Korean joint-venture automobile factories all use foreign machine tools from their partners, and China enterprises simply cannot enter these industries. The development of automobile industry in German, American, Japanese, French, Korean and other countries has promoted the development of machine tool industry in their respective countries. China is an exception. This also requires the efforts of several generations of machine tool enterprises to reverse this situation. Can some business leaders who are eager for quick success and instant benefit make up their minds?

The basic theories of static and dynamic stiffness, thermal deformation and vibration of machine tools, which affect machining accuracy and smoothness, have matured in the prototype test of Beijing Machine Tool Research Institute in the 1960s, and dozens of machine tools, including high-precision coordinate boring machines and edging machines, have been tested. Some are made by factories and some are made by factories. The author and a group of colleagues once lived in the guest house of Wuhan Machine Tool Plant for three months. The effects of static and dynamic stiffness, thermal deformation and vibration of German Kapp blade opener and domestic blade opener on the machining accuracy and smoothness of machine tools are compared, and suggestions for improvement are put forward. The test conditions are much better now. There are many non-contact testing instruments, such as measuring vibration and thermal deformation to submicron level and measuring temperature to 0.5℃. The noise can be analyzed by BK noise meter and Fourier function made in Denmark, and the source of noise can be analyzed. Taylor Hobson roundness tester can be used to measure roundness and multiple harmonics to analyze the source of vibration. At that time, special classes were held in various factories to train experimental researchers. Old machine tool workers may still be impressed. It is suggested that Beijing Machine Tool Research Institute sort out the past data, hold training courses and train personnel for promotion in the industry. Last year, the author saw in Kunming Machine Tool Plant that its newly developed high-precision CNC horizontal boring machine was doing thermal deformation test. I hope that academicians, professors and experts of the 04 special project will pay attention to the promotion of these achievements. At that time, there were some scientific methods to compensate thermal deformation, including symmetrical design and complementary error, and now there is numerical control. The deformation measured dynamically can be compensated by software, which is not very mysterious. Just do it honestly.