Technical characteristics and development of CNC machine tools
1948, the U.S. air force provided equipment research funds for aircraft parts manufacturing, which came from G&; Company L cooperated with MIT for four years, and in 1952, the world's first CNC milling machine was trial-produced, and 100 units were immediately produced and delivered to the military industry. The results show that it is the crystallization of social demand, scientific and technological level and personnel quality; Technically, it shows the great innovation of mechatronics machine tool control.
Technical characteristics of CNC machine tools
CNC machine tools have the following three outstanding features:
Using binary mathematical input, the machining program can be compiled at will, and the spindle and feed speed can be changed according to the machining process needs, so that multi-coordinate linkage can be realized and complex surfaces can be easily machined. For the processing object, it has the characteristics of "variable, variable and variable", which is convenient for batch change and adjustment, and can realize the flexible production of multi-variety and small-batch miscellaneous parts and meet the needs of society for product diversification. But it is expensive, so it is necessary to correctly analyze the economic rationality of its use;
The combination of software and hardware can realize the functions of information feedback, compensation and automatic acceleration and deceleration, which can further improve the machining accuracy, efficiency and automation of machine tools.
It is an electromechanical integrated machine tool with electronic control as the main body, which gives full play to the unique advantages of microelectronics and computer technology and is easy to realize informationization, intelligence and networking. It can easily form various advanced manufacturing systems, such as FMS, FTL, FA and even CIMS in the future, which can maximize industrial productivity and labor productivity.
Conditions for the development of CNC machine tools
Everything has its own characteristics and development conditions, and only by mastering it can people accelerate their development. The development conditions of CNC machine tools mainly include:
It is a synthesis of many high-tech disciplines such as machinery, electricity, liquid, gas and light, especially based on modern advanced technologies such as electronics and computers. It must have a solid technical foundation, complement each other and be indispensable. If it is not complete, it is difficult for CNC machine tools to develop smoothly;
A CNC machine tool consists of a main machine, various components (functional components) and a CNC system. Advanced automation tools are needed to realize machining. All links must pass technical and quality tests to ensure reliable and stable work, thus ensuring the accuracy, efficiency and automation of CNC machine tools. Otherwise, it will be difficult to use them in production practice.
It is a combination of social needs, scientific and technological level and personnel quality, and it is indispensable. If the quality of personnel is poor and the level of science and technology cannot be reached, it will be difficult to meet the needs of society. People are the main body of all activities, and they need all kinds of experts, talents and skilled workers who are proficient in business to cooperate with each other and complete them together. Otherwise, it is difficult for CNC machine tools to develop smoothly.
Main experience of developing CNC machine tools in industrialized countries
With the progress of science and technology, especially the progress of microelectronics and computer technology, CNC machine tools have been developing for 50 years. The United States, Germany and Japan are the countries with the most advanced technology and experience in the research, design, manufacture and use of CNC machine tools. Because of their different social conditions, each has its own characteristics.
The characteristic of the United States is that the government attaches importance to the machine tool industry, and the US Department of Defense and other departments constantly put forward the development direction and scientific research tasks of machine tools and provide sufficient funds to recruit talents from all over the world, paying special attention to "efficiency" and "innovation" and attaching importance to basic scientific research. Therefore, machine tool technology is constantly innovating, such as 1952, the development of the world's first CNC machine tool, 1958 machining center, the development of FMS in the early 1970s, and 1987 open CNC system. Because the United States first developed a large number of automated production lines to automate mass production in combination with the production requirements of automobiles and bearings, and its electronics and computer technology are world-leading, its CNC machine tool host design, manufacturing and CNC system are solid, and it has always attached importance to scientific research and innovation, so its high-performance CNC machine tool technology has always been in the leading position in the world. Today, the United States not only produces high-performance CNC machine tools for aerospace, but also produces cheap and practical CNC machine tools for small and medium-sized enterprises (such as Haas and Fadal). The existing lesson is to pay more attention to basic scientific research and ignore applied technology. In the 1980s, the government relaxed its guidance, which led to a slow growth in the output of CNC machine tools. 1982 was overtaken by backward Japan and imported in large quantities. Since the 1990s, correcting the past bias, CNC machine tools have turned to practical technology, and the output has gradually increased.
The German government has always attached importance to the important strategic position of the machine tool industry and given strong support in many aspects. Pay special attention to "reality" and "actual effect", adhere to "people-oriented", mentor and help, and constantly improve the quality of personnel. On the basis of developing a large number of production automation, 1956 has been insisting on seeking truth from facts, stressing scientific spirit and making steady progress since it developed the first CNC machine tool. Germany pays special attention to scientific experiments, combines theory with practice, and pays equal attention to basic research and applied technology research. Enterprises work closely with scientific research departments in universities to conduct in-depth research on the commonness and characteristics of user products, processing technology, machine tool layout structure and CNC machine tools, and strive for perfection in quality. German CNC machine tools have good quality and performance, advanced and practical, genuine, and exported to all parts of the world. Especially large, heavy and precise CNC machine tools. Germany pays special attention to the advanced nature and practicability of CNC machine tools and accessories. The quality and performance of its machinery, electricity, liquid, gas, light, tools, measurement, numerical control system and various functional components are among the highest in the world. For example, Siemens' numerical control system and Heidenham's precision grating are world-famous and scrambling to adopt them.
The Japanese government attaches great importance to the development of machine tool industry and guides the development through planning and laws (such as Mechanical Vibration Law, Electromechanical Law and Mechanical Information Law). Learn from Germany in attaching importance to talents and machine tool parts, and learn from the United States in quality management and CNC machine tool technology, even shine on you is better than Blue. Similar to the United States and Germany, Japan has fully developed a large number of production automation, and then fully developed small and medium-sized CNC machine tools for flexible production automation. Since 1958 developed the first CNC machine tool, the output of 1978 (7342 sets) has surpassed that of the United States (5688 sets), and its output and export volume have always ranked first in the world (200 1 produced 46604 sets, with 27409 sets exported, accounting for 59%). Strategically, mid-range CNC machine tools with large and wide output are exported in large quantities, occupying a vast global market. In 1980s, we began to further strengthen scientific research and develop into high-performance CNC machine tools. Strategically, first, we should learn from Total Quality Management (TQC) in the United States and turn it into a conscious collective activity for employees to ensure product quality. Then accelerate the development of electronics and computer technology, and enter the forefront of the world, paving the way for the development of mechatronics CNC machine tools. In the process of developing CNC machine tools, Japan pays close attention to the key points and highlights the development of CNC system. Japan FANUC Company has a correct strategy, combines imitation and creation, and develops all kinds of low, medium and high-grade numerical control systems needed by the market with leading technology and the highest output in the world. The company has 3674 employees, more than 600 scientific researchers and a monthly production capacity of 7000 units. Its sales account for 50% of the world market and 70% of the China market, which has played a great role in accelerating the development of CNC machine tools in Japan and even in the world.
Present situation and main problems of NC machine tool development in China
Present situation of NC machine tools
At present, there are many people in China Machine Tool Industry Factory. In 2000, there were about 358 metal cutting machine tool factories (206,000 people) and about/kloc-0 machine tool factories (65,000 people), totaling 549 (27 1 10,000 people). Among them, there are about 150 CNC metal cutting machines and about 30 CNC forming machines, totaling about 180, accounting for 1/3 of the total number of production enterprises. 200 1 year metal cutting machine tool output192,000 sets, of which17,521,accounting for about 9%.
Generally speaking, the output of CNC machine tools is increasing, which is 3.6 times that of 20065438 199 1. Imports grew rapidly, reaching 29 times, while exports increased, but the quantity was small, 4.8 times; The consumption of CNC machine tools increased rapidly, reaching 7.9 times. Output can't meet the needs of social development.
In terms of the amount, in 2006, 5438+0 imported CNC machine tools 17679 sets, accounting for 14 1 billion dollars, and exported 2509 sets, accounting for 44 million dollars, and the import amount was 32 times of the export value. A large number of imports and a small number of exports.
Main problems in developing CNC machine tools in China
China developed the first CNC machine tool in 1958, and the development process can be roughly divided into two stages. The first stage is from 1958 to 1979 and the second stage is from 1979. In the first stage, there was a lack of understanding of the characteristics and development conditions of CNC machine tools. In the case of poor personnel quality, poor foundation and poor accessories, they rushed up and down, and finally stopped because of poor performance and could not be used for production. The main problems are blindness and lack of scientific spirit of seeking truth from facts. In the second stage, CNC system technology was introduced from Japan, Germany, the United States and Spain, and advanced technology, cooperation and joint venture production of CNC machine tools were introduced from Japan, the United States, Germany, Italy, Britain, France, Switzerland, Hungary, Austria, South Korea and 1 1 country (region) Taiwan Province Province, which solved the reliability and stability problems.
In more than 20 years, the design and manufacturing technology of CNC machine tools has been greatly improved, mainly in three aspects: (1) training a group of talents for design, manufacture, use and maintenance; Through the cooperative production of advanced CNC machine tools, the level of design, manufacture and use has been greatly improved, and the gap with the world's advanced technology has been narrowed; Using foreign advanced components and numerical control systems, we can design and manufacture high-speed, high-performance five-axis or five-axis CNC machine tools to meet the needs of the domestic market, but it is poor in testing, digesting, mastering and innovating key technologies. Up to now, many important functional parts, automatic tools and numerical control systems are supported by foreign technology, and cannot be independently developed. They are basically in the stage from imitation to independent development, which is far from the level of Japanese numerical control machine tools. The main problems include: lack of guidance like Japan's Electromechanical Law and Machine Letter Law; There is a serious shortage of experts and skilled workers in various fields; Lack of in-depth and systematic scientific research work; Components are not compatible with CNC system; There is a lack of cooperation between enterprises and majors, and they are basically fighting alone. Although there are many people in the factory, they cannot form a joint force.
China Road to Accelerate the Development of CNC Machine Tool Industry
In order to accelerate the development of China's CNC machine tool industry in the future, we should not only sum up the past experience and lessons, but also seriously improve the existing problems, learn from foreign advanced experience and move forward along the right path. The following actions are recommended:
China factory has a large population, and it is in urgent need of correct policies to guide the development of CNC machine tools. We should learn from the experience of the United States, Germany and Japan. The government attaches great importance to it, makes correct decisions and strongly supports it. In terms of principles and policies, we should pay attention to the scientific spirit and economic benefits, and take the principle of effectively improving productivity and labor productivity. In terms of methods, we should go deep into users, master technology, pay equal attention to low, medium and high grade, and learn from Japan. One is to solve the problem of mass production, occupy the market, reduce imports and expand the export of mid-range CNC machine tools. In terms of steps and measures, we should make the domestic CNC system advanced and reliable, pay close attention to product quality and accessories, and lay a good technical foundation. In the near future, it is important to lay a foundation, establish credibility, expand the domestic market share of domestic CNC machine tools, and seek to catch up with the world advanced level in the long run and stride towards the world market;
We must pay close attention to the fundamentals, adhere to "people-oriented", speed up the improvement of personnel quality and train all kinds of experts, and fundamentally change the current inefficient and backward state. People are the foundation of the success or failure of all undertakings. All levels should attach importance to "training, selecting and using talents", establish a learning enterprise, establish a corporate culture, accelerate the training of new people, train on-the-job personnel, establish a tutorial system, hold various technical lectures, training courses and symposiums, and even hire foreign experts and consultants to try their best to improve CNC. The technical improvement of 300 machinery factories has a high demand for CNC machine tools.
According to the forecast of the Investment Research Institute of the State Planning Commission, the total investment in fixed assets in China will reach 22 trillion yuan during the Tenth Five-Year Plan period, with an average annual growth rate of 37%. According to the interaction between investment in fixed assets and consumption in machinery market in the past, during the Tenth Five-Year Plan period, the business opportunities in China machinery market reached 32-40 billion yuan.
It is predicted that by 20 10:
The automobile market will reach 44-80 million vehicles, of which the machinery market will increase by 0.54% for every increase in automobile production 1%;
In terms of transportation, the investment in western railway development during the Tenth Five-Year Plan period is 100 billion yuan, and the investment in western transportation in the future is 700-800 billion yuan. Special equipment such as wheel lathe, hook milling machine, 2m sawing machine and spiral welded pipe expanding machine will be of great use.
In the next five years, 530 billion yuan will be invested in water conservancy projects, 654.38+0888 billion yuan in the first phase of environmental protection, and 260 billion yuan in the second phase. There is a huge demand for corresponding machinery and equipment.
300 machinery manufacturing enterprises will carry out technical transformation, and the number of CNC machine tools purchased is very considerable;
At present, there are 65.438+0.7 million mold factories in China, with an annual output value of about 22 billion yuan. It is estimated that the output value will reach 46 billion yuan by 2005. The required machinery tends to be high-precision, high-efficiency and high-speed milling equipment, virtual axis machine tools, compound machining machines and wire cutting machines. The declining market share of domestic CNC machine tools is about to be reversed.
With the progress of world science and technology and the development of machine tool industry, CNC machine tools, as the mainstream products of machine tool industry, have become the key equipment to realize the modernization of equipment manufacturing industry and the strategic materials for the development of national defense military equipment. The number and performance level of CNC machine tools is an important symbol to measure a country's comprehensive strength. Accelerating the development of CNC machine tool industry is also a realistic requirement for the development of China's equipment manufacturing industry.
According to the user survey organized by cmtba, aerospace, national defense and military manufacturing need large-scale, high-speed, precision, multi-axis and efficient CNC machine tools; Automobile, motorcycle and home appliance manufacturing industries need high efficiency, high reliability and high automation CNC machine tools and complete sets of flexible production lines; Power station equipment, shipbuilding, metallurgical and petrochemical equipment and rail transit equipment manufacturing industries need high-precision and heavy-duty CNC machine tools; High-tech industries such as IT industry and bioengineering demand nano-scale submicron ultra-precision machining CNC machine tools; The industrial upgrading of traditional manufacturing industries such as construction machinery and agricultural machinery, especially the vigorous development of private enterprises, requires a large number of CNC machine tools for equipment.
At present, the number and variety of CNC machine tools in China can not fully meet the domestic market demand. According to Wu Bolin (right), chairman of cmtba, recently, the draft of the National Special Plan for the Development of CNC Machine Tool Industry has been formulated and is currently being revised by the National Development and Reform Commission. After the revision is completed, it will be submitted to the leaders of the State Council for examination and approval, and then formally implemented. It is understood that after the implementation of the Plan, the problems of low industrialization and independent development ability of CNC machine tools that plague the development of China's machine tool industry will be solved to a certain extent, and the domestic market share of domestic CNC machine tools will be reversed year after year.
The national policy supports the construction of the industrialization base of CNC machine tools.
According to the plan, in the next five years, the machine tool industry will build 20 CNC machine tool industrial bases and 10 basic functional parts industrial bases, and the base enterprises will enjoy national policies and financial support. It is clearly pointed out in the "Planning" that the new products and high-grade CNC machine tools developed and produced by enterprises in the industrialization base of CNC machine tools shall be subject to the policy of VAT being levied first and then returned. When asked whether enterprises in Dalian, Shenyang and other places that have implemented consumption-oriented value-added tax in the transformation of the old industrial base in Northeast China will enjoy double tax incentives, Wu Berlin gave a positive answer. After the reform of value-added tax in Northeast China, the voice of value-added tax transformation in other parts of the country, especially in the central and western regions, is very high. After the implementation of "Planning", enterprises in the NC machine tool industrialization base outside Northeast China are likely to take the lead in implementing consumption-oriented value-added tax, thus obtaining double tax benefits.
In fact, the state has given some enterprises in the machine tool industry a VAT refund policy, but the strength is too small, and the new policy is expected to increase. However, Wu Bolin believes that it should be returned according to the proportion of new products produced by enterprises and the sales of high-end CNC machine tools, and the return ratio is 3%~5%.
Wu Berlin also talked about the issue of import tariffs. "To make functional parts, we need to import some parts and spare parts. At present, the import tariff on spare parts is still high, which increases the production cost of enterprises. On the other hand, the import tariff of the whole machine can be greatly reduced or even tax-free. " He said, "There are still some tariff policies that need to be adjusted." It is also known that the Plan will also provide financial support for national debt projects for enterprises entering the industrialization base. The initial construction of enterprise technology development center and technology engineering research center, as well as the first and first new products, will also be given certain risk subsidies.
Adjust the industrial structure and strengthen the development and manufacturing capacity of functional components.
The low industrialization of mid-range CNC machine tools is one of the problems to be solved. "We can make mid-range CNC machine tools, but what we do, from quality, delivery time to after-sales service, lacks market competitiveness." Wu Bolin said, "Don't compare with Europe and America. Even China and Taiwan Province Province can't compare with us now. He took the typical ordinary vertical machining center in mid-range CNC machine tools as an example: in 2004, the mainland consumed about 654.38 million sets, but all enterprises in the mainland produced about 2,000 sets, while Taiwan Province Province, which had only eight or nine production and machining centers, sold 3,300 sets to the mainland. This shows that our competitiveness is poor and our industrialization level is low. "
In terms of developing specialized production, Wu Bolin believes that to improve the level of industrialization, we should vigorously promote specialized production from the perspective of government guidance. "It is impossible to engage in machine tools, especially popular or economical machine tools, large and complete production methods, and small and complete production methods." He also specifically mentioned a problem in the industrial structure of machine tools in China, that is, there are many main engine factories, but there are few professional manufacturers of key functional parts, and their strength is weak. In terms of numerical control system, more than 80% of our numerical control system is imported. Not only the price is high, but also the import cycle can not meet the requirements of the main engine factory. And the reliability and quality of machine tools assembled with imported things will also be affected.
Wu Bolin therefore believes that to improve the level of industrialization, we must first adjust the industrial structure and strengthen the development and manufacturing capabilities of functional components. Secondly, the technological transformation of enterprises should also be strengthened, and in this respect, enterprises owed too much in the past. "It is very difficult to manufacture high-precision machine tools and use low-precision ordinary machine tools."
Improving the development ability of high-grade CNC machine tools
If we can still make mid-range CNC machine tools, but the level of industrialization is low, then the problem of insufficient development capacity is particularly prominent in high-end CNC machine tools. The "Planning" clarifies the policy of improving development ability with enterprises as the main body. Wu Bolin mentioned that enterprises that are expected to enter the national NC machine tool industrialization base, such as Dalian, Shenyang, Beijing, Shanghai, Jinan, Qinchuan, Qiqihar, etc., all have a certain level and have a good development momentum in recent years. "If the country supports them again, they may be able to come up soon."
However, improving the development ability is not an easy task. Take the numerical control system as an example. At present, large western companies adopt the market strategy of blockade and dumping. The first is blockade, which does not realize dumping. The price of its numerical control system in China market is very expensive, and it has gained high profits. As soon as China enterprises developed the same products, they immediately cut prices sharply, even lower than the cost price of China enterprises. In this case, it is even more important for the state to support domestic enterprises, just as the United States, Germany and Japan supported domestic enterprises at the beginning.
On the other hand, Wu Berlin reminded enterprises to attach importance to development investment subjectively. "A few years ago, most domestic machine tool enterprises were in a state of loss, unable to carry out scientific research and technological development, and now they live a comfortable life. But you can't just produce those small machine tools that cost 10 thousand yuan each. In that case, you can never develop a machine tool with millions of dollars and millions of euros. "
Experts pointed out that if machine tool enterprises want to enter the industrialization base, their investment in technology development should not be less than 5% of product sales revenue. If you achieve this goal, you will enjoy a certain degree of state subsidies every year. According to the planning goal, by the end of the 11th Five-Year Plan, the domestic market share of domestic CNC machine tools will increase to over 50% in terms of sales, and at the same time, the domestic market share of all domestic machine tools will also increase to over 60%.