From the reality and historical analysis of the machine tool industry how to get out of the dilemma

Thinking of the third: weak functional components caused by the foundation is not solid

The machine tool industry, there is an imbalance in the structure of enterprises and products, heavy hosts light supporting; heavy quantity light quality; heavy "face" light foundation; heavy hard power light soft power and so on. Some of the homogenization is serious, and some of the "blank"; these problems have not been solved, but also very difficult to solve.

Currently, government leaders and enterprises have no sense of urgency, in the global economic integration today, the host plant used in the supporting parts, functional components in the domestic procurement of globally renowned enterprises to produce products. And the domestic production of functional components of the number of enterprises would have been very small, weak competitiveness, so it is difficult to have a sense of threat, which is a double-edged sword.

This also creates conditions for the user to develop specialized CNC machine tools, because the user is familiar with the use of technology, their development of specialized CNC machine tools, practical, cost-effective, surplus functions are removed. Such as Shandong Binzhou Piston Factory, there is a special manufacturing CNC machine tools below the professional manufacturing sub-factory, only two or three hundred people, annual sales of 30 million yuan, the production of piston special CNC production line one-third of their own use, one-third of domestic sales, one-third of the foreign sales. Another example is Changshu Bearing Factory, according to the need to produce bearing ring rough finishing CNC lathe, in order to chip removal is easy, the spindle on the inverted, the effect is very good. U.S. Timkin's wholly-owned bearing plant in China, all using this special CNC lathe. Other enterprises such as Dongfang Turbine have also developed and produced special CNC lathes. Specialized production of functional components for the user to manufacture machine tools to provide convenience, which may be a trend, the machine tool industry has increased a competitive "rivals". Objectively and for the machine tool industry to fill a gap.

Functional components in the most important than the CNC system and its servo drive, in the long history of China's machine tool development, a few ups and downs. Fifty or sixty years have passed, so far in the high-end CNC systems and drives are mostly dependent on imports. Although there are 04 special support, high-grade systems mainly by Fanuc and Siemens supply, low-grade rely on Guangzhou CNC Equipment Co., Ltd. and a few other domestic plant to provide, there is a certain degree of competitiveness, of which Guangzhou CNC Equipment Co., Ltd. has become a climate, last year's sales, output value than the year before a large increase in the number, is really encouraging. And multi-axis linkage of high-grade CNC system manufacturers in China, such as CNC, Koyo, only a few hundred sets, while the production of mid-range CNC system has been more than 1,000 sets of China CNC, domestic CNC system has achieved gratifying results at the same time, but also faced with the promotion of difficult problems, the host factory does not dare to use the end-users do not like to use the results of the industrialization can not be. No "quantity" there is no "quality", the cost can not be reduced. This "knot" how to untie, completely rely on the market mechanism, I am afraid that can not be solved. In the "market plays a decisive role in resource allocation" to further deepen the reform situation, domestic high-grade CNC may be more marginalized, the dream of a strong machine tool will be out of reach, can only rely on the wisdom of decision-makers and means to solve.

Thinking of the fourth: reliability, accuracy consistency and retention is the weakness

Users reflect the CNC machine tools are not many big problems, a lot of small problems, coupled with maintenance services to keep up with the high end users do not dare to use the 04 special support for the Push Ningjiang Machine Tool Factory and Chongqing University, the reliability of the results of the study, the small and medium-sized precision vertical, horizontal machining centers, the initial failure frequency of period The initial failure frequency period of small and medium-sized precision vertical and horizontal machining centers, about three months, while foreign machine tools in the user with little or no initial failure, what MTBF (trouble-free time), MTTR (maintenance time) can not compete with foreign machine tools. According to Push Ningjiang Machine Tool Factory five or six years of research, mass production of small and medium-sized precision horizontal and vertical machining centers, MTBF can reach 900 hours, the goal of 1,500 hours, the factory based on the results of the research to develop a set of guaranteed reliability of the management system, and more than 40 self-manufactured reliability testing equipment, to eliminate unreliable factors in the plant. I think the target must be achievable, which depends on stupid efforts and loneliness tolerance to eliminate one unreliable factor after another. The results are incorporated into the design, process, manufacturing process into a specification, strictly enforced. And then get feedback from the user to improve, this many times inside and outside the feedback of the PDCA way, the accumulation of a lot of valuable data, the future will be able to form a unique database for the "problem-oriented" innovation provides a digital foundation.

Looking at other companies, according to media reports, the MTBF of heavy-duty CNC machine tools is only 200-300 hours, downtime for the user, that is, can not create value, the user does not have the opinion of the strange.

Japan's Fanuc company produces CNC systems and servo devices, failure rates have strict statistics and cause analysis. According to the company's statistics from January to December 2012, the total number of units in need of maintenance services in China from January's 349,000 units, increased to 385,000 units in December, with the amount of coverage of the full life cycle of all phases of the failure rate of only 0.004 to 0.008 pieces / month - Taiwan. Fanuc's founder, Mr. Inaba old, already 90 years old, every month, personally asked about the cause of the faults and research, and take the necessary measures to be Reasons, and take the necessary measures to be resolved. China's high-grade CNC equipment companies can produce this data?

Consistency of precision, that is, Cpk (process capability index, is a modern enterprise used to indicate the process capability of the index, that is, the quantitative response of a project or process level, but also a type of engineering evaluation index - ed.) value to reach 1.33 or more, which is the automotive industry, such as mass production enterprises to buy machine tools. Mass production enterprises such as the purchase of machine tools must be considered, and now the accuracy of domestic machine tools is not high, these large users do not dare to use domestic machine tools and their production lines. Of course, there are some other reasons, Germany, Japan, the United States, France, South Korea, joint venture automobile factories are using its partners in foreign machine tools, Chinese companies simply can not enter these industries. Germany, the United States, Japan, France, South Korea and other countries in the automotive industry development to pull the development of their respective countries machine tool industry, but China is an exception. This also requires the machine tool companies to work hard for several generations in order to reverse the situation, some of the quick success of the business leaders can make up their minds?

The impact of machining accuracy, finish, static and dynamic rigidity of the machine tool, thermal deformation, vibration and other basic theories, in the 1960s, Beijing Machine Tool Research Institute in the prototype test, there are mature specifications, has done dozens of (Taiwan) machine tool tests, including high-precision coordinate boring machine, open-edge grinder, etc., some of them in the Institute to do, and some of them in the production plant to do. The author and a group of colleagues have lived in Wuhan machine tool factory in the guest house for three months, the German Kapp open-edge grinding and domestic open-edge grinding static and dynamic rigidity, thermal deformation, vibration, etc. on the machine tool machining accuracy and finish of the impact of the comparison, and domestic machine tools and put forward the improvement of the views. Now the test conditions are much better, with a lot of non-contact test instruments, such as measuring vibration and thermal deformation can be up to submicron level, the measurement of temperature up to ± 0.5 ℃, measuring noise can be used in Denmark to produce the BK noise meter plus Fourier function analysis, you can analyze the source of the noise, the measurement of roundness can be used in the roundness of the Taylerhobson instrument, and can be measured many times the harmonic wave, analyze the source of the vibration. At that time, a special class was held to train the factory test researchers. The old machine tool workers may still have the impression that the Beijing Machine Tool Research Institute is recommended to organize the past information, organized classes to train personnel to promote in the industry. I saw last year in Kunming Machine Tool Works, its newly developed high-precision CNC horizontal boring is doing thermal deformation test. I hope that the 04 special academicians, professors, experts pay attention to, to promote these existing results. At that time, there have been some scientific ways to compensate for thermal deformation, including symmetrical design, complementary errors, etc., and now there is a CNC, with dynamic measurement of deformation, can be compensated by software, is not very mysterious, as long as you do it honestly.