Improve the level of domestic machine tools
2022-09-05 04:03:41
Targeting the needs of the automotive industry to effectively improve the level of domestic machine tools
Machine tools are important equipment for automobile production. The level and quality of automobile manufacturing depend to a certain extent on the level of machine tools. Machine tools are a major part of the investment in automotive manufacturing companies. In general, machine tool investment accounts for about 2/3 of the total investment in fixed assets of automobile manufacturers, which directly affects the manufacturing cost of automobiles. The automotive industry is the largest user of machine tools and the mainstay of machine tool consumption. The automotive industry needs a large number of flexible, efficient and reliable domestic machine tools to meet the needs.
Automotive manufacturing requirements for machine tools
With the improvement of the technical level of automobiles and the transformation of manufacturing technology, the requirements of the automotive industry for domestic machine tools are getting higher and higher. The new machine tools required are qualitatively different from the traditional ones. Flexible production lines consisting of CNC machine tools have become the focus of demand.
First, higher flexibility
Equipment flexibility: The machine tool can complete a variety of processing, which is conducive to mass production, reduce inventory costs, improve equipment utilization and shorten processing cycle.
Material handling flexibility: Material handling equipment can transport a variety of materials, with high availability and utilization.
Manufacturing process flexibility: The manufacturing process can produce a variety of products at the same time, with a mixture ratio flexibility, to improve customer satisfaction by providing a variety of products.
Operational flexibility: Workpieces of different machining processes can be machined in a variety of ways, making it easy to implement dynamic scheduling in the event of a machine failure.
Second, high production efficiency
Production efficiency is an important indicator of the company's production capacity. High productivity requires high movement and high feed rate for the machine, large-cut machining, and short auxiliary time. A multi-variety production line can produce more than 200,000 pieces per year; a large auto body cover punch presses 9 to 13 times per minute; if necessary, a compound machine tool is required in the production line, on one machine The compounding process and the processing of a plurality of workpieces can be completed, so that the production efficiency can be further improved.
Third, the precision is good
High-quality automotive products require high-precision machine tools, and high-precision requires not only high positioning accuracy and repeatability of the machine tool, but also important engineering assurance capability, ensuring stable accuracy of the processed products and good dimensional accuracy. To achieve high precision, the machine tool not only needs to adopt excellent mechanical structure such as spindle system, transmission system and guiding system, but also needs reliable control system and online detection technology.
Fourth, high reliability
Ensuring consistency and trouble-free manufacturing processes is important to the automotive industry. If the reliability of the machine is not good, it will not create a higher output value for the user.
Five, in line with environmental requirements
The machine tool should adopt low-energy, low-noise driving device; use less cutting fluid or no cutting fluid to process; the cutting fluid transitions from oil base to water base; set safety protection device; promote centralized cooling lubrication system; no leakage.
The gap between domestic machine tools
First, technical performance, variety can not fully meet the needs of automotive high-end products
In domestic automobile manufacturing, medium and low-grade domestically produced machine tools are much more used, and there are fewer high-grade machines; there are many general-purpose machine tools, and there are fewer special functions and individualized machine tools. As a result, many high-precision CNC machine tools, CNC compound machine tools, and high-efficiency dedicated CNC machine tools still rely heavily on imports.
Second, more faults, less reliable
Over the years, the reliability of domestic machine tools has become more prominent, affecting the reputation of domestic machine tools in the domestic and foreign markets, and needs to be highly valued. Many machine tool manufacturers often neglect the quality control in the machine tool manufacturing process. Most of the functional components have not been subjected to engineering tests and destructive tests. At the same time, the quality of components selected by many machine tool manufacturers is not good, resulting in high failure rate and high precision after machine tool sales. Less than the contract requirements.
Third, the system integration ability is low
At present, the world's leading machine tool manufacturers have completed the transformation from simply selling equipment to providing a complete, integrated solution. This change requires machine tool suppliers to have strong innovation capabilities and comprehensive technical strength. In general, China still lacks mature experience and technology to integrate process systems, logistics systems, and information systems into manufacturing units or production lines. Especially the fault diagnosis expert system technology, the development and application of the process parameter optimization expert system technology is not enough, which is one of the important reasons for the widening gap between China and the international level.
The phenomenon of four or three leaks has not been completely eradicated, and the appearance still needs to be improved; there is still a gap between service awareness and support ability and user expectations.
Many domestic machine tools do not pay enough attention to the appearance, logo, and three leaks of the equipment. At the same time, it is not ideal in terms of delivery time and after-sales service, which directly affects the normal use of user equipment.
Joint innovation and coordinated development
At present, the automotive market is highly competitive, requiring constant reductions in manufacturing costs. Statistics show that for every 1% increase in the import rate of machine tools in the automotive industry, the total investment in machine tools will increase by 2% to 3%. Therefore, the adoption of domestically produced machine tools in the automotive industry is a requirement for the survival of automobile enterprises. Automobile production should not rely on imports for a long time in equipment, but should be based on domestic machine tools. To achieve sustainable development of the two industries, and support and cooperation with each other, the automobile industry and the machine tool industry should follow the path of joint innovation and coordinated development.
The automotive industry provides more support for the machine tool industry to solve automotive manufacturing process solutions and improve the system integration capabilities of the machine tool industry in automotive manufacturing process solutions.
The process plan is the key to product quality and production capacity guarantee, which directly affects the manufacturing cost, and determines the investment cost. At the same time, it is also the embodiment of advanced manufacturing technology. Therefore, the automotive industry should provide more support for the machine tool industry to solve automotive manufacturing process solutions, especially with long-term accumulated experience, so that Chinese machine tool suppliers can more deeply grasp the automotive manufacturing process and develop processes suitable for automotive production. Expert system software that provides users with a high level of turnkey engineering.
Seeking a breakthrough in the hot spot of imported machine tools, the automotive industry provides more opportunities for the machine tool industry to replace imported machine tools. In recent years, the automotive industry has introduced a large number of imported machine tools in the manufacture of high-end products and key processes, and the investment is huge. The automobile industry and the machine tool industry must work together to build a foothold in the national conditions and be brave in technological innovation. The automotive industry provides more opportunities for the machine tool industry to replace imported machine tools. The machine tool industry must constantly track the development of the automotive industry, research advanced automotive equipment technology, and jointly develop more and better new machine tools in the automotive industry to improve the level of automobile manufacturing.
At present, in the face of strong competitors such as Lin, the Chinese machine tool industry should further analyze the industry characteristics and industrial characteristics, adjust the industrial structure, and gradually form serialized and modular CNC machine tools to meet the needs of the automotive and parts manufacturing industries.
In recent years, Dongfeng Motor Corporation and domestic machine tool manufacturers have jointly developed and applied domestic machine tools. For example, in 2004, they jointly developed with Jinan Jiemai Casting and Forging Co., Ltd., and took the lead in adopting advanced technology to make front frame wide and narrow bending forming machine. It realized flexible forming and replaced imported; in 2002, it jointly developed the flat CNC punching machine with Jinfangyuan Company. The domestic first adopted Harley high-speed large-tonnage stamping system and servo conveying positioning system.
According to the overall plan for the development of China's automobile industry, the annual output of automobiles will reach 14 to 18 million in the next 15 years, becoming a major automobile producing country in the world. At the same time, China's auto parts are gradually being incorporated into the global procurement system, and the demand for auto parts exports is also large. The realization of these goals requires great efforts from the automotive industry and the machine tool industry. It also hopes that the state will give strong support to the policy.
Machine tools are important equipment for automobile production. The level and quality of automobile manufacturing depend to a certain extent on the level of machine tools. Machine tools are a major part of the investment in automotive manufacturing companies. In general, machine tool investment accounts for about 2/3 of the total investment in fixed assets of automobile manufacturers, which directly affects the manufacturing cost of automobiles. The automotive industry is the largest user of machine tools and the mainstay of machine tool consumption. The automotive industry needs a large number of flexible, efficient and reliable domestic machine tools to meet the needs.
Automotive manufacturing requirements for machine tools
With the improvement of the technical level of automobiles and the transformation of manufacturing technology, the requirements of the automotive industry for domestic machine tools are getting higher and higher. The new machine tools required are qualitatively different from the traditional ones. Flexible production lines consisting of CNC machine tools have become the focus of demand.
First, higher flexibility
Equipment flexibility: The machine tool can complete a variety of processing, which is conducive to mass production, reduce inventory costs, improve equipment utilization and shorten processing cycle.
Material handling flexibility: Material handling equipment can transport a variety of materials, with high availability and utilization.
Manufacturing process flexibility: The manufacturing process can produce a variety of products at the same time, with a mixture ratio flexibility, to improve customer satisfaction by providing a variety of products.
Operational flexibility: Workpieces of different machining processes can be machined in a variety of ways, making it easy to implement dynamic scheduling in the event of a machine failure.
Second, high production efficiency
Production efficiency is an important indicator of the company's production capacity. High productivity requires high movement and high feed rate for the machine, large-cut machining, and short auxiliary time. A multi-variety production line can produce more than 200,000 pieces per year; a large auto body cover punch presses 9 to 13 times per minute; if necessary, a compound machine tool is required in the production line, on one machine The compounding process and the processing of a plurality of workpieces can be completed, so that the production efficiency can be further improved.
Third, the precision is good
High-quality automotive products require high-precision machine tools, and high-precision requires not only high positioning accuracy and repeatability of the machine tool, but also important engineering assurance capability, ensuring stable accuracy of the processed products and good dimensional accuracy. To achieve high precision, the machine tool not only needs to adopt excellent mechanical structure such as spindle system, transmission system and guiding system, but also needs reliable control system and online detection technology.
Fourth, high reliability
Ensuring consistency and trouble-free manufacturing processes is important to the automotive industry. If the reliability of the machine is not good, it will not create a higher output value for the user.
Five, in line with environmental requirements
The machine tool should adopt low-energy, low-noise driving device; use less cutting fluid or no cutting fluid to process; the cutting fluid transitions from oil base to water base; set safety protection device; promote centralized cooling lubrication system; no leakage.
The gap between domestic machine tools
First, technical performance, variety can not fully meet the needs of automotive high-end products
In domestic automobile manufacturing, medium and low-grade domestically produced machine tools are much more used, and there are fewer high-grade machines; there are many general-purpose machine tools, and there are fewer special functions and individualized machine tools. As a result, many high-precision CNC machine tools, CNC compound machine tools, and high-efficiency dedicated CNC machine tools still rely heavily on imports.
Second, more faults, less reliable
Over the years, the reliability of domestic machine tools has become more prominent, affecting the reputation of domestic machine tools in the domestic and foreign markets, and needs to be highly valued. Many machine tool manufacturers often neglect the quality control in the machine tool manufacturing process. Most of the functional components have not been subjected to engineering tests and destructive tests. At the same time, the quality of components selected by many machine tool manufacturers is not good, resulting in high failure rate and high precision after machine tool sales. Less than the contract requirements.
Third, the system integration ability is low
At present, the world's leading machine tool manufacturers have completed the transformation from simply selling equipment to providing a complete, integrated solution. This change requires machine tool suppliers to have strong innovation capabilities and comprehensive technical strength. In general, China still lacks mature experience and technology to integrate process systems, logistics systems, and information systems into manufacturing units or production lines. Especially the fault diagnosis expert system technology, the development and application of the process parameter optimization expert system technology is not enough, which is one of the important reasons for the widening gap between China and the international level.
The phenomenon of four or three leaks has not been completely eradicated, and the appearance still needs to be improved; there is still a gap between service awareness and support ability and user expectations.
Many domestic machine tools do not pay enough attention to the appearance, logo, and three leaks of the equipment. At the same time, it is not ideal in terms of delivery time and after-sales service, which directly affects the normal use of user equipment.
Joint innovation and coordinated development
At present, the automotive market is highly competitive, requiring constant reductions in manufacturing costs. Statistics show that for every 1% increase in the import rate of machine tools in the automotive industry, the total investment in machine tools will increase by 2% to 3%. Therefore, the adoption of domestically produced machine tools in the automotive industry is a requirement for the survival of automobile enterprises. Automobile production should not rely on imports for a long time in equipment, but should be based on domestic machine tools. To achieve sustainable development of the two industries, and support and cooperation with each other, the automobile industry and the machine tool industry should follow the path of joint innovation and coordinated development.
The automotive industry provides more support for the machine tool industry to solve automotive manufacturing process solutions and improve the system integration capabilities of the machine tool industry in automotive manufacturing process solutions.
The process plan is the key to product quality and production capacity guarantee, which directly affects the manufacturing cost, and determines the investment cost. At the same time, it is also the embodiment of advanced manufacturing technology. Therefore, the automotive industry should provide more support for the machine tool industry to solve automotive manufacturing process solutions, especially with long-term accumulated experience, so that Chinese machine tool suppliers can more deeply grasp the automotive manufacturing process and develop processes suitable for automotive production. Expert system software that provides users with a high level of turnkey engineering.
Seeking a breakthrough in the hot spot of imported machine tools, the automotive industry provides more opportunities for the machine tool industry to replace imported machine tools. In recent years, the automotive industry has introduced a large number of imported machine tools in the manufacture of high-end products and key processes, and the investment is huge. The automobile industry and the machine tool industry must work together to build a foothold in the national conditions and be brave in technological innovation. The automotive industry provides more opportunities for the machine tool industry to replace imported machine tools. The machine tool industry must constantly track the development of the automotive industry, research advanced automotive equipment technology, and jointly develop more and better new machine tools in the automotive industry to improve the level of automobile manufacturing.
At present, in the face of strong competitors such as Lin, the Chinese machine tool industry should further analyze the industry characteristics and industrial characteristics, adjust the industrial structure, and gradually form serialized and modular CNC machine tools to meet the needs of the automotive and parts manufacturing industries.
In recent years, Dongfeng Motor Corporation and domestic machine tool manufacturers have jointly developed and applied domestic machine tools. For example, in 2004, they jointly developed with Jinan Jiemai Casting and Forging Co., Ltd., and took the lead in adopting advanced technology to make front frame wide and narrow bending forming machine. It realized flexible forming and replaced imported; in 2002, it jointly developed the flat CNC punching machine with Jinfangyuan Company. The domestic first adopted Harley high-speed large-tonnage stamping system and servo conveying positioning system.
According to the overall plan for the development of China's automobile industry, the annual output of automobiles will reach 14 to 18 million in the next 15 years, becoming a major automobile producing country in the world. At the same time, China's auto parts are gradually being incorporated into the global procurement system, and the demand for auto parts exports is also large. The realization of these goals requires great efforts from the automotive industry and the machine tool industry. It also hopes that the state will give strong support to the policy.
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