Independent innovation of automobile manufacturing equipment

As a pillar industry of the national economy, the automobile industry also plays a supporting role in building innovative countries. At present, everyone is discussing the independent innovation of China's auto industry, but there are few auto-innovations involving automobile manufacturing technology--including equipment technology. What is a car manufacturing power? The answer is not only the cars that run many Chinese brands on the road, but also the Chinese cars that are made with Chinese production lines. Achieving this goal will drive the development of China's automobile and machine tool industries, making the two industries of automobiles and machine tools an innovative industry.
In the past ten years, the automobile industry has become the main body of Chinese machine tool consumption, and it consumes about 40% of the machine tools of the whole society. At the same time, more than half of the investment in the automotive industry is used to purchase machine tools, of which about 80% are imported machine tools. Statistics show that since the 1990s, the investment rate of China's auto industry has accelerated significantly. During the 10th Five-Year Plan period, the total investment in the automobile industry has exceeded 200 billion yuan, that is to say, more than 100 billion yuan has been used to purchase machine tools, of which about 80 billion yuan (10 billion US dollars) purchased imported machine tools, accounting for about 5 years of total machine tool imports ( 45% of the approximately $21.7 billion. This is the main reason for the rapid growth of domestic sales and imports in China's machine tool market.
From the perspective of historical development, China's automobile manufacturing equipment can be divided into four stages:
The first is the Soviet-style equipment stage. In the 1950s, the newly built first automobile factory was basically Soviet-style equipment.
The second is the stage of domestic equipment. In the 1970s, in order to equip the second automobile factory (predecessor of Dongfeng Company), more than 130 machine tool production and research units were organized, providing 117 automatic lines and 1004 kinds of 5,500 high-efficiency and special equipments. The localization rate of equipment is 96%, which is called “treasure bowl”. The third is the Western equipment stage. In the 1990s, China's automobile industry entered the era of cars. Due to the lagging development of the domestic automobile equipment manufacturing industry, Chinese cars can only be manufactured with imported production lines, and more than 80% of equipment investment depends on imports. According to incomplete statistics, the flexible automatic line adopted by modern engine advanced manufacturing technology--FTL has installed more than 100 pieces, and the unit price is about 20 million US dollars, of which imports account for more than 90%. China is the hottest and most imported country in the world for FTL applications. Another example is that in the four major process equipments for vehicle manufacturing, except for the stamping production line, domestic products account for most of the market, and almost all of them are imported.
The fourth is the combination of innovation and introduction. The next 15 years will be the best and last strategic opportunity for the development of domestic automotive equipment. We can only and must take the road of combining independent innovation and introduction, and gradually increase the proportion of independent innovation.
Manufacturing technology is an important core competitiveness of the automotive industry. On the one hand, international automobile manufacturing technology is changing with each passing day, and the level of products depends on the level of manufacturing technology. It is the adoption of a large number of advanced numerical control equipments in recent years, which has enabled China's sedans to enter the flexible era as a whole, and has supported the continuous development of China's automobile industry. On the other hand, the international competitiveness of automobile companies depends on manufacturing costs. As China's auto industry begins to enter the micro-profit phase, enterprises will not be able to pay high prices for imported equipment for a long time. It can be said that equipment localization is the need of enterprise survival competition, and the era of relying on imported production lines to manufacture Chinese cars has come to an end.
From a historical perspective, the development of automotive products is bound to be accompanied by a revolution in manufacturing technology and equipment, and vice versa.
At the beginning of the 20th century, Ford Motor Company founder Ford invented a large number of production lines, from which the car entered the society. At the end of the 20th century, due to technological advances, the cycle of upgrading automobile products was shortened from several decades to three to five years. The combined machine automatic line cannot be adapted due to lack of flexibility. Ford and Ingersoll have cooperated to develop a high-speed machining center with high flexibility and high efficiency. The advent of a flexible automatic production line has accelerated the upgrading of automotive products. In the 21st century, engine manufacturing technology is brewing a new revolution in order to resolve the increasingly prominent contradictions of diversity and economy, to meet the needs of variable varieties, variable batches and rapid market response. New production methods such as Lean Production, AgileManufacturing, Reconfigurable Manufacturing Systems, and GreenManufacturing have become strategic choices for 21st century automotive manufacturing systems.
In order to meet the needs of energy saving and safety, Hyundai Motor generally adopts lightweight design. This has led to the development of high-pressure forming technology – the manufacture of hollow and lightweight components.
Laser processing technology. Including laser cutting, laser welding, laser tailor-welded sheet stamping forming technology, is an advanced technology developed internationally. Foreign laser applications are growing at a rate of 20% per year, and General Motors uses more than 200 lasers online. Laser processing has become an indispensable technology in modern automobile manufacturing. The laser tailor-welded blank is formed by laser welding the unequal thickness steel plates into blanks, and then integrally stamping, which can reduce the weight of the parts, improve the matching quality of the whole vehicle, reduce the material consumption, and improve the productivity. The three-dimensional CNC laser cutting of the car body is a recently developed flexible manufacturing technology, which replaces the traditional manual cutting + punching die manufacturing method, shortening the production preparation cycle from 2.5 months to 5 days, greatly shortening the new car development cycle.
Warm forging forming technology. It has the advantages of hot forging and cold forging. It is mainly used as a light material (aluminum, magnesium, titanium) for hot forging and isothermal forging superplastic forming. The automotive, aerospace and aerospace industries are widely used in the United States, and warm forgings account for about 50% of precision forgings.
Powder metallurgy sintering forging technology. The powder metallurgy forged link has a weight accuracy of 1%, while the forged link has a weight accuracy of 2.5%. Compared with the conventional machined connecting rod, after the economic batch is reached, the processing cost can be saved by 35%.
The automobile industry is the locomotive that drives the development of the machine tool industry. In the international arena, the automobile power is generally a powerful machine tool. Not only the United States, Japan, Germany, and Italy, the machine tool industry of the emerging machine tool countries South Korea and Spain is also driven by the automobile industry. At the same time, in the world, all machine tool enterprises that can meet the needs of the automotive industry must be the world's first-class machine tool enterprises.
The automotive industry's technical drive to the machine tool industry is mainly reflected in the following aspects:
First, the size and geometry accuracy of car parts is one to two precision levels higher than that of general machinery, which drives the development of machine tools to high precision.
Second, automobile manufacturing belongs to mass production, characterized by automatic flow line. The core technology is system integration technology—the integration of process system, logistics system and information system into automatic production line. In the 21st century, it is required to design a new generation of flexible automatic lines according to the concept of lean and agility, and it is required to provide a complete set of “turnkey” projects. Its technical content, technical added value and difficulty are several grades higher than traditional single machines, requiring machine tool manufacturing enterprises. Very familiar with the modern automotive parts manufacturing process, able to master a variety of modern manufacturing technologies (such as digital technology, flexible automation technology, high-speed processing technology, simulation technology, green manufacturing technology, etc.), and has the integration capabilities of various technologies. Due to the rapid changes in modern manufacturing technology, there is also the need for integrated innovation. It can be said that the ability to provide modern flexible automatic lines for engine assembly (PT) has become the symbol of the world's top machine tool manufacturers, including Dalian and Shenyang Machine Tool Group Co., Ltd., which have entered the top 10 in the world.
At the same time, the current automatic line equipment arrangement is serial, and the whole line machine can't work independently. If one machine fails, the whole line will be discontinued, which will cause huge economic losses. For example, an engine plant with an annual output of 300,000 units can lose up to 150 million yuan in one day. This puts stringent requirements on machine tool reliability (MTBF).
Third, high-volume production requires efficient special machine tools and dedicated automatic production lines. The basic requirements for machine tools are high stiffness, high speed, and high power, all equipped with superhard tools. The basic feature of high-efficiency special-purpose machine tools is “tailor-made”, which is to provide personalized products according to user needs. Its technical difficulty is much higher than that of a general-purpose machine tool, and it also requires a complete turnkey project.
Fourth, on the basis of the “turnkey” project, the international solution has been developed to provide a total solution (TotalSolution), which puts higher requirements on equipment supply, such as the ability to independently innovate and require equipment suppliers. It provides not only a comprehensive solution, but also a “best” solution that can be achieved at the level of contemporary technology. It has the ability to analyze economics, provide excellent cost performance, create value after production, and quickly recover investment. A comprehensive solution has made service a major part of the supplier's supply, which is also a watershed between modern manufacturing and traditional manufacturing – the greater the proportion of services, the more modern.
Fifth, due to mass production, high precision retention is also required. When the automobile industry accepts the machine tool, it must not only assess the accuracy of the single-piece machining, but also assess its accuracy retention, that is, evaluate its process capability index (Cpk value). It can drive the development and design capabilities of the machine tool industry, the quality of processing, assembly and quality assurance systems for production management.
Sixth, due to fierce competition, there are strict requirements for reducing manufacturing costs, which requires continuous innovation in processing technology and equipment. If you use Lean Machine (LeanMachine) - remove redundancy, it has small footprint, high efficiency and strong targeting; agile fixture (flexible fixture) - controllable, adjustable fixture; intelligent tool ( SmartTools) - a series of controllable, adjustable and special efficient tools designed for specific parts processing; composite machining; cutting processing into less, no cutting, non-traditional processing. This has also led to an increase in the innovation capability of the machine tool industry.
Seventh, China has become a big mold producing country and a big consumer country, and the world mold production center is shifting to China. The automobile industry is the industry with the most mold applications. There are many types of molds, high precision, complex shapes, and short delivery times. At present, there are still a large number of sophisticated and complex automotive stamping dies and plastic molds, car cover molds, electronic connectors and other high-end molds rely on imports. Due to the high-tech characteristics of the mold products, only the use of precision equipment can guarantee the process requirements. It requires the machine tool industry to provide precision five-axis machining gantry type, bed type high-speed milling, a series of advanced electric processing machine tools, CAD/CAM integration technology, and rapid model. Manufacturing technology, etc.
In addition, the automotive industry has also put forward comprehensive requirements for automatic stamping lines, automatic casting automatic lines, robotic welding automation equipment, robotic spray equipment, assembly automation equipment, CNC tool systems, laser cutting and welding equipment, and testing equipment. Therefore, it can be said that the independent innovation of automobile manufacturing equipment will comprehensively improve the level of China's CNC machine tools and related equipment manufacturing.
The independent innovation capability and product performance of China's automobile manufacturing equipment still lag behind foreign high-end machine tools such as modern engine assembly manufacturing technology, high-speed machining center, manufacturing unit composed of advanced composite machine tools, and our independent innovation capability and foreign technology. The gap in development is gradually widening. Gu Yongsheng, a famous engine expert, said that foreign machine tool designers are very familiar with the customer's manufacturing process and improve the product export every year. For example, after the 1990s, the parts of the engine were processed by flexible processing, and the cylinder bore of the engine was mechanically processed, such as flat top honing and laser honing, which were the result of continuous improvement. In China, machine tools are difficult to improve for several years, let alone improved every year.
China's automobile manufacturing equipment is still stuck in the traditional manufacturing --- selling machines, only provide A / S (After Service) - after-sales service; and international equipment suppliers have entered to provide T / S (Total Solution) - - The era of solutions. This is a new and more serious gap between China's auto manufacturing equipment suppliers and international auto manufacturing equipment suppliers.
At present, most of China's automotive manufacturing equipment suppliers can only provide a single machine, can not provide production lines, only manufacture MT (Machine Tool), not manufacture MC (Manufacturing Cell), especially the lack of system integration technology.
There is a gap between the performance of machine tools produced in China and the international level. The main CNC machine tools can not meet the needs of modern cars for accuracy, precision retention and reliability. For example, the international processing precision has increased by 50 times from 1950 to 2000. The gap between the accuracy of domestic processing centers and the international advanced level is generally 15 years; the value of process capability index is generally 1.33, and the value of process capability index for car manufacturing is ≥1.67; domestic The MTBF of the machine tool only reaches about 500 hours, while the MTBF of the imported production line can reach about 5000 hours.
Select key breakthrough projects, and establish an automobile manufacturing technology and equipment innovation system in accordance with the guidelines set by the National Medium- and Long-Term Science and Technology Development Plan and the State Council's Several Opinions on Accelerating the Revitalization of Equipment Manufacturing Industry, selecting key breakthroughs and striving for inclusion in the country. Promote projects—develop national technical standards, organize national acceptance, identification, and promotion.
In the vehicle production and key component assembly line equipment, aiming at the medium and long-term demand of the automotive equipment market and the world's leading technologies in automobile manufacturing technology and equipment development, select a group of major impacts on industrial upgrading, have significant promotion value, and have a major society. Projects that are economically efficient and capable of achieving core technology and system integration capabilities.
First, choose a number of key breakthrough projects.
The first is the application-oriented independent innovation project. Such projects must be proposed by the company itself and have its own capital investment, with technical strength and market foundation. The state gives funds and policy support, and organizes project owners to cooperate with manufacturing companies and universities to carry out joint design and joint manufacturing. Manufacturing companies and colleges and universities are chosen by the owners. It is necessary to carry out "scientific and technological management innovation" to break the old scientific research management model, and the results are shared by enterprises and countries, and the whole society benefits.
Internal high pressure forming automotive pipe fittings technology.
———The internal high pressure forming technology is a high-pressure forming process for filling the hollow pipe fittings enclosed in the mold cavity with extremely high pressure, forcing the pipe wall to be close to the inner cavity wall. In order to meet the needs of energy saving and safety, Hyundai Motor generally adopts lightweight design. The internal high-pressure forming parts are light in weight, and the weight of the hollow shaft parts is reduced by 40%~75%, which improves the rigidity and strength of the parts, the number of parts is small, the welds are small, and the production cost (including the mold cost) is reduced by 15%~30% compared with the stamping parts. , developed rapidly in Europe and America. In typical cars made in North America, hollow pipe fittings account for 16% of the total number of car parts.
Hollow pipe fittings are mainly used for structural pipe fittings such as the opposite pipe fittings of the engine exhaust system, the pipe fittings in the engine bracket, the chassis structural members, the body frame, the front and rear axles, and the drive shaft. Several domestic joint ventures have imported high-pressure molded parts from Germany, the United States and Japan for their mid- to high-class cars. Domestic Harbin Institute of Technology, Yanshan University, FAW Technology Center and other units are also studying the internal high pressure forming technology, but due to limited conditions, they are basically in the laboratory research and development stage.
This project is based on the technical center of FAW Group Corporation and has been approved by the Ministry of Science and Technology. Its successful research and development will provide technical equipment for the lightweight design of China's automobiles, which has significant promotion value, has a major impact on industrial upgrading, and has significant social and economic benefits.
———Development of laser welding automatic tooling equipment system for car body.
Laser welding of car body is the key technology for body manufacturing. It has played a huge role in reducing weight, reducing costs, improving efficiency, improving quality and safety performance.
The laser welding tooling system is technically high and difficult. It is characterized by automation, intelligence, opto-mechatronics, and contains many patents and proprietary technologies. At present, the body laser welding automatic tooling equipment system is a bottleneck restricting the body laser welding, and there is no product in China.
This project includes research on welding tooling equipment systems and their compatibility, welding expert systems (including welding process database), welding system integration, and welding system control.
This project relies on the technical center of FAW Group Corporation. Its research and development success and promotion and application will improve the quality of economic cars headed by Xiali, change the status quo of domestic economy cars equal to low-end cars, realize technology upgrading, improve the core competitiveness of self-owned brands, and have significant promotion value. It has a major impact on industrial upgrading and has significant social and economic benefits.
At the same time, the "high-efficiency, high-precision complete sets of equipment needed for the automotive industry" included in the "National Science and Technology Development Major Project of High-end CNC Machine Tools" is of course a key breakthrough project, including the forming and processing of light materials (aluminum, magnesium, titanium). Complete sets of equipment, automatic stamping lines, automatic casting automatic lines, robotic welding automation equipment, robotic spray equipment, assembly automation equipment.
The second is the key common technology and cutting-edge technology.
To be included in national projects, universities and research institutes will tackle the problem. For example, first increase the reliability of machine tools into national projects. Transplanting China's successful aerospace reliability engineering, establishing theoretical methods and software tools for reliability analysis design and test evaluation of automotive key component assembly line equipment, theoretical methods and software tools for structural and structural dynamic reliability analysis design.
It is also necessary to speed up the development of reconfigurable manufacturing systems, RMS, from the current theoretical exploration stage to the prototype stage of reconfigurable prototypes and reconfigurable production lines.
Of course, key common technologies, cutting-edge technologies and a number of application-based independent innovation projects are also linked to many industries, first and foremost the aerospace industry. The automobile manufacturing technology of the United States and Japan benefits from aircraft manufacturing technology. The same is true in China. There are even many aircraft manufacturing companies in China that make cars, which requires more collaborative integration between the two industries.
For example, the first CNC isothermal forging hydraulic press jointly developed by Tianjin Tianforging Press Co., Ltd. and Hongyuan Aviation Forging & Casting Industry Co., Ltd. was included in the national major technical equipment innovation research project, and the product appraisal has been completed. The company has successfully manufactured The largest titanium alloy die forgings in China. If this technology can be promoted and applied in the automotive industry, it will promote the project of “forms and processing of light materials (aluminum, magnesium, titanium) required for the automotive industry” included in the above-mentioned major special projects. The internal high pressure forming technology is not only a new technology urgently needed for the manufacture of modern automobile pipe fittings, but also a new technology urgently needed for hollow crankshafts and complex pipe fittings of aircraft engines. In engine manufacturing technology, cars and airplanes have much in common and can be used for reference. High-speed processing technology has made breakthroughs in the automotive, aerospace and aerospace industries at home and abroad.
At the same time, the demand for high-precision and high-precision maintenance of CNC machine tools is the most prominent in the defense technology industry such as automobile and aviation, and aerospace.
Second, create an automotive manufacturing technology and equipment innovation system.
At present, the scientific research system of machine tools under China's planned economic system has been "transformed into enterprises," and the scientific research and innovation system suitable for the market economy system has not been established. The United States is a country with a developed market economy. Their experience in organizing the National Center for Manufacturing Science (NCMS) can serve as a reference for building our automotive manufacturing technology innovation system (see related material link). Namely: the government subsidizes, the machine tool industry and the automobile industry join forces to organize the automobile manufacturing equipment R&D center, and the university implements the project. The power of colleges and universities is especially important in the absence of old research systems. At present, the most feasible way to establish a research and development team is the cooperation of production, learning and research, especially the cooperation of production and learning. The most important technology development projects in the United States are in universities, including CNC machine tools and RMS--reconfigurable manufacturing systems. The China Automotive Engineering Society has a number of college car group members. If we can learn from American experience, they will be the new force in China's automobile manufacturing technology and equipment innovation system.
Creating a car manufacturing technology and equipment innovation system is a complex system engineering. The most difficult of these is the integration of institutions and people. The China Automotive Engineering Society is constructing a communication and dialogue mechanism between automobile enterprises and machine tool enterprises, and establishing an "automobile engineering construction and equipment branch" to synchronize the development of the machine tool industry with the development of the automobile industry, and establish a policy of "cooperative integration, independent innovation, and key leapfrogging". Production (automotive industry) - production (machine tool industry) - learning virtual research and development complex.

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