CNC machine tool transformation, a hot spot for enterprises

CNC heaven and earth manufacturing technology is the foundation for directly creating material civilization. It plays a vital role in the prosperity of any country and society.

Machine Tool Text / Beijing Aviation Technology Research Institute Chen Hao Deng Ling CNC transformation enterprise focuses on a hot spot manufacturing technology is the basis for directly creating material civilization, it plays a vital role in the prosperity and prosperity of any country and society. In the 1990s, advanced manufacturing technology has been widely used in various fields of the national economy, such as automobile manufacturing, shipbuilding, petrochemicals, etc., especially the rapid development of computer technology, resulting in CIMS, FMS, FMC, DNC, CNC and other technologies. The basic machine tool technology of the manufacturing industry is even more powerful. However, many of the old equipment produced in the 1960s and 1970s still have good mechanical properties, and the green manufacturing industry does not allow a large proportion of discards. How to effectively use existing equipment to make it more economical and socially beneficial is a concern of many companies at home and abroad. The numerical control transformation of machine tools is one of the hotspots. It includes the numerical control transformation of general machine tools and the numerical control transformation of the original old CNC machine tools. In this regard, many companies at home and abroad have done a lot of things.

According to the relevant data, the sample survey of the current situation of machine tool equipment conducted by Japan and the advanced countries in Europe and America is: survey data of 252 companies, accounting for 41.3% of enterprises with less than 30%, and enterprises with 30%-50% of NC rate 33.7%, that is, 75% of enterprise machine tools have an NC rate of less than 50%, which is independent of the size of the company.

The product of the year accounts for 60% and is the main body of the active machine tool.

The factory purchased new machine tools to improve machining accuracy by 38%, to increase productivity by 35%, and to save 22% of labor. Due to the continuous purchase of new machine tools and the scrapping of old machine tools, this data is difficult to calculate, but preliminary estimates It accounts for about 20%-30%, and will maintain this value for five years. Another valuable data is that the proportion of old CNC machine tools in the output value of the old machine tools has risen rapidly.

The average old machine tool can be rebuilt within 10 years, while the old NC machine tools are less than 15 years old, and most of the work is commissioned by the original machine tool manufacturer and enterprises with supporting technology (mechanical, electrical, programming, process, etc.). This can achieve low cost, high quality (with a one-year guarantee period), sufficient spare parts and complete maintenance information. Ordinary machine tool repair time is generally 8 weeks, NC machine tool is 12 weeks.

Most of the machine tools are CNC machines, which require mechanical parts and CNC system updates (sometimes need to convert ordinary machine tools into CNC machines), such as the use of lead screws, guides, gears, electrical boxes, etc., for the feed rate of machines that were not CNC. Generally, it can not be improved, but the CNC machine tool can increase the feed rate by 75%. The spindle speed can be improved without any redesign.

An old CNC equipment has been refurbished (the machine tool is completely dismantled, re-CN machine tool market. 64. CNC world design and CNC transformation) costs about 30%-40% of the new machine tool. Due to some market irregularities and user awareness reasons The problems with CNC machine tool transformation are: M) The image is not high, and some large companies believe that the accuracy and productivity of the old machine tools are much less than that of the new machine tools.

Insufficient confidence, people in the circulation field are not complete with the old machine tool transformation management system, the price is opaque, lack of after-sales service experience, and the user's trust in comprehensive quality is not high.

There are few people in the future, and the people who are transforming the old machine tools are getting older and lacking. It is said that it takes 10 years to develop this industry into a successful business.

People in this industry need to accumulate a large amount of product knowledge, can identify the degree of use of the original users of the equipment, have a personal relationship network, all need to have a long preparation time, also need the skills of commodity circulation work, these should be affected by society Respect, outsiders are often difficult to understand.

The status quo of CNC machine tools in the domestic aviation industry With the improvement of the international financial industry and the development of the domestic economy, machine tools are growing rapidly. In recent years, the large-scale complex CNC machine tools in the defense industry system have become more and more straight. As far as the aviation system is concerned, in the past ten years, due to the increase in the demand for new machine pre-research, model development, civil subcontracting production and cooperative production tasks, CNC technology has been greatly developed, and a considerable number of numerical control devices have been deployed. As of 1999, there have been more than 1,500 types of numerical control equipment for aviation industry enterprises and institutions, and the numerical control rate of machine equipment has reached 5°/., which is higher than the national level (1.5°/.).

It is expected that in the future, key OEMs and airborne equipment plants will purchase CNC equipment, and the total number of CNC equipment will reach more than 1,700. The manufacturing capacity of the aviation industry will be significantly improved and improved.

However, in general, the current development status and application level of NC machining technology in the aviation industry is still backward, and it is completely unable to meet the needs of current and future military and civil aircraft development and production tasks, and the gap with foreign advanced levels is growing. trend. Mainly reflected in the utilization and efficiency of CNC machining equipment. The utilization rate of CNC machining equipment of the main engine factory is generally 30%-40% according to the spindle start time, and the individual factory is less than 10% (70%-80% abroad), the processing efficiency is only 20%-30%, and the processing time is The ratio of preparation time is 1:5-1:8. This value is much lower than 1:0.5 in advanced countries, and lower than the average level of 1:1 to 1:2 of similar enterprises, resulting in great numerical control equipment. waste.

One of the important contents to improve the efficiency of CNC technology is to improve the utilization rate of equipment, and the time when equipment should be shut down for work is about 5%-15% of the whole process (different factories). Faults come from control systems, machine tools, computer software, hardware, and other ancillary equipment, and are a random process.

The aviation industry system purchased more than half of the total number of CNC equipment before 1986. The numerical control system of these machine tools has been aging, the spare parts supply is “broken grain”, the mechanical transmission mechanism is seriously worn out, and some factory shutdown maintenance equipment accounts for 2/5, so the old equipment renovation has been refurbished. At the necessary stage, some units have actually been carried out in succession and have received some results. It should be said that it is economical to retrofit an old machine tool with less than 1/3 of the cost (new machine tool). Some specialized units within the aviation system also have this ability. The main problem at present is that the head office should strengthen organization and management. Give full play to the enthusiasm of factories and professional units, combine concentration and decentralization, establish "CNC machine tool (equipment) technology and transformation (refurbishment) center" as soon as possible, establish standardized technical services and actively carry out inter-plant exchanges and cooperation.

Our work in this field has been developed since 1958 by the 625 and the machine tool and Beihang, and developed the X53K-SK CNC machine. We have successfully developed the XK53-1G tape recording CNC vertical milling, XSK- 5040(丨V)G four-axis CNC milling, SKX-3000 three-axis gantry mobile CNC milling, cooperated with French FOREST company, adopted international advanced level of design and manufacturing technology, and cooperated to produce a large number of aircraft industry with three-five coordinates On the basis of this, the gantry mobile milling machine has developed a four-axis gantry mobile CNC milling machine. It also cooperated with FOREST to produce a double-turn CNC gantry milling machine and a large four- and five-coordinate machining center for processing large automobile cover moulds. In the design of CNC machine tools and equipment, 625 has the experience of designing and developing three- and four-coordinate large-scale gantry moving milling machines (SKX-3000, SKX-3000AC and V12000BT), and has designed and developed aircraft wind molds with double-rotation. Experience with five-axis CNC machine tools (SKX-8000AC). Through international cooperation, we have mastered the most advanced and complex high-precision, high-stiffness and high-power five-axis machine tool design and development technology of V1 20002T five-axis gantry mobile CNC milling machine and FLEXIAX 510 five-axis machining center. Design and develop the initiative of various types of CNC machine tools for the aviation industry.

: CNC machine tool market order machine name using unit number 2000B three-coordinate CNC milling machine Shen Fei (112 factory) 2000B three-coordinate CNC milling machine Hafei 2000B three-coordinate CNC milling machine Chengfei (132 factory) 2000B three-axis CNC milling machine cloud Fei (130 factory) 2000B three-coordinate CNC milling machine Xifei (172 factory) 2000B three-coordinate CNC milling machine aerospace (211 factory) 2000B three-coordinate CNC milling machine Nanfei (320 factory) 1250MN three-axis CNC milling machine Xifei (172 Factory) 2000BT four-coordinate CNC milling machine Hafei (122 factory) 20002T five-coordinate CNC milling machine Shen Fei (112 factory) 20002T five-axis CNC milling machine Chengfei (132 factory) 20002T five-coordinate CNC milling machine Xifei (172 factory) 20002T Five-axis CNC Gantry Milling Machine Nanfei (320 Factory) F410 Four-axis CNC Machining Center F510 Four-axis CNC Machining Center VL205 Six-coordinate CNC Tool Grinder Shen Fei (112 Factory) VL205 Six-axis CNC Tool Grinder Dawn (410 Factory) VL205 Six-axis CNC Tool grinding machine flying (5703 factory) S240 three-coordinate CNC copying gantry milling machine Changfei (372 factory) S240 three-coordinate CNC copying gantry Milling machine into flying (132 factory) S240 three-axis CNC copying gantry milling machine Hafei (122 factory) S240 three-coordinate CNC copying gantry milling machine Shen Fei (112 factory) S240 three-coordinate CNC copying gantry milling machine Jiangling automobile manufacturer S240 three-axis CNC Copying gantry milling machine Changchun First Automobile Group S240 three-coordinate CNC copying gantry milling machine North China Automobile Manufacturing Plant S240 three-coordinate CNC copying gantry milling machine space (211 factory) S240 three-coordinate CNC copying gantry milling machine Xifei (172 factory) S240 three Coordinate CNC copying gantry milling machine Zhejiang Yongkang Machinery Factory has a total of 8 kinds of products. Since 1994, due to the difficulties of the machine tool industry and the actual needs of CNC machine tools in aviation and other fields, the 260th has begun to enter the CNC machine tool transformation industry. Successful CNC milling and grinding machine 9 sets, with a production value of 5.3 million yuan, including 2 large-scale five-axis linkage milling machines, 1 large-scale three-axis linkage milling machine, 2 high-precision grinding machines and 4 general CNC machine tools. In our work, we have gained some experience and experience for peers and users: the purpose of teaching and controlling machine tools and the actual use of CNC machine tools must be refurbished for 10 to 15 years. The meaning of this transformation is different from machine tool maintenance. It is completely refurbished according to the needs of users and the condition of the old machine tools. The key moving parts are often completely refined or replaced to achieve the new machine level. The control components are updated to take full advantage of all the functions of the original design of the machine, and the parts can be added or expanded due to the power of the new system. This kind of refurbishment avoids the strangeness and trouble brought by the new machine tool to the user, which brings great benefits: the renovation of the old CNC machine tool can save a lot of money, and the domestic renovation and transformation of a medium and large-scale complex CNC machine tool worth more than 1 million yuan It is 20%-30% of the price of new machine tools (40%-60% abroad). As far as the statistics of major aviation companies are concerned, about 300 sets of such machine tools can save a total of 240 million yuan. We refurbished a V22000B large-scale three-axis CNC milling machine for the Chengdu Aircraft Manufacturing Industry Company (the bed is 2.5 meters long). The price is 20% of the new machine tool, and the 14 indexes of the machine positioning accuracy fully meet the new machine tool factory level. The NAS device was successful and received favorable comments from users.

Green manufacturing is a major indicator of the future manufacturing industry. The numerical control transformation of machine tools can utilize large castings (or welded parts) such as beds, columns and beams to greatly reduce the environmental pollution caused by the manufacture of these parts, thereby benefiting human beings and benefiting them. Descendants.

The old equipment has been used for ten years, and the operation, programming, and maintenance personnel are familiar with its various functions. Therefore, the equipment can shorten the training time after the modification, and it is not necessary to re-ground the foundation, shorten the installation and debugging time, and save the aging period. It can save 3~4 months and save 3%~5%. The performance of the machine after refurbishment is more stable than that of the new machine. Its original problems and defects have been fully exposed after more than ten years of use. The enterprises responsible for the transformation can be based on users. It is required to eradicate these defects and add some new functions, such as the machine tool we refurbished for Chengdu Aircraft Company mentioned above. In order to process the parts, we need to extend the bed to 2.5 meters. For the convenience of operation, the suspension button station is added, which increases the cooling effect. Coolant nozzle, increased cooling tank volume, etc.

The steps and points for renovating and reforming the teaching and control machine are jointly negotiated by the user's user (shop) and the technical reform department, and a demand analysis report (or technical requirement report) is submitted according to the use of the old equipment and the characteristics of the machined parts. All bidders (or contractors) must be uniform in size and requirements in order to have a mutually comparable indicator.

Intentional contractors and enterprise users jointly analyze and test various static and dynamic accuracy indicators of the original equipment. If the machine tool has been stopped, the indicators are analyzed according to the original data and usage records. It should be noted that both parties should use a scientific and realistic attitude. Faithful to history. Because this is a major basis for determining the transformation plan, in some cases, due to the falseness of the data, there will be many hidden dangers in the equipment after the transformation.

It is very important to select the appropriate contractor. For the transformation of a large complex CNC machine tool, the selected contractor must have comprehensive supporting technology, such as mechanical, electrical control, process, operation, training, in addition to basic trust. , guarantee period service, etc. (foreign is mostly contracted by the original production factory of CNC Tiandi in the teaching and control machine tool market). At present, some contracting companies in China often reduce irresponsibly in price, or use some illegal means to win the contracting right, and finally cause The product quality is inferior, the life is short, and the loss is often the user. There are also some manufacturers or distributors of CNC systems. They have an undeniable technical level and capability in terms of systems. There are sufficient spare parts, but there is a lack of capacity or poor consideration in machinery, especially in terms of technology. For large-scale, multi-axis CNC Machine tool transformation, we believe that users should carefully consider.

Signing contracts and attachments: An attachment is an inseparable part of a contract. It generally consists of two necessary items: a technical agreement and an acceptance document. The technical agreement must meet or cover all the contents of the technical report, and detailed materialization and quantification. Remarks should be made for the content that may be unclear to both parties. For example, if the device used for the transformation is imported or domestically produced, it is necessary to replace the device range and mechanical transmission parts. Can be repaired, which needs to be replaced, etc. The acceptance document should be specific. It includes the acceptance party and the data. The positioning accuracy and repeat positioning accuracy of the CNC machine tool are two important indicators. The qualified contractor can make the transformation equipment index reach the level of the new machine tool, but the dynamic precision is often not directly measured. In the precision index of the test piece, large-scale complex CNC machine tools must have the acceptance standard for test pieces (the international use of NAS standards).

Contract execution, large and complex CNC machine tools are large in size and heavy in weight, and many of them are still in operation at work. It is impossible to transport the entire equipment to the contractor's factory site, so the contract execution is divided into two phases, the first phase. The contractor carries out design, outsourcing, outsourcing, component manufacturing and installation and commissioning according to the contract requirements. The CNC system runs offline. This stage is generally in the contractor's factory, accounting for 2/3 of the total contract period, because the CNC system and servo and The motor ordering period is 3-4 months. The second stage is carried out at the user's site. In order not to affect the user's processing needs, this stage should be shorter. The large and complex equipment is mostly 1-2 months (foreign service is to find a proxy processing unit or equipment for the user). Although the second stage of work is also contracted to the manufacturer, the site conditions need to be provided and guaranteed by the user. It will be related to the quality of the equipment and the installation and commissioning cycle. In order to make the work smooth, the basic requirements for friendly cooperation between the two parties should be clarified in the contract. Acceptance is the main sign of the end of the on-site implementation phase of the contract. It is jointly completed by the user and the contractor. The user of the participant shall have an inspection and technical transformation management department in addition to the use unit. The acceptance report must have an acceptance report and the responsible persons of both parties signature. In addition to the qualified items in the report, it can be recorded in the content that does not affect the processing to be perfected, but the deadlines and requirements must be clearly defined. (6) Others: Training and one-year guarantee period are guarantees for the transformation work. In order to be responsible for the whole life cycle of the product, the training is mostly in two stages. The first stage is carried out by the contractor (also in the place arranged by the CNC system supplier), mainly for the control system, servo system and auxiliary control (hydraulic, Cooling, lubrication, safety protection, etc.) training. The second stage is at the user's site, mainly: operation, maintenance, maintenance, troubleshooting and mechanical technical training. At this stage, some practical operations, part cutting and troubleshooting methods training can be flexibly arranged.

Binding and selection of CNC systems. The servo system knows how to enter the main five-axis engine bed of the control system selected by the large-scale multi-coordinate aviation numerical control machine. (For some five-axis linkage CNC machines with turntables, there are individual systems to be tested). The selection of CNC system in the transformation of CNC machine tools is mainly based on user requirements and machine tool performance. Here are some points worth noting: the selection of the five-axis linkage CNC system should read the manual carefully. Many systems have a clear definition of the linkage axis, especially the A, B and C axes with the angle machine, and the machining process according to the machining process. Features Select the necessary tool compensation software (optional).

The CNC system and the servo system should be matched, especially when the two components are not produced by a company. For example, the NUM1060 system cannot be equipped with the Siemens 611D. The servo motor must be carefully selected in addition to the load and the speed. Allowable value of the torque speed characteristic curve of the motor (spindle motor).

Conclusion There are hundreds of old equipment refurbished and repaired within the aerospace industry, and this market is enduring. Through the transformation of enterprises and the adjustment of industrial structure, we have formed a high-tech industrial group integrated with group companies, research institutes and factories. The time has come to establish CNC equipment maintenance, service and transformation, and training centers. The high-tech industry is not unattainable and must be met before it can be implemented. As long as the market matures, starting from a certain point, slowly improving and gradually expanding is a feasible way. Bath: CNC machine tool market

(Finish)

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