Power generation equipment industry has seven expectations for domestic machine tools

"To meet the needs of the power generation equipment industry, in addition to gradually increasing the trust of domestic CNC machine tools, the machine tool industry should further improve efficiency and precision, and gradually overcome the weak links such as CNC systems." Liang Weiyan, an academician of the Chinese Academy of Engineering, recently stressed to China Industry News reporter Say.

In recent years, the domestic machine tool industry has strongly supported the rapid development of the power generation equipment industry, but it is undeniable that there are still some shortcomings in meeting its high-end needs. Then, as one of the main users, what kind of expectations does the power generation equipment field have for China's machine tool industry? What are the suggestions and requirements for the next step in the development of the machine tool industry?

Recently, our reporter interviewed insiders in the power generation equipment industry, and let us listen to the most intuitive feelings of users and the most urgent requirements.

Basic satisfaction is still lacking

Turbine mechanical products for power generation are heavy-duty, precision equipment, large in weight, complex in structure, and many parts (up to tens of thousands). They are usually operated under high temperature and high pressure unsteady flow medium. The working speed is up to 3000 rpm, requiring long-term and stable operation. Continuous operation, service life of 20~60 years—high efficiency and high reliability will inevitably require turbine machining parts with extremely high machining accuracy and quality. That is to say, high efficiency and high precision CNC machining machines are inevitable. To guarantee.

In order to reverse the "big but not strong" situation of the machine tool industry as soon as possible, the state has listed the development of high-end CNC machine tools as one of the 16 major special projects identified in the National Medium- and Long-Term Science and Technology Development Plan (2006~2020). It is focused on the development of high-end CNC machine tools needed for aerospace, shipbuilding, automobile manufacturing, power generation equipment, etc., to meet the needs of major domestic industries.

It is understood that during the "Eleventh Five-Year Plan" period, "high-end CNC machine tools and major manufacturing equipment major projects" jointly established 268 projects, arranged for more than 9 billion yuan, and participated in more than 10,000 research and development personnel.

“The national major project proposes to develop high-end CNC machine tools. The so-called 'high-end' is reflected in cutting speed, machining accuracy, reliability and stability,” an insider of China Dongfang Electric Group Dongfang Steam Turbine Co., Ltd. told this reporter. In general, in terms of meeting the processing needs of power generation equipment, the domestic CNC machine tool industry has made many progress in recent years, and localization is gradually advancing.

In Liang Weiyan's view, the current domestic CNC machine tools can basically meet domestic needs. “Five-coordinate linkage milling machines have been developed, but most of the users are still importing Swiss products. During this period, there is a problem of gradually building confidence.”

In this regard, an old expert of the China Electrical Equipment Industry Association also told this reporter that "almost all domestic machine tools are now available, but high-end CNC machine tools and a multi-purpose machining center are still unable to catch up with foreign countries."

Referring to the five-axis milling machine machining center, the above-mentioned person from Dongqi told reporters that "there are also domestically produced, and Dongqi itself is doing it, but the reliability, processing efficiency and precision are not as good as those of Switzerland and Germany. low."

“At the same time, large gantry boring mills and milling machines are still imported,” he said, such as gantry milling with a length of 12 meters and a width of more than 7 meters, and a boring machine with a diameter of 260 mm or more. ”

“The number of CNC machine tools for power generation is small but the precision is very high. At present, some equipments have met the requirements in China, but users are also willing to choose to import. This requires domestic machine tool enterprises to continuously improve the process and improve product quality.” Experts of the Electrical Association Said.

The seven recommendations point to the soft underbelly

So, how can the machine tool industry better meet the needs of the power generation equipment field?

In this field, compared with power station boilers and generators, the accuracy of turbine machining is higher and more stringent. Therefore, the first line from the steam turbine enterprise is also the most representative. Referring to this topic, the above-mentioned people from Dongfang Steam Turbine Co., Ltd. are full of emotions.

Combining the experience of the front line over the years, he threw seven suggestions to the reporter, or hoped:

First, focus on improving the level of CNC equipment, thereby improving the competitiveness and level of power generation equipment manufacturing.

China's manufacturing industry must rely on technological innovation to achieve the transformation from big country to strong country, low-end to high-end, and from Chinese manufacturing to China. The rapid development of the current economy has caused major changes in manufacturing technology. However, China is still only a major manufacturing country for non-innovative products. It relies on labor, price, resources and other advantages to occupy a place in low-end products.

CNC machine tools are the key equipment of modern manufacturing industry and an important basic industry that is related to the country's strategic position and reflects the country's overall national strength. “In order to meet the demand of power generation equipment manufacturing industry, the country spends a lot of dollars every year to introduce CNC machine tools, which makes China's numerical control equipment grow rapidly. However, compared with Germany and Japan, the application level of digital technology in China's manufacturing industry is still too low. This kind of challenge is of great significance to improve the level of CNC equipment and master high-speed, high-efficiency and high-precision machining technology," he said.

The market demand for CNC machine tools is growing. For example, the person said, such as the digital control transformation of Dongqi Company in recent years and the purchase of a large number of imported CNC machine tools after the earthquake, according to incomplete statistics: Dongqi imported CNC machine tools in 2006 costs 118.7 million yuan, 2007 reached 7.438 100 million yuan, from 2008 to 2009, was 1.06 billion yuan (including reconstruction).

In this regard, the experts of the above-mentioned China Electrical Equipment Industry Association also told reporters that many enterprises in the electrical field are facing the relocation or expansion, but also to achieve technological transformation and upgrading of products, which require a large number of advanced machining equipment, the industry The demand for CNC machine tools is very large.

Second, the machine tool industry should study and solve the bottleneck problem of CNC machine tool production in China, focus on improving the design and manufacturing level of CNC machine tool components, and accelerate the research and development of CNC system.

One of the weakest links in China's machine tool industry is the CNC system, which is equivalent to the "brain" of CNC machine tools. "When the CNC system is mentioned, everyone thinks of Siemens, FANUC, etc. Their CNC system software is powerful and stable, and the domestic high-end CNC systems are almost all imported."

It is understood that during the "Eleventh Five-Year Plan" period, China has developed multi-axis multi-channel, bus-type high-end numerical control device products in the numerical control system. Wuhan Huazhong Numerical Control Co., Ltd. has completed the production of 50 sets of open all-digital high-end numerical control devices. .

"The domestic CNC system has developed rapidly, but after all, it has just begun industrialization, and it is still in its infancy and is still catching up with foreign countries."

In addition, he said, the gap is also reflected in the mechatronics. "In high-speed cutting, foreign countries can reach tens of thousands or even tens of thousands of revolutions, ensuring the efficiency, speed and accuracy of processing, but the domestic speed is only a few thousand revolutions. Not as mature as foreign technology."

At present, the current status of the production of functional components in China is developed by the machine tool manufacturers themselves, with fewer professional manufacturers, weak R&D teams, non-series of functional components, too few brand products, and too long research and development time. In order to produce CNC machine tools with high quality and speed, it is necessary to produce high-quality and fast-functioning tools such as tool magazines, robots, spindle units, ball screws and linear guides for CNC machine tools.

"To solve these bottleneck problems, we must change the production mode and industrial structure. The state should support specialized factories of functional components, focus on the design and process of functional components, and increase the research and development of numerical control systems," he stressed.

Third, the level of CNC machine tools needs to be improved.

The development direction of CNC machine tools is intelligent, networked, high-speed, high-precision, composite, and environmentally friendly. In terms of precision and rigidity, the German and Swiss machine tools are the best. The overall situation is the highest in Germany and the largest in Japan. "From the situation of Dongqi in the bidding for CNC machine tools in recent years, at the product level, there is still a certain gap between domestic CNC machine tools and foreign machine tools."

The person took a machining center and a CNC lathe as an example and made a comparison:

For example, high-speed machining centers, foreign machine tools in the feed drive, the ball screw drive machining center rapid feed is mostly above 40m / min, the highest has reached 90m / min. The machining center driven by linear motors has been put into practical use. The rapid feed of domestic machining centers is mostly around 30m/min, and the linear motor-driven machining center only produces samples. The spindle speed of foreign high-speed machining centers is generally between 12,000 and 25,000 r/min, and the gantry structure suitable for high-speed machining is adopted in the structure.

In terms of machining accuracy, foreign horizontal machining centers are equipped with machine tool precision temperature compensation systems, and the machining accuracy is relatively stable, while the domestic research and development is still in progress. The positioning accuracy of foreign machining centers is basically checked according to the VDI standard. The stroke is less than 1000mm, the positioning accuracy can be controlled within 0.006~0.01mm, and the domestic positioning accuracy is relatively low. In addition, in order to meet the increasing requirements for improved machining accuracy (such as the accuracy of heavy-duty gas turbine rotors produced by Dongqi has reached the precision requirements of extreme manufacturing), many foreign companies have also developed more high-precision machining centers.

In terms of CNC lathes, the domestic functions of CNC lathes are less accurate and the imported functions are more powerful and more precise. Most of the domestically produced are economical CNC lathes, and the production of multi-function CNC lathes and turning centers is relatively small; while the foreign production is basically a multi-function CNC lathe and turning center. The foreign turning center has a double main shaft, a double turret, a Y-axis, a C-axis, and even a B-axis, and has many functions. The spindle speed and spindle power of foreign CNC lathes are generally higher than those of domestic CNC lathes. In addition, it can produce high-power, high-rigidity CNC lathes and turning centers suitable for high-strength heat-resistant alloy processing and titanium alloy processing, as well as precision CNC lathes and turning centers for car grinding, and such products are basically blank in China. In addition, the precision of the spindle, such as the company's 3500×15000 CNC sleeper, can reach 0.007mm, and the domestic machine tool with the same specifications is 0.03~0.04mm, which is unstable.

Fourth, advanced cutting technology needs to be studied and promoted.

According to reports, in terms of processing technology, foreign countries have conducted research on high-speed machining technology for many years, and have systematically studied the mechanism of high-speed machining, the structure of machine tools, the rigidity and precision of machine tools, and developed and produced various kinds of High-speed milling center and high-speed machining center are widely used in aviation aluminum alloy parts and mold processing. Multi-axis machining technology has been widely used in various types of machine tools abroad, and its variety and demand are expanding. However, only new products have been developed in China, and only individual products have passed production verification. The majority of multi-axis CNC machine tools purchased by Dongqi are imported.

“Dry cutting and semi-dry cutting technology, because of environmental protection, foreign special attention,” he said, semi-dry cutting – less lubricant lubrication technology is currently applied, dry cutting technology is also on the high-speed gear hobbing machine for gear processing Get applied, and the future will be the development trend.

Fifth, the manufacturing capabilities and manufacturing techniques of the machine tool plant itself need to be improved.

According to reports, the manufacturing technology of China's machine tool manufacturing enterprises, such as the fine grinding of the spindle, the precision of the spindle box, and the finishing of the guide rail, are basically the same as those of foreign countries, but the overall manufacturing technology is quite different from that of foreign countries.

“The numerical control rate of equipment manufacturing enterprises in China only accounts for 3%~5%. The dimensional consistency of machine tool parts is mainly guaranteed by manual, the quality of products is greatly affected by human factors, and the delivery time is difficult to guarantee. Most of the company's manufacturing equipment is CNC machine tools, and some companies use flexible manufacturing units, flexible manufacturing systems and intelligent network manufacturing technology to intelligently manage and monitor the entire production process through computer networks and intelligent production centers," he said.

Sixth, reliability, delivery capability, and service quality need to be improved.

Compared with foreign products, there is a significant gap in the reliability of machine tools for domestic CNC machine tools. The average time between failures (MTBF) of foreign machine tools is more than 5,000 hours, while domestic machine tools are much lower than this number. “The failure rate of domestic machine tools is very high,” he said. The company’s well-known machine tool factories in the country have frequent sleep, trampoline, mechanical, electrical and hydraulic system failures, especially machine tool leaks (oil, liquid, gas). serious.

Compared with foreign countries, the delivery time of domestic CNC machine tools is relatively long. The delivery time of foreign general CNC machine tools is about 3 months, the slightly complicated is 5~6 months, and the large and heavy machine tools are 12~14 months. After the contract of the domestic machine tool factory was signed, it was delayed to deliver, and some had a delay of two years. In this regard, Dongqi felt quite a lot.

Many foreign companies set up demonstration training centers to demonstrate the promotion of products on the one hand and technical training for user operators on the other. Pre-sales service is very good, fully understand the trend of domestic enterprise technological transformation projects, take the initiative to introduce products to potential users, and the level and quality of its maintenance service personnel is relatively high, with knowledge of both machine and electricity, troubleshooting capabilities Strong. Most domestic enterprises are not timely enough, and the comprehensive quality of maintenance service personnel and their ability to troubleshoot are relatively poor.

Seventh, the tool industry should strengthen the development and application of high-performance and complex tools, and strive to improve the efficiency of CNC machine tools.

With the development of high-speed, high-precision, intelligent, composite and environmental protection of CNC machine tools, new requirements for high-precision, high-efficiency, high-reliability and specialization have been put forward for CNC tools. The domestic CNC tool technology is seriously lagging behind, and the gap between life and reliability is obvious. It is far from meeting the requirements of power generation equipment manufacturing in terms of variety, performance and quality. Due to the small variety of domestically produced tools and low life, it seriously affects the efficiency of CNC machine tools.

“The majority of domestic high-end CNC machine tools are imported, and the proportion can reach 890%, especially for carbide tools. There is almost no product in China that can replace foreign ones.” He revealed that their company imported CNC Machine tools, equipped with a large number of imported CNC tools, due to the high price, the manufacturing costs have increased significantly. According to the statistics of the tool management department, their company imported CNC tools: more than 140 million yuan in 2007, more than 110 million yuan in 2008, and more than 200 million yuan in 2009. ”

Therefore, he suggested that the tool industry strengthen the development and application of high-performance tools and complex tools, promote ceramics, diamond tools and cubic boron nitride super-hard tools, improve the application ratio of cemented carbide tools, develop various special tools; research and Develop new materials and new processes for tool coating; encourage the introduction of advanced technology and equipment, and increase the scale and level of specialized production, with a view to improving the efficiency of CNC machine tools.
 

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