Concerning the progress of China's manufacturing technology and equipment, it is necessary to contact the development and changes of the world, because technology and science have no national boundaries and are mutually reinforcing. From this perspective, the evolution of the world's manufacturing technology and equipment belongs to at least four aspects of the "quality change" nature, while other "quantity change" (or "gradient") can also be listed more. "Quality change" means: First, there is a fundamental difference between the innovative thinking and the traditional "quantitative change"; second, the material carrier relied on is fundamentally different from the conventional one. Third, the benefits and impacts formed in human production activities are more extensive and far-reaching. In the past 30 years, China has been actively participating in and making important contributions to the four major qualitative changes in the world of manufacturing technology and equipment. Some aspects have even entered the forefront of the world.
The emergence of human intelligent production tools The development of intelligent production tools is an important development in the past 30 years. Recently, at the "Strategic Industry Choice" symposium of the Central Committee of the Central Committee of the Central Committee of the Communist Party of China, the author put forward a point of view. "The intelligent nature of machine tools as production tools is an epoch-making development of human production tools. Human beings are welcoming an era of intelligent production tools. The arrival of the comrades of the meeting was endorsed by many comrades.
The emergence of CNC machine tools marks the beginning of the development of machine tools to intelligence. Back to the development history of machine tools, from the first CNC machine tool in 1952 to more than 50 years, including 30 years of maturity and 20 years of large-scale application, especially in recent years, the further development of machine tool intelligent functions The addition marks the qualitative change of machine tool technology on the road of development. It can be said that computer control technology, network technology and software function expansion provide a material basis for machine tool intelligence.
There is no comprehensive definition of intelligent machine tools. Simply put, it is a machine tool that can make self-judgment and correct and correct choices and make decisions on various parameters and functions that affect the machining process; that is, intelligent machine tools can monitor and diagnose , evaluate, compensate, and correct various types of deviations that occur during machining (such as automatic tool radius detection, tool breakage detection, and multi-axis synchronization differences), and provide optimized machining options (such as adjusting machine processing time, routing) Select the best machining parameters, spindle operating conditions, position compensation, accuracy correction and thermal deformation compensation, etc.). The earliest machine tools with intelligent control functions can be traced back to the adaptive control EDM machine tool, which is to adjust the discharge gap between the electrode and the workpiece according to the processing parameters to achieve the best processing effect. ).
In recent years, Japan's Yamazaki Mazak Company has successively developed systems such as intelligent spindle vibration control, intelligent thermal barrier, intelligent anti-collision barrier and language prompts; Japan's Otsuka has developed the system of thinkinc intelligent digital control. This shows that with the development of technology, the intelligent function of the production tool of the machine tool will become more and more advanced and more and more. The development of human intelligent production tools is in the ascendant and bright prospects.
Rapid Prototyping Technology is a processing method that has emerged in the past 20 years. It is a major breakthrough in the reverse thinking of processing methods. It is a tremendous change in the processing principle, and the traditional “removal of materials†that has been in use ever since. The methods of (cutting, punching, cutting, grinding) are fundamentally different. Rapid prototyping technology is actually the opposite of "material stacking" or "material accumulation" method, "additive manufacturing method" "To achieve a method of manufacturing a prototype of a workpiece." (The design concept is to be quickly formed into a solid by computer 2D or 3D imaging, computer controlled "material addition"). Composite paper, high-polymerization materials, metal powders, high-temperature alloys, composite ceramics and foundry sands are used as processing raw materials; electrothermal, laser beam and electron beam are used as energy sources, and layered solid manufacturing (LOM), fused deposition molding (FDM) ), UV laser curing (SLA), laser area sintering (SLS) and other methods to achieve prototype part modeling, to accelerate the assessment of the correctness and feasibility of part design, greatly shorten the development cycle of the machine, in addition to the application of mechanical parts Prototypes, sand cores, and even into the three-dimensional art shape shaping and human medical biomimetic parts (such as bone and joint) manufacturing and other related fields.
This is the latest product of the integrated development of computer science, new materials science and new energy science. In this field, there are active investment in state-owned and private research institutes and enterprises such as Huazhong University of Science and Technology, Tsinghua University, Xi'an Jiaotong University, Tongji University, Chinese Academy of Sciences and Shanghai Liantai, Beijing Ruikeda, Wuhan Binhu Electromechanical Technology Industry Co., Ltd. . The products developed have entered the world first. There are many varieties of products on the market, with an annual output of several hundred units, and technology has been exported to Singapore.
Revolutionary changes in machine tool structure In the past 20 years, the world's machine tool design has undergone revolutionary changes, and a "parallel structure" machine tool has emerged. The “parallel structure†is completely different from all the traditional machine tool structures. The traditional machine tool structure is a series structure, that is, it moves in the direction of three coordinate lines according to Cartesian coordinates and rotates in series around these three coordinates to form the relative of the required tools. The structure of the machine tool of the trajectory, all the structural geometric accuracy errors, the transmission of the force and the loss of the stiffness, will form a weak link in the series accumulation and become fatal. The parallel structure machine tool moves the spindle head by moving the multi-rod structure in space simultaneously. Compared with the series structure, the parallel structure has more simplification, higher stiffness and better dynamic performance (including precision guarantee and motion efficiency). A series of main advantages. In the past 20 years, more than 20 teams in more than 10 countries around the world are engaged in research and development in this area. Among them, Sweden TRICEPT has supplied more than 400 products, which are widely used in Airbus, Boeing and General Motors, and Caterpillar. Construction machinery companies, in addition to a number of teams have exhibited prototypes, although further reports have decreased in recent years, but have not stopped, according to the author and some of the teams (such as Daxie and Germany Index) They are still speeding up the research and trying to improve performance. China's machine tool industry also has five or six production, study and research combinations in this area of ​​research and development work (all prototypes come out, and now continue to improve and improve), including Harbin Measuring Tool Group ("Haliang Group") and Harbin Industry The parallel structure variety (six-bar structure) developed by the university has been mass-produced in 5 sets, which has been successfully applied to the blade processing production line of Harbin Steam Turbine Works; the gantry-type “hybrid†structure (ie, serial connection) developed by Qiqihar Second Machine Tool Group and Tsinghua University The machine tool, which is mixed with the parallel connection, is a kind of independent concept conceived in China and has been successfully used in the manufacture of large hydropower station equipment of Harbin Electric Machinery Factory.
At the China CNC Machine Tool Exhibition (CCMT2008) held recently, China Harbin Group CNC Equipment Factory exhibited a new type of parallel structure machine tool LINKS-EXE700 with new breakthrough significance. It was invented by the original Swedish TRICEPT. Founded by EXCHON, Harbin Group is a company that exclusively introduces this technology in China for production and continues to cooperate in developing application areas. The newly developed LINKS-EXE700 parallel structure machine tool is characterized by further simplification of the structure (the general parallel machine tool is a six-bar structure, the original structure of the TRICEPT parallel machine tool is a four-bar structure, and the parallel machine tool newly developed by EXCHON on the basis of TRICEPT is further modified. It is a three-bar structure, the spherical joint is changed to a rotary hinge, the structure is simplified, the accuracy is more easy to guarantee), and the processing range is increased. The EXCHON parallel structure machine tool has various specifications and sizes. Taking the medium-sized machine tool of EXE700 as an example, the processing coverage space x The axial direction is 2 m, the y-axis direction is 1 m, and the z-axis direction is 0.5 m. Fast action: the rapid feed of the x and y axes reaches 125m/min (this is the highest record in the world), the acceleration is 3g (also the highest in the world), the z-axis is 45m/min, the acceleration is 1g, and the rigidity and precision are significantly improved. The five-axis linkage NC programming is further improved and easy to master. It can process space surfaces and pentahedrons. In the case of special clamping of the workpiece, it can also be processed on six sides, which is currently impossible for any machine tool structure. After different functions, it can be widely used in aerospace, aviation, locomotive, automobile, engineering machinery, mold industry for milling, drilling, grinding, welding, riveting, burring and assembly. It can be used in stand-alone mode. Multiple units are configured as production lines. For the processing of super long wings or huge locomotives and tanks, it is also possible to use the "parallel mechanism" on the track or on the moving base on the gantry frame (the long distance can be segmented and then segmented during processing) Automatic and precise repositioning, equivalent to the so-called "ant sacral bone type" to small dry, workpiece landing processing method), to achieve large-scale workpiece processing. Therefore, in order to rapidly expand the field of use, in addition to the supply of "parallel structure universal machine tools" products (competing with certain machining center varieties), the "parallel structure" (such as Haliang Group) should also provide "parallel structure" Partially combined with different types of pedestal or moving frames provided by user industry equipment manufacturers (such as automotive, locomotive, construction machinery and aerospace professional process equipment factories) and machine tool factories that are willing to develop special equipment, targeted Expand the use of such machine tools and expand sales. It can be seen that the development prospect of this new type of structural machine tool is very broad.
Variation of tool concept The traditional machining process system is generally composed of machine tool-tool (clamp)-workpiece, and the tool part is traditionally classified into turning tool, milling cutter, boring tool, drill bit, broach, grinding wheel, die and Stamping and the like. All of these tools (also known as carriers for performing processing functions) are nothing but solids with a certain hardness, such as high-speed steel, tool steel, hard alloy, cubic boron nitride, single crystal and polycrystalline diamond, ceramics, etc. A tool made of material (used to achieve the so-called "hard" gram "hard"). Later, the high-temperature cutting method of oxyacetylene appeared. The electric energy processing method (EDM, wire electrode cutting), electrochemical processing, laser processing, electron beam processing, ion implantation, photolithography, etc. appeared until In recent years, the high-pressure water jet (commonly known as "waterjet") processing method belonging to "cold energy" and "soft medium" has debuted in a new attitude (for sheet metal, plastic, rubber cutting processing), and multi-coordinate numerical control technology in the automotive industry. The trial production of new products (such as cover parts, trimming of interior parts) can greatly shorten the cycle, and the use of small parts is very extensive. China has already provided products to the market, such as Nanjing Waterjet Co., Ltd. and Nanjing Process Equipment Manufacturing Co., Ltd. High-pressure water jet (waterjet) processing is rapidly expanding in other applications (processing of pipe joints, etc.). The emergence of such "soft" and "hard" processing tools is dazzling and overwhelming.
There are still many advances in the field of machining that are “quantitative changes†or “gradientsâ€. For example, the improvement of machining precision is increased by an order of magnitude every 10 years, and sub-micron and nano-machining are constantly being upgraded. At the end of the article, it is advisable to forecast a new type of “transform†machine tool that has a relatively large span of “gradient†(or “quantitative change†span: the author introduces the “Transflex†machine tool from Sweden to China (expected in 2009). China is about to debut in the market with new products first put into production, and it is also the first time in the world. Transflex, as its name suggests, includes both the Transfer line and the Flexible line. Its principle is that it is composed of a variety of power heads, still in line with the production line, but the execution sequence or action of the machining is controlled by the CNC system. The clamping of the workpiece is performed by a suspended robot. More novelty is that its manipulator is holding the workpiece downwards along the bridge rail and the vertical ram for three-coordinate movement and two rotation coordinates above the power head. This robot grips the workpiece rigidity compared with the traditional multi-joint robot. Better and more accurate, in addition to the step-by-step transmission mechanism that replaces the transmission line (its slower delivery speed and poorer adjustability), it also adds two rotational coordinate movements that are not available in the step-and-feed mechanism. The manipulator is commanded by the CNC system to “feed†the workpiece (this is the outstanding feature) to the power head of the different stations, and cooperate with the tool movement on the power head to complete each process. Obviously, this Transflex machine has a compact structure, a small footprint, saving auxiliary time, convenient chip removal, and can adapt to more complex workpieces in the machining area. It is a kind of machine tool that is worthy of attention.
The emergence of human intelligent production tools The development of intelligent production tools is an important development in the past 30 years. Recently, at the "Strategic Industry Choice" symposium of the Central Committee of the Central Committee of the Central Committee of the Communist Party of China, the author put forward a point of view. "The intelligent nature of machine tools as production tools is an epoch-making development of human production tools. Human beings are welcoming an era of intelligent production tools. The arrival of the comrades of the meeting was endorsed by many comrades.
The emergence of CNC machine tools marks the beginning of the development of machine tools to intelligence. Back to the development history of machine tools, from the first CNC machine tool in 1952 to more than 50 years, including 30 years of maturity and 20 years of large-scale application, especially in recent years, the further development of machine tool intelligent functions The addition marks the qualitative change of machine tool technology on the road of development. It can be said that computer control technology, network technology and software function expansion provide a material basis for machine tool intelligence.
There is no comprehensive definition of intelligent machine tools. Simply put, it is a machine tool that can make self-judgment and correct and correct choices and make decisions on various parameters and functions that affect the machining process; that is, intelligent machine tools can monitor and diagnose , evaluate, compensate, and correct various types of deviations that occur during machining (such as automatic tool radius detection, tool breakage detection, and multi-axis synchronization differences), and provide optimized machining options (such as adjusting machine processing time, routing) Select the best machining parameters, spindle operating conditions, position compensation, accuracy correction and thermal deformation compensation, etc.). The earliest machine tools with intelligent control functions can be traced back to the adaptive control EDM machine tool, which is to adjust the discharge gap between the electrode and the workpiece according to the processing parameters to achieve the best processing effect. ).
In recent years, Japan's Yamazaki Mazak Company has successively developed systems such as intelligent spindle vibration control, intelligent thermal barrier, intelligent anti-collision barrier and language prompts; Japan's Otsuka has developed the system of thinkinc intelligent digital control. This shows that with the development of technology, the intelligent function of the production tool of the machine tool will become more and more advanced and more and more. The development of human intelligent production tools is in the ascendant and bright prospects.
Rapid Prototyping Technology is a processing method that has emerged in the past 20 years. It is a major breakthrough in the reverse thinking of processing methods. It is a tremendous change in the processing principle, and the traditional “removal of materials†that has been in use ever since. The methods of (cutting, punching, cutting, grinding) are fundamentally different. Rapid prototyping technology is actually the opposite of "material stacking" or "material accumulation" method, "additive manufacturing method" "To achieve a method of manufacturing a prototype of a workpiece." (The design concept is to be quickly formed into a solid by computer 2D or 3D imaging, computer controlled "material addition"). Composite paper, high-polymerization materials, metal powders, high-temperature alloys, composite ceramics and foundry sands are used as processing raw materials; electrothermal, laser beam and electron beam are used as energy sources, and layered solid manufacturing (LOM), fused deposition molding (FDM) ), UV laser curing (SLA), laser area sintering (SLS) and other methods to achieve prototype part modeling, to accelerate the assessment of the correctness and feasibility of part design, greatly shorten the development cycle of the machine, in addition to the application of mechanical parts Prototypes, sand cores, and even into the three-dimensional art shape shaping and human medical biomimetic parts (such as bone and joint) manufacturing and other related fields.
This is the latest product of the integrated development of computer science, new materials science and new energy science. In this field, there are active investment in state-owned and private research institutes and enterprises such as Huazhong University of Science and Technology, Tsinghua University, Xi'an Jiaotong University, Tongji University, Chinese Academy of Sciences and Shanghai Liantai, Beijing Ruikeda, Wuhan Binhu Electromechanical Technology Industry Co., Ltd. . The products developed have entered the world first. There are many varieties of products on the market, with an annual output of several hundred units, and technology has been exported to Singapore.
Revolutionary changes in machine tool structure In the past 20 years, the world's machine tool design has undergone revolutionary changes, and a "parallel structure" machine tool has emerged. The “parallel structure†is completely different from all the traditional machine tool structures. The traditional machine tool structure is a series structure, that is, it moves in the direction of three coordinate lines according to Cartesian coordinates and rotates in series around these three coordinates to form the relative of the required tools. The structure of the machine tool of the trajectory, all the structural geometric accuracy errors, the transmission of the force and the loss of the stiffness, will form a weak link in the series accumulation and become fatal. The parallel structure machine tool moves the spindle head by moving the multi-rod structure in space simultaneously. Compared with the series structure, the parallel structure has more simplification, higher stiffness and better dynamic performance (including precision guarantee and motion efficiency). A series of main advantages. In the past 20 years, more than 20 teams in more than 10 countries around the world are engaged in research and development in this area. Among them, Sweden TRICEPT has supplied more than 400 products, which are widely used in Airbus, Boeing and General Motors, and Caterpillar. Construction machinery companies, in addition to a number of teams have exhibited prototypes, although further reports have decreased in recent years, but have not stopped, according to the author and some of the teams (such as Daxie and Germany Index) They are still speeding up the research and trying to improve performance. China's machine tool industry also has five or six production, study and research combinations in this area of ​​research and development work (all prototypes come out, and now continue to improve and improve), including Harbin Measuring Tool Group ("Haliang Group") and Harbin Industry The parallel structure variety (six-bar structure) developed by the university has been mass-produced in 5 sets, which has been successfully applied to the blade processing production line of Harbin Steam Turbine Works; the gantry-type “hybrid†structure (ie, serial connection) developed by Qiqihar Second Machine Tool Group and Tsinghua University The machine tool, which is mixed with the parallel connection, is a kind of independent concept conceived in China and has been successfully used in the manufacture of large hydropower station equipment of Harbin Electric Machinery Factory.
At the China CNC Machine Tool Exhibition (CCMT2008) held recently, China Harbin Group CNC Equipment Factory exhibited a new type of parallel structure machine tool LINKS-EXE700 with new breakthrough significance. It was invented by the original Swedish TRICEPT. Founded by EXCHON, Harbin Group is a company that exclusively introduces this technology in China for production and continues to cooperate in developing application areas. The newly developed LINKS-EXE700 parallel structure machine tool is characterized by further simplification of the structure (the general parallel machine tool is a six-bar structure, the original structure of the TRICEPT parallel machine tool is a four-bar structure, and the parallel machine tool newly developed by EXCHON on the basis of TRICEPT is further modified. It is a three-bar structure, the spherical joint is changed to a rotary hinge, the structure is simplified, the accuracy is more easy to guarantee), and the processing range is increased. The EXCHON parallel structure machine tool has various specifications and sizes. Taking the medium-sized machine tool of EXE700 as an example, the processing coverage space x The axial direction is 2 m, the y-axis direction is 1 m, and the z-axis direction is 0.5 m. Fast action: the rapid feed of the x and y axes reaches 125m/min (this is the highest record in the world), the acceleration is 3g (also the highest in the world), the z-axis is 45m/min, the acceleration is 1g, and the rigidity and precision are significantly improved. The five-axis linkage NC programming is further improved and easy to master. It can process space surfaces and pentahedrons. In the case of special clamping of the workpiece, it can also be processed on six sides, which is currently impossible for any machine tool structure. After different functions, it can be widely used in aerospace, aviation, locomotive, automobile, engineering machinery, mold industry for milling, drilling, grinding, welding, riveting, burring and assembly. It can be used in stand-alone mode. Multiple units are configured as production lines. For the processing of super long wings or huge locomotives and tanks, it is also possible to use the "parallel mechanism" on the track or on the moving base on the gantry frame (the long distance can be segmented and then segmented during processing) Automatic and precise repositioning, equivalent to the so-called "ant sacral bone type" to small dry, workpiece landing processing method), to achieve large-scale workpiece processing. Therefore, in order to rapidly expand the field of use, in addition to the supply of "parallel structure universal machine tools" products (competing with certain machining center varieties), the "parallel structure" (such as Haliang Group) should also provide "parallel structure" Partially combined with different types of pedestal or moving frames provided by user industry equipment manufacturers (such as automotive, locomotive, construction machinery and aerospace professional process equipment factories) and machine tool factories that are willing to develop special equipment, targeted Expand the use of such machine tools and expand sales. It can be seen that the development prospect of this new type of structural machine tool is very broad.
Variation of tool concept The traditional machining process system is generally composed of machine tool-tool (clamp)-workpiece, and the tool part is traditionally classified into turning tool, milling cutter, boring tool, drill bit, broach, grinding wheel, die and Stamping and the like. All of these tools (also known as carriers for performing processing functions) are nothing but solids with a certain hardness, such as high-speed steel, tool steel, hard alloy, cubic boron nitride, single crystal and polycrystalline diamond, ceramics, etc. A tool made of material (used to achieve the so-called "hard" gram "hard"). Later, the high-temperature cutting method of oxyacetylene appeared. The electric energy processing method (EDM, wire electrode cutting), electrochemical processing, laser processing, electron beam processing, ion implantation, photolithography, etc. appeared until In recent years, the high-pressure water jet (commonly known as "waterjet") processing method belonging to "cold energy" and "soft medium" has debuted in a new attitude (for sheet metal, plastic, rubber cutting processing), and multi-coordinate numerical control technology in the automotive industry. The trial production of new products (such as cover parts, trimming of interior parts) can greatly shorten the cycle, and the use of small parts is very extensive. China has already provided products to the market, such as Nanjing Waterjet Co., Ltd. and Nanjing Process Equipment Manufacturing Co., Ltd. High-pressure water jet (waterjet) processing is rapidly expanding in other applications (processing of pipe joints, etc.). The emergence of such "soft" and "hard" processing tools is dazzling and overwhelming.
There are still many advances in the field of machining that are “quantitative changes†or “gradientsâ€. For example, the improvement of machining precision is increased by an order of magnitude every 10 years, and sub-micron and nano-machining are constantly being upgraded. At the end of the article, it is advisable to forecast a new type of “transform†machine tool that has a relatively large span of “gradient†(or “quantitative change†span: the author introduces the “Transflex†machine tool from Sweden to China (expected in 2009). China is about to debut in the market with new products first put into production, and it is also the first time in the world. Transflex, as its name suggests, includes both the Transfer line and the Flexible line. Its principle is that it is composed of a variety of power heads, still in line with the production line, but the execution sequence or action of the machining is controlled by the CNC system. The clamping of the workpiece is performed by a suspended robot. More novelty is that its manipulator is holding the workpiece downwards along the bridge rail and the vertical ram for three-coordinate movement and two rotation coordinates above the power head. This robot grips the workpiece rigidity compared with the traditional multi-joint robot. Better and more accurate, in addition to the step-by-step transmission mechanism that replaces the transmission line (its slower delivery speed and poorer adjustability), it also adds two rotational coordinate movements that are not available in the step-and-feed mechanism. The manipulator is commanded by the CNC system to “feed†the workpiece (this is the outstanding feature) to the power head of the different stations, and cooperate with the tool movement on the power head to complete each process. Obviously, this Transflex machine has a compact structure, a small footprint, saving auxiliary time, convenient chip removal, and can adapt to more complex workpieces in the machining area. It is a kind of machine tool that is worthy of attention.
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