(2) Adopting error compensation technology: adopting reverse clearance compensation, pitch error compensation and tool error compensation to comprehensively compensate the thermal deformation error and spatial error of the equipment. The research results show that the application of comprehensive error compensation technology can reduce the machining error by 60% ~ 80%.
(3) Using the grid to check and improve the movement trajectory accuracy of the machining center, and predicting the machining accuracy of the machine tool through simulation, so as to ensure the positioning accuracy and repetitive positioning accuracy of the machine tool, make its performance stable for a long time, complete various machining tasks under different working conditions, and ensure the machining quality of parts.
The opening of the German system
(1) is open to future technologies: because the software and hardware interfaces follow the recognized standard protocols, a new generation of general software and hardware resources may be adopted, absorbed and compatible by the existing system with only a small amount of redesign and adjustment, which means that the development cost of the system will be greatly reduced, the performance and reliability of the system will be continuously improved, and it will be in a long life cycle;
(2) Open to users' special requirements: update products, expand functions, and provide various software and hardware product combinations to meet special application requirements;
(3) Establishment of CNC standard: A new CNC system standard ISO 14649(STEP-NC) is being studied and formulated internationally, in order to provide a neutral mechanism that can describe the whole product life cycle without relying on a specific system, thus realizing the standardization of product information in the whole manufacturing process and even in various industrial fields. The standardized programming language is not only convenient for users to use, but also reduces the labor consumption directly related to the operation efficiency.
Green processing
With the increasingly strict constraints of environment and resources, the greening of manufacturing and processing is becoming more and more important, and the problems of resources and environment in China are particularly prominent. Therefore, in recent years, energy-saving and environmental-friendly dry cutting and semi-dry cutting machine tools have emerged and developed continuously. 2 1 century, the general trend of green manufacturing will accelerate the development of various energy-saving and environment-friendly machine tools and occupy more world markets.
Application of multimedia technology
Multimedia technology combines computer, audio-visual and communication technologies, which makes the computer have the ability to comprehensively process sound, text, images and video information, so it also puts forward graphical requirements for user interface. The reasonable and humanized user interface greatly facilitates the use of non-professional users, and people can operate through windows and menus, which is convenient to realize the functions of blueprint programming and rapid programming, three-dimensional color three-dimensional dynamic graphic display, graphic simulation, graphic dynamic tracking and simulation, views in different directions and scaling of local display.
In addition, the application of multimedia technology in the field of numerical control technology can make information processing comprehensive and intelligent, and can be applied to real-time monitoring system, fault diagnosis of production site equipment and monitoring of production process parameters, so it has great application value.
Domestic CNC machine tools lack core technology, and they basically rely on imports from high-performance CNC systems to key functional components. Even though some domestic manufacturers have tried to create their own brands in recent years, the reliability of their products' functions and performance still lags behind that of foreign products. In recent years, domestic CNC machine tool manufacturers have obtained some advanced CNC technologies through technology introduction, domestic and foreign mergers and acquisitions, and foreign procurement. However, they lack the research on basic technologies such as machine tool structure, precision, reliability and humanized design, and neglect the cultivation of independent development ability. There is still a big gap between domestic CNC machine tools and foreign countries in terms of technical level, performance and quality, and it is difficult to be recognized by most users.
Some domestic CNC machine tool manufacturers do not pay enough attention to the improvement of overall technology and manufacturing level. The processing methods are mainly ordinary machine tools and inefficient tools, and the assembly and debugging are completely manual. Under the pressure of production schedule, the processing quality cannot be stabilized and improved. In addition, the production management of many domestic CNC machine tool manufacturers still adopts the original manual ledger management method, and the technical level and management efficiency are low, which makes the enterprises unable to form enough production scale. For example, foreign machine tool manufacturers can load and export products every week, while the domestic production cycle is too long to control. Therefore, while introducing technology, we should pay attention to strengthening our own technological transformation and improving management level.
Due to the rapid development of CNC machine tool industry, some enterprises ignore long-term interests, pay insufficient attention to improving their comprehensive service level, or even lack a real understanding of service, and only pay attention to sales promotion without paying attention to pre-sales and after-sales service. The personnel sent by some enterprises lack sufficient understanding of the CNC machine tools produced, and they will not use or use CNC machine tools badly, let alone guide users to use CNC machine tools well; Some people lack a basic understanding of advanced and efficient tools and cannot provide better process solutions, so users naturally lack confidence in manufacturers.
The manufacturer's service should start with the study of users' processed products, processes, production types and quality requirements, help users choose equipment, recommend advanced processes and tools, equip professional trainers and a good training environment, and help users maximize the benefits of machine tools and process high-quality final products, so as to gradually gain users' recognition and improve the market share of domestic CNC machine tools.
Drive parallelization
The parallel motion machine tool overcomes the inherent defects of the traditional machine tool series mechanism, such as large moving parts, low system stiffness, low working freedom, insufficient flexibility and operability of equipment processing, etc. The multi-bar parallel mechanism is used to drive the machine tool spindle (generally a moving platform) and the machine tool base (generally a static platform). The platform supported by the bar system can obtain corresponding free movement by controlling the length of the bars in the bar system. It can realize multi-coordinate linkage NC machining, assembly, measurement and other functions, and can better meet the processing of complex special parts. It has the advantages of high modularity, light weight and high speed of modern robots.
As a new type of processing equipment, parallel machine tool has become an important research direction of machine tool technology and has been highly valued by the international machine tool industry. It is considered as "the most significant progress in machine tool industry since the invention of numerical control technology" and "2 1 century new generation numerical control processing equipment".
Extreme (large scale and small scale)
The development of national defense, aviation, aerospace and large-scale equipment in basic industries such as energy need the support of large-scale CNC machine tools with good performance. Ultra-precision machining technology and micro-nano technology are strategic technologies in the 265,438+0 century, and it is necessary to develop new manufacturing technologies and equipment that can adapt to micro-size and micro-nano machining accuracy. Therefore, the demand for micro-machine tools, including micro-cutting (turning, milling and grinding) machines, micro-electric machining machines, micro-laser machining machines and micro-presses, is gradually increasing.
Information interaction network
For enterprises facing fierce competition, it is very important for CNC machine tools to have two-way and high-speed networking communication function to ensure the smooth information between departments in the workshop. It can not only realize the sharing of network resources, but also realize the remote monitoring, control, training, teaching and management of CNC machine tools, and also realize the digital service of CNC equipment (remote diagnosis and maintenance of CNC machine tools, etc.). ).
For example, the new generation machining center launched by Mazak Company in Japan is equipped with an external device called e-Tower, including computers, mobile phones, cameras inside and outside the machine, etc. , which can realize voice, graphics, video and text communication fault alarm display, online help troubleshooting and other functions. This is an independent and self-managed manufacturing unit.
New functional components
In order to improve the performance of CNC machine tools in all aspects, the application of new functional components with high precision and high reliability becomes inevitable. Representative new functional components include:
(1) High-frequency motorized spindle: High-frequency motorized spindle is the integration of high-frequency motor and spindle components, which has a series of advantages such as small size, high speed and stepless speed regulation, and has been widely used in various new CNC machine tools;
(2) Linear motors: In recent years, linear motors have been widely used. Although its price is higher than the traditional servo system, the application of key technologies such as load change disturbance, thermal deformation compensation, magnetic isolation and protection simplifies the mechanical transmission structure and improves the dynamic performance of the machine tool. For example, 1FN 1 series three-phase AC permanent magnet synchronous linear motors produced by Siemens have been widely used in high-speed milling machines, machining centers, grinders, parallel machine tools and machine tools with high dynamic performance and motion accuracy. XHC horizontal machining center of EX-CELL-O company in Germany adopts two linear motors to drive in three directions.
(3) Electric ball screw: Electric ball screw is the integration of servo motor and ball screw, which can greatly simplify the structure of CNC machine tools and has a series of advantages such as less transmission links and compact structure.
high reliability
Compared with traditional machine tools, CNC machine tools add CNC systems and corresponding monitoring devices, and use a large number of electrical, hydraulic and electromechanical equipment, which easily leads to an increase in the probability of failure. The fluctuation and interference of industrial power grid voltage are extremely unfavorable to the reliability of CNC machine tools. The parts machined by CNC machine tools have complex surfaces and long processing cycle, and the average time between failures is more than 20,000 hours. In order to ensure the high reliability of CNC machine tools, we must carefully design the system, strictly manufacture it, make clear the reliability target, analyze the failure mode through maintenance and find out the weak links.
The average time between failures of foreign CNC systems is more than 70 ~ 65438+ 10,000 hours, while the average time between failures of domestic CNC systems is only about 10000 hours. The average trouble-free working time of foreign machines is over 800 hours, and the highest in China is only 300 hours.
Development prospect of CNC machine tools
In recent years, China's CNC machine tools have made rapid development in product types, technical level, quality and output, and made major breakthroughs in some key technologies. Since China's CNC machine tool technology has developed to a mature stage, various fields have begun to pay extensive attention to CNC machine tools. However, compared with the rapid development of CNC machine tool industry, skilled talents engaged in CNC machine tool industry in China are always in short supply. According to the statistics of authoritative departments, there is a great demand for talents in the top ten key areas of manufacturing in China. It is estimated that by 2020, the talent gap of high-end CNC machine tools and robots will be 3 million.
Nowadays, the demand for CNC machine tool talents in manufacturing industry has greatly increased, and employment benefits are generous. Many enterprises report that talents of CNC machine tools are "hard to find". Because of the hot demand, the talent value of CNC machine tools continues to rise, and the monthly income is more than 1.5 million yuan. As far as I know, the Vocational Education Center of Quzhou County, Handan City, Hebei Province has taken CNC machine tool specialty as the key development specialty, which will surely become stronger and bigger, and deliver a batch of skilled talents for China manufacturing.
At present, as an important development field of Industry 4.0, CNC machine tools have become a key competitive field in major industrial countries. With the support of national strategy, China's CNC machine tool industry has shown a rapid development trend in recent years, and the momentum of technology catching up is unstoppable. In the new round of industrial development cycle, China is expected to catch up with the CNC machine tool industry by increasing technology research and development. Therefore, under the advantages of excellent industrial development, the employment prospects of CNC machine tool talents will be bright.
Development prospect of high-grade CNC machine tools
At present, the demand structure of downstream users in machine tool industry is in a high-end development trend, and many industries will carry out large-scale and deep-seated structural adjustment and upgrading. There is an urgent demand for high-quality and high-tech machine tools. Generally speaking, the market demand for high-end CNC machine tools is rising rapidly, and users need more high-speed, high-precision, compound, flexible, multi-axis, intelligent, high-rigidity and high-power CNC machine tools, which have broad development prospects. For example, the automobile industry presents the development trend of mass production, multi-variety and rapid vehicle renewal, and the development of new energy vehicles is also accelerating, which requires the processing equipment to develop in the direction of precision, efficiency and intelligence. In the aerospace field, with the rapid increase in the demand for civil aircraft and the intergenerational development of military aircraft, the new generation of aircraft is developing in the direction of lightweight, high reliability, long life, high stealth, multi-configuration, rapid response and low cost manufacturing. The new generation of technology urgently needs more advanced processing equipment, and aviation manufacturing equipment is developing in the direction of automation, flexibility, digitalization and intelligence. For example, in the "double-engine project" dedicated to the breakthrough of aircraft engine manufacturing, typical parts such as engine blades, casings and bladed disks are gradually developing in the direction of large size, complex profile, lightweight structure and precision manufacturing, especially the wide application of new lightweight materials such as high-strength high-temperature heat-resistant alloys. The geometric configuration of these integral structural parts is complex and difficult to process, which puts forward new and higher requirements for high torque and high precision CNC machine tools. Portable or movable multi-axis CNC equipment for the maintenance of large-scale structural parts and gas turbine equipment in different places, this machining method of machining large-scale workpieces with small machine tools without fixed base and reconfigurable assembly poses greater challenges to the structural design, process specification and efficient and energy-saving machining technology of new CNC equipment.
Employment direction of CNC machine tool specialty
China's manufacturing enterprises have widely used advanced numerical control technology, which is followed by a large demand for numerical control talents. The employment prospect of CNC is very bright. In rich countries, CNC machine tools have been widely used. There is a big gap between China's manufacturing industry and international advanced industrial countries, and the numerical control rate of machine tools is less than 2%. At present, a limited number of CNC machine tools (mostly imported products) in China have not been fully applied. There are many reasons, one of which is the lack of CNC employment talents. Because numerical control technology is the most typical and widely used mechatronics technology, China urgently needs a large number of numerical control technical talents at all levels from research and development to operation and maintenance.
A, CNC employment talent demand is mainly concentrated in the following enterprises and regions:
1, large and medium-sized state-owned enterprises, especially military enterprises with good economic benefits and manufacturing enterprises with serious national equipment. The military manufacturing industry is the main application object of numerical control technology in China, and the employment space of numerical control is very large. Hangzhou power generation equipment factory can't recruit CNC technicians with a monthly salary of 6000.
2, with the rapid development of private economy, China's coastal economic prosperity areas (such as Guangdong, Zhejiang, Jiangsu, Shandong), CNC employment talents are in short supply, mainly concentrated in mold manufacturing enterprises and auto parts manufacturing enterprises. The annual salary of mold technicians with CNC knowledge has reached 300,000 yuan, exceeding the "doctor".
Second, the knowledge structure of CNC talents-CNC employment skills demand:
Another source is to select people from the existing employees of enterprises to participate in short-term and medium-term training of different levels of CNC technology to meet the urgent needs of enterprises for CNC talents. These people generally have the technical background and rich theoretical experience needed by enterprises, but most of them are graduates of traditional mechanical or electrical majors at all levels, with narrow knowledge, especially computer application technology and computer numerical control system.
Employment direction
In industrial enterprises, engaged in CNC programming, CNC equipment use, maintenance and technical management, CNC equipment sales and after-sales service. The major of numerical control technology is mainly oriented to machinery, mold, electronics, electricity, light industry and other industries, and can be engaged in product design and processing, numerical control programming, numerical control machine tool operation, multi-axis machining of commonly used CAM software, debugging and maintenance of numerical control equipment and other related work. The distribution units of graduates majoring in numerical control technology application are as follows: foreign-funded enterprises account for 58%, state-owned enterprises account for 26%, private enterprises account for 9% and others account for 5%. The job nature of the graduates majoring in numerical control technology application is as follows: operation accounts for 55.7%, programming accounts for 13.4%, maintenance accounts for 9.4%, technology accounts for 8.0%, production management accounts for 7. 1%, quality inspection accounts for 4.5%, integration accounts for 1.2%, and marketing accounts for/kloc.
Career prospects
The major of numerical control technology is a knowledge-intensive technology integrating mechanical, electrical, hydraulic, optical, computer and automatic control technologies. It is the basis of modernization, flexibility and integrated production in manufacturing industry, and it is also an essential material means to improve product quality and productivity. Japan, the United States, Germany and other industrialized countries have achieved economic benefits by adopting numerical control technology: the number of operators is reduced by 50%, the cost is reduced by 60%, the utilization rate of machine tools is 60%-80%, the number of machine tools is reduced by 50%, and the production area is reduced by 40%. Due to the wide application of numerical control technology in the world manufacturing industry, ordinary machinery is gradually replaced by high-efficiency and high-precision numerical control equipment. The wide application of numerical control technology in machinery manufacturing industry has become a powerful driving force for the development of national economy. After China's entry into WTO, with the rapid development of economy, China is gradually becoming a "world manufacturing center", and the numerical control rate has become one of the important indicators to measure the manufacturing technology level and economic strength of a country or enterprise (numerical control rate: the proportion of numerical control equipment in equipment ownership). At present, the numerical control rate of machine tools in China is only 1.9%, while it is as high as 30% in Japan and over 40% in the United States. CNC machine tools have been widely used in developed countries, but there is a big gap between China and developed countries in the application and promotion of CNC technology. China will increase 400,000-500,000 sets of CNC machine tools in a few years, and correspondingly need 600,000-800,000 CNC professionals.
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