In order to learn and draw lessons from the development strategies and industrial policies of high-end CNC machine tool industries in developed countries, improve the level of my country's high-end CNC machine tool industry, and promote the development of my country's high-end CNC machine tool industry,
In order to learn and draw lessons from the development strategies and industrial policies of high-end CNC machine tool industries in developed countries, improve the level of my country's high-end CNC machine tool industry, and promote the development of my country's high-end CNC machine tool industry, the Ministry of Industry and Information Technology successfully held the "International High-end CNC Machine Tool Industry Development Strategy and Industrial Policy Advanced Training Course" in Germany from November 7 to 27, 2012, with the approval of the State Administration of Foreign Experts Affairs. 24 people from the Ministry of Industry and Information Technology, industrial and information management departments of some provinces (cities, regions), relevant enterprises and colleges and universities under the Ministry received training, visits and exchanges at universities and research institutes such as the Technical University of Berlin, the University of Karlsruhe, the Technical University of Aachen, and the IWU in Flandershof, as well as companies such as MAG, DMG, TRUMPF, EEW, HEIDENHAIN, and COBURG. With the joint efforts of all the trainees, the study of the International High-end CNC Machine Tool Industry Development Strategy and Industrial Policy Advanced Training Course was a complete success, and a summary was written. Below, we will present their advanced technology of German CNC machine tools, the professional talent training system of German CNC machine tools, the practices and experiences of German high-end CNC machine tool industry, and their experience for everyone to learn and draw lessons from.
Advanced technology of German CNC machine tools
In recent years, German CNC machine tools have continued to work hard in high precision, high speed, high efficiency, and composite, and deeply reflect the characteristics of high efficiency and energy saving.
1. Advanced technology to improve CNC machining efficiency
Improving CNC machining efficiency is represented by increasing cutting speed, feed speed, acceleration, reducing tool change time, loading and unloading time, etc., such as linear feed speed of 150m/min and acceleration of 1g.
⑴Use linear motors and torque motors to shorten the transmission chain and improve the dynamic characteristics of the system.
⑵Lightweight design: optimize the structure of moving parts, use composite materials such as carbon fiber to reduce the mass of moving parts. For example, lightweight manufacturing of automotive parts uses carbon fiber material glue die casting, temperature control at 150°C, vacuum extrusion, and hot pressing curing. The material has high strength and light weight, which is about 30% lighter than metal materials. It can be used as a replacement material for major parts such as automobile shells. BMW and Mercedes-Benz use this material to make chassis and bodies. EEW Company uses a large amount of carbon fiber materials in machine tool moving parts for large-span gantry mobile machine tools to achieve high dynamic and high-speed movement.
⑶ Use electric spindle to increase spindle speed.
⑷ Exchange worktable, material change time 2.2s, improve loading and unloading efficiency.
⑸ Robot loading and unloading, instead of manual loading and unloading.
⑹ High acceleration, from 50m/s3 to 150m/s3, processing efficiency increased by 30%.
⑺ Secondary tool change, tool change time shortened to less than 1s.
2. Advanced technology for composite processing
In addition to the commonly used milling and turning composite processing machines and dual-spindle processing machines, the Aachen University of Technology in Germany explored the combination of milling and laser surface treatment, milling on a base material with low hardness and good toughness, and then welding a layer of material with special properties on the surface through laser processing; EEW in Germany cooperated with Hugo Rost to combine X-ray flaw detection equipment on a five-axis processing machine for wind turbine blades, realizing milling and flaw detection in one clamping.
3. Advanced technology for improving processing accuracy
⑴ Cooling the heating elements in CNC machine tools, such as the primary and secondary of linear drives, CNC turntables, spindles, etc., to reduce the impact of thermal deformation on machine tool accuracy. Positioning accuracy is 6μm, and repeated positioning accuracy is 4μm.
⑵ Application of GPS positioning technology in improving assembly accuracy.
4. Modular machine tool technology
German machine tool companies have a very detailed division of labor, and the concept of modularization runs through the entire process of machine tool production:
⑴ Modular design of machine tools: divide the machine tools into modular and reasonable parts, and design them in an integrated manner of electromechanical and hydraulic.
⑵ According to the modular design results, motors, lead screws, guide rails, tool magazines and other components are directly purchased, and frames, columns, beams and other components are outsourced for processing, so that most machine tool companies do not perform or perform a small amount of machining.
⑶ Modular assembly: In order to improve the assembly efficiency of machine tools, component-level assembly (including electromechanical, hydraulic and gas) is performed first, and there are convenient interfaces between modules, which makes the modules more independent and convenient for transportation, transmission and assembly.
5. Intelligent and automated machine tool technology
One of the manifestations of Germany's high-tech development strategy in machine tools is the digital factory, which automates the production and processing processes, saves energy and adapts to various requirements.
In Heidenhain, the internal logistics of small parts uses fully automatic intelligent AGV vehicles, which realize functions such as automatic planning, automatic obstacle avoidance, automatic door opening and closing, and automatic elevator access, and are highly intelligent.
The development trend of German machine tools is automation, high efficiency and energy saving. In addition to meeting basic processing functions, machine tools gradually provide users with integrated and automated solutions. For example, Trumpf not only sells machine tools in China, but more importantly, it plans and provides overall automobile manufacturing workshops, production lines and equipment for Chinese automobile manufacturers. Its products widely use automated loading and unloading devices, which greatly improves the processing efficiency and automation of machine tools.
The automatic manufacturing line of BMW automobile and motorcycle frames was previously manufactured manually. The Machine Tool Research Institute of the University of Karlsruhe uses machine tools and space forming technology, machine tool CNC system control, robot processing and forming, automatic cutting, process automatic control, measuring machine station for measurement, subsequent punching and other processes, automatic assembly and welding. Research is being conducted on the adaptive processing flow of different models, and the whole process will be completed by robot automation in the future.
6. Other machine tool technologies
① Three-point support, no foundation is needed. ② Ergonomics, better accessibility. ③ Advanced green manufacturing technology. ④ Minimum lubrication, low-temperature minimum lubrication MQL. ⑤ Liquid nitrogen cooling technology. ⑥ Energy-saving equipment.
Germany has completely stopped nuclear power and plans to fully adopt renewable energy by 2050. This not only poses challenges to the energy sector, but also requires energy-saving equipment in the machine tool manufacturing industry.