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According to experts' prediction, by the year 2000, the consumption of CNC machine tools in China will reach 24.02 billion yuan. On the one hand, these needs are met by purchasing new equipment. On the other hand, if we make full use of our existing stock assets, replacing and reducing the purchase of new equipment with updated equipment can achieve a multiplier effect. With an estimated demand of 24.02 billion yuan, even if 10% of the demand is realized through the regeneration of equipment, there will be a market of 2.4 billion yuan every year.
The numerical control transformation market of imported equipment and production lines Since the reform and opening up in China, many enterprises have introduced technology, equipment and production lines from abroad to carry out technological transformation. According to incomplete statistics, from 1979 to 1988, there were 18,446 technical transformation projects introduced nationwide, about 16.58 billion US dollars.
Most of these projects have played their due role in China's economic construction. However, due to various reasons, some of the imported projects are not functioning properly or even paralyzed, which has affected the efficiency of the enterprise and seriously caused the enterprise to be in trouble. In order to make full use of these equipment and production lines, we conducted a survey on some technological transformation projects that have been introduced for more than 10 years and related to the machinery industry. We have learned that some equipments and production lines have been imported from abroad, some have poor digestion and absorption, spare parts are not complete, improper maintenance, and the results are not working well; some are only introduced to the introduction of equipment, instruments, production lines, neglecting software, technology, management, etc. The project is incomplete, the potential of the equipment can not be played; some can not even start the operation, did not play its due role; some products of the production line sell well, but because the equipment failure can not reach the standard; some because of high energy consumption, products The pass rate is low and the loss is incurred; some have been introduced for a long time and require technical updates. For various reasons, some equipment not only does not create wealth, but consumes wealth.
These unusable equipment and production lines are a burden, and they are also a large stock of assets. If they are repaired, they are wealth. As long as we identify the main technical difficulties and solve the key technical problems of the "card neck", we can minimize the investment and revitalize the largest stock assets, and strive for the greatest economic and social benefits. This is also a huge transformation market.
2 The content, technology and principle of numerical control transformation The rise of foreign transformation industry In the developed countries such as the United States, Japan and Germany, the machine tool industry is in a slump. Today, their machine tool transformation is a new economic growth industry, and it is full of business. The golden age. Due to the continuous advancement of machine tools and technology, machine tool transformation is an "eternal" subject. China's machine tool transformation industry has also entered the new industry dominated by numerical control technology from the old industry. In the United States, Japan, and Germany, the use of numerical control technology to transform machine tools and production lines has a broad market, and has formed a new industry for machine tool and production line CNC transformation. In the United States, the machine tool transformation industry is called the machine tool regeneration (Remanufacturing) industry. Well-known companies engaged in the recycling industry are: Bertsche Engineering, Ayton Machine Tool, Devlieg-Bullavd (Dabao) Service Group, US Equipment Company, etc. American Depot has opened a company in China. In Japan, the machine tool transformation industry is called the Retrofitting industry. Well-known companies engaged in the conversion industry include: Otsuka Engineering Group, Gangsan Machinery Co., Chiyoda Machinery Co., Ltd., Nozaki Engineering Co., Hamada Engineering Co., Ltd., Yamamoto Engineering Co., Ltd., etc.
The main contents of the numerical control transformation of machine tools and production lines are as follows:
The first is to restore the original function, diagnose and recover the faulty parts of the machine tool and the production line; the second is NC, add digital display device on the ordinary machine tool, or add CNC system, transform into NC machine tool and CNC machine tool; It is a refurbishment. In order to improve the accuracy, efficiency and automation, the mechanical and electrical parts are refurbished, the mechanical parts are reassembled and processed, and the original precision is restored. The CNC system that does not meet the production requirements is updated with the latest CNC; the fourth is technology. Updates or technological innovations, in order to improve performance or grade, or in order to use new processes and new technologies, carry out large-scale technical updates or technological innovations on the original basis, and greatly improve the level and grade of renovation.
The criteria for assessing CNC transformation are as follows:
The investment of the transformation is within 30% of the price of the new machine tool, and 70% to 80% of the use efficiency can be achieved, which is considered to be successful; the recovery period of the conversion input fee is lower than the payback period of the purchase of the new machine tool (generally For less than half of the 5 to 6 years (usually 2 to 3 years), the transformation is valuable.
There are exceptions. For example, if the key equipment of a project is purchased from a foreign country and its delivery time and price are unacceptable, the evaluation criteria for its transformation should be considered separately.
The advantages and disadvantages of numerical control transformation reduce the investment amount and short delivery time, compared with the purchase of new machine tools, generally can save 60% to 80% of the cost, and the transformation cost is low. Especially for large and special machines, it is especially obvious. Generally, large-scale machine tools are rebuilt, only 1/3 of the cost of new machine tools is purchased, and the delivery time is short. However, in some special cases, such as the production and installation of high-speed spindles, automatic tool changers and automatic pallet changers, it is too laborious and costly. The cost of retrofitting is often increased by 2 to 3 times. Compared with the purchase of new machine tools, only 50 investment can be saved. %about.
The mechanical properties are stable and reliable, and the basic parts such as the bed and column used for the limited structure are heavy and solid casting components, instead of the welded components. The modified machine tool has high performance and good quality and can be used as a new equipment. for many years. However, due to the limitations of the original mechanical structure, it is not advisable to make a breakthrough transformation.
Familiar with the equipment, easy to operate and repair, purchase new equipment, do not know whether the new equipment can meet its processing requirements. The transformation is not the case, the machining capacity of the machine tool can be accurately calculated; in addition, due to the use of the machine for many years, the operator has already understood the characteristics of the machine tool, and the training time is short and effective in operation and maintenance. Once the modified machine tool is installed, it can be fully loaded.
The existing conditions can be fully utilized to make full use of existing foundations, without having to rebuild the foundation as when purchasing new equipment. At the same time, fixtures, software programs, prototypes and peripherals can be reused. Taking the machining center as an example, the cost of process equipment generally accounts for more than 10% of the total price of the machine tool.
The latest control technology can be used to improve the automation level and efficiency of production equipment, improve the quality and grade of equipment, and change the old machine tool into the current level of machine tools according to the development speed of technological innovation.
3 The numerical control transformation example is affiliated to the National Engineering Research Center of High-end Numerical Control of Shenyang Institute of Computing, Chinese Academy of Sciences. It is the national engineering center for research and development and engineering of numerical control systems. The center successfully developed China's first high-end numerical control system, Blue Sky No.1; solved the problem of China's high-end CNC system from scratch; during the "Eighth Five-Year Plan" period, the center undertook and completed five national high-level numerical control system projects, Two major projects of the Chinese Academy of Sciences have formed four series of 13 models of blue sky (LT) numerical control products.
The center blue sky high-grade CNC has achieved many domestic firsts: it is China's first high-end CNC system; it has obtained the first high-end CNC software copyright in China; equipped with China's first five-axis linkage machining center; five-axis linkage processing out of China The first high-grade impeller; equipped with China's first dual-process crankshaft milling machine; equipped with China's first aspheric optical lens processing center; it is China's first high-end CNC system for mass export.
In the past few years, the CNC Center has mainly used the blue sky series CNC system, and has successfully transformed nearly 20 machine tools and production lines with various numerical control technologies. It has done a lot of work for the numerical control transformation of machine tools and production lines with advanced numerical control technology. Some common problems of numerical control transformation have achieved significant economic and social benefits.
For example, using the blue sky numerical control system, in 1992, two special CNC machine tools for producing supercharger impellers were rebuilt in the Tianjin Locomotive and Rolling Stock Machinery Plant of the Ministry of Railways; in 1993 and 1995, respectively, in the Anshan Seamless Steel Tube Plant, the oil pipeline production line was rebuilt. Two CNC machine tools were introduced. In 1994, four CNC machine tools and machining centers were transformed for the Shenyang Liming Engine Manufacturing Company. In 1995, two spinning machine closing machines were built for the Anshan High Pressure Container Factory. Some of the above modified equipments have been in operation for 7 years and are still in normal operation, and are well received by users. In addition, using the blue sky CNC and other systems, it has successfully transformed eight CNC machine tools for the FAW Group's automotive production line. An example of a typical modification is as follows.
NC transformation of the oil pipe production line of Anshan Seamless Steel Tube Plant The workshop uses CNC lathe to process the petroleum steel pipe for petroleum drilling. The shape is special, and the processing precision and repeatability are high. The original CNC system of this machine is the 550NC system of GE Company of the United States. Due to years of disrepair, often failure, no data and spare parts, the technical strength of the factory can not solve the problem, the machine is in a state of production suspension. We adopted the latest results of the national “Eighth Five-Year Plan†and advanced dual-process four-axis linkage Z-axis technology to replace the relatively backward GE 550NC system, which restored production and improved automation. The workshop has successively transformed two wire machine tools, with an investment of 440,000 yuan in equipment cost, an annual new output value of 21.6 million yuan, and a new profit and tax of 1.62 million yuan.
Shenyang Liming Engine Manufacturing Company's CNC Reconstruction China Aviation Industry Corporation Shenyang Liming Engine Manufacturing Company used the blue sky high-grade CNC system to transform four imported CNC machine tools and machining centers for the company's CNC center. These CNC machine tools were introduced earlier, the original CNC system was in disrepair, the function was not enough, the faults were frequent, and it could not meet the production requirements. Since the cost of purchasing new machine tools is too high, and these CNC machine tools still have value in use, we have modified the CNC system and its related control components with the latest technological achievements. As a result, production was restored, product quality was improved, and output value and efficiency were improved.
The CNC system of the TFM160N large vertical lathe (worth 3 million RMB) imported from France in the 1970s was rebuilt and re-equipped with electrical wiring. After the transformation, the machine tool processed an aircraft engine component of the United States, with an output value of 4 million US dollars, and the transformation investment was only 160,000 yuan. It also modified the CNC milling machine imported from the UK 200C (worth more than 1 million yuan) and the imported CNC lathe V800 (worth more than 1 million yuan). The control system of the BMC-10B (5) five-axis machining center (for second-hand goods, whose value is more than 4 million yuan) imported from abroad has been updated. The advanced blue sky high-grade CNC system is upgraded and transformed. The modified machine tool has the international advanced technical performance in the 1990s: five-axis linkage, six-axis servo control, powerful cutting, full-closed large-stroke fast feed, ATC control; chain tool magazine capacity 60 knives, random tool change; three double pallets exchange freely, work surface 1000mm×1000mm, table rotation axis (A axis) synchronous control; symmetrical gear transmission structure, dual servo system (A1 and A2 axes) synchronized by CNC Control, the worktable flipping force is large; temperature compensation, temperature difference compensation between the main shaft and the column ensures the high-precision processing needs; the renovation fee is 530,000 yuan.
The numerical control transformation of the automatic production line of Anshan High Pressure Container Factory Anshan High Pressure Container Factory has two high-pressure gas cylinder production lines, one of which is a second-hand production line imported from the United States in 1986 with more than 3 million US dollars, and the other is a domestic production line. The imported production line has been in a state of paralysis for many years due to congenital shortages. Our center undertakes the transformation task of the key closing machine of the production line. With the blue sky 8530 high-grade numerical control system, servo drive system and closed-loop control technology, it has transformed the original backward, faulty programmable controller system, stepping drive system and open-loop control. In just three months, not only the closing machine was rebuilt, the production was resumed, the level of automation was improved, and the products produced passed the DOT quality certification of the US authority, and the reputation of exemption was obtained. The American company must underwrite the product. Then, the PLC technology was used to transform the control of Salem heat treatment furnace, so that the two major problems of the production line were solved satisfactorily. The annual production capacity of the transformed production line can reach 100,000, each bottle is 75 US dollars, and the annual output value can reach 7.5 million US dollars, equivalent to 60 million yuan. These two reforms only invested 400,000 yuan, but they revitalized assets of tens of millions of yuan.
The NC results of the “Eighth Five-Year Plan†not only repaired and rebuilt a production line that was discontinued, but also saved a bankrupt enterprise. The project was highly praised by the leaders of Liaoning Province and the mayor of Anshan City. The leaders of the Anshan Science and Technology Commission made a special trip to the Shenyang Institute of Computing, and the special awards were RMB 100,000. At present, another domestic high-pressure gas cylinder production line has been transformed with the blue sky 8530 high-grade numerical control system.
4 Problems and Suggestions for Technical Reform The technical transformation is not valued in some units. It is believed that tinkering can not make up the atmosphere. With funds, new projects will be launched, and new equipment will be opened to open new lines. In addition, the old equipment, domestic equipment, domestic systems, and domestic technology are not confident enough to look down.
Some units look down on domestic technology. If you ask foreigners to repair the equipment, from the time you board the plane from abroad, the cost of more than ten dollars per hour, plus the airfare and accommodation for the exchange, will cost tens of thousands of dollars in a few days. Such a large overhead is considered normal and acceptable. But the same service, the Chinese will not have the same price. Even if an agreement is reached with a fraction of the price of a foreigner, it is very difficult to ask for money after the job is completed, which restricts the technological transformation and the development of domestic equipment and domestic technology.
There is no unified standard in the technical transformation market. Units with transformation tasks do not know where to find people. Some people do not know where to go to find jobs. The technical reform service has no clear service standards, and the teams participating in the technical reform are uneven. Some people temporarily pulled up the team to work, and after the completion of the work, they disbanded, and the users did not receive subsequent technical support and protection.
It is recommended that the relevant departments plan and standardize the technical transformation market and service standards, and establish some specialized transformation teams. It is recommended that all industry departments establish and establish a tendering and bidding system for all technical transformation projects, formulate corresponding policies and regulations, and open up funding channels for technological transformation, so that technological transformation can be incorporated into the normal healthy development track. Using computer network technology, establish a domestic CNC technology resource library and a faulty equipment library that needs to be modified. Create a market that is open, fair, fair, reasonable, efficient and efficient.
5 Conclusion According to incomplete statistics, China has used electronic technology to transform old machine tools since the 1970s. According to the statistics of 320 large and medium-sized enterprises across the country, there have been about 10,000 old machine tools that have been electronically transformed in the past 10 years, including more than 4,700 lathes, nearly 500 milling machines, more than 2,000 boring machines, 1,700 grinding machines, and other types of machine tools. More than 800 units. This shows that China has a team of machine tool transformation, accumulated a certain amount of practical experience, which is undoubtedly very beneficial to promote and develop the transformation industry centered on CNC technology.
Liaoning Province is China's old industrial base. Shenyang City is known as the hometown of machine tools in China. There are many equipments that need to be upgraded. According to the planning of the relevant departments of the province, during the “Ninth Five-Year Plan†period, Liaoning Province will transform about 5,000 CNC machine tools and update 200 automatic production lines. The market for renewal and transformation is very broad.
First, visual conflict.
When buying cosmetics, women attach great importance to the Iron Box packaging of cosmetics. When buying cosmetics, women pay special attention to the appearance of the goods to determine the purchasing power! Therefore, the appearance design of the iron box is very attractive to women, but also out of the psychological characteristics of paying attention to appearance.
Second, the function of packaging.
Women pay more attention to the practicality and function of the product when shopping, and women are more careful when shopping. Many women will carefully observe the packaging when buying products, and will carefully see the instructions on the packaging, and then make a careful comparison. Therefore, they also attach great importance to the detailed design of commercial products, and women will pay attention to the description of the appearance of the iron box packaging when buying cosmetics!
Third: The grade of cosmetics iron box packaging.
Many women pay attention to the brand and product grade when buying cosmetics. In her opinion, using high-quality cosmetics is a noble life. Therefore, the purchase of cosmetics has a strong aristocratic flavor!
Contents, techniques and principles of numerical control transformation of old machine tools and production lines
1 CNC machine tools and production line transformation industry market CNC machine tool transformation market China's total number of machine tools is more than 3.8 million units, of which the total number of CNC machine tools is only 113,400 units, that is, China's machine tool numerical control rate is less than 3%. In the past 10 years, the annual output of CNC machine tools in China is about 0.6-0.8 million units, and the annual output value is about 1.8 billion yuan. The annual output of the machine tool is 6%, and the annual output value is 12% (the latter two are 31.6% and 75.4% respectively). Moreover, economical CNC machine tools account for more than 80% of CNC machine tools, and there are not many advanced machine tools such as automatic machine tools. More than 60% of China's machine tools have been in service for more than 10 years; less than 20% of automatic/semi-automatic machines are available for machines under 10 years, and there are only a handful of automated production lines such as FMC/FMS (60% for automatic and semi-automatic machines in the US and Japan). the above). It can be seen that most of the manufacturing and processing equipment of most of our manufacturing industries and enterprises are traditional machine tools, and more than half of them are old machine tools with a service age of more than 10 years. Even CNC machine tools, most of which are economical CNC machine tools, are outdated in production equipment and technology. The products processed with this equipment generally have poor quality, low variety, low grade, high cost and long delivery period, so they lack competitiveness in the international and domestic markets, directly affecting a company's products, markets, benefits, and influence. The survival and development of enterprises. Therefore, it is necessary to greatly improve the numerical control rate of the machine tool.
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