China's machine tool industry development status and trend forecast

“Green and smart are the theme of this exhibition, and it is also the development trend of the world's machine tool industry. Green machine tool refers to the greenization of the machine tool in the process of production and application, ie, lower energy consumption, less material, lighter weight and efficiency. Higher.” Hao Ming, president of China National Machine Tool Corporation, said at the 11th China International Machine Tool Show held recently.

In the intelligent and green manufacturing summit held at the same time during the exhibition, the participating experts unanimously appealed that environmental protection, energy saving and emission reduction are the dominant trends in industrial upgrading of the machine tool industry as a machine tool, and it can be said that in the face of traditional high energy consumption, The current situation of high material consumption, the development of high energy consumption green machine tool technology is the only way to achieve sustainable development of the manufacturing industry, and it is of great significance to the modernization of the industrial structure of the Chinese machine tool industry.

“The world is optimistic about the Chinese market, coupled with the inability of local companies to make high-end products, which has caused imports to continue to increase for many years.” Hao Ming pointed out that the large-scale aerospace industry using machine tools and cutting tools has pointed out that on the one hand, the level of domestic machine tools and cutting tools cannot To meet the requirements of the rapid development of the aviation industry, imported machine tools and tools account for a large proportion; on the other hand, Western developed countries have restricted the export of key components and manufacturing equipment in the aviation sector. "Therefore, this is a key user area where the Chinese machine tool industry can make a difference and it should strive to break through."

The country has proposed the goal of achieving 80% localization of machine tools in the aerospace industry by 2020, which requires the concerted efforts of the entire industry including CNC systems, functional components, and host companies. “The machine tool is a working machine, and the state supports the machine tools needed by the aerospace industry. In addition, the company must also position the product with special features, focus on the user field to develop its own strong products, and increase its investment in the development of specialty products to occupy more. In the high-end market, otherwise the price war in the low-end market will seriously affect the efficiency.” He admits that even if the domestic high-end machine tools, the key parts are mostly imported, objectively, the imported parts in the stability, reliability, function There are many advantages over domestic products. "We must break this bottleneck, otherwise we can only follow other countries."

Professor Cao Huajun, director of the Institute of Green Manufacturing Technology at Chongqing University, believes that the key to achieving green manufacturing in China's metal processing industry is the development of high-efficiency green machine tool technology. Data from the National Bureau of Statistics in 2010 also showed that China’s manufacturing energy consumption accounts for 60% of total energy consumption, and it generates about 5.5 billion tons of non-hazardous waste and 700 million tons of hazardous waste each year. “The machine tool inventory in our country exceeds 8 million units. In 2011, the machine tool output reached 859,900 units, ranking first in the world. However, the material consumption of the machine tool industry in China is high, the energy consumption is high, and the reliability is not high.”

According to the EU "Next Generation Production System" research program, the green machine tool should have the following characteristics: First, the main machine tool parts are made of renewable materials; Second, the weight and volume of the machine tool is reduced by more than 50%; Third, the quality of moving parts is reduced, Measures such as reducing the airborne operating power reduce the power consumption by 30 to 40%. Fourth, the use of various waste materials in the process is reduced by 50% to 60% to ensure that there is basically no pollution in the working environment. The fifth is that the material of scrapped machine tools is nearly 100% recyclable. .

Wang Zemin, a senior engineer at Qiqihar Machine Tool Co., Ltd., believes that green design should be promoted in the design process first, such as virtual design, low-carbon design and lightweight design through technical structural innovation. "To fully meet such requirements is not an easy task, but academic and business circles at home and abroad are working hard." Cao Huajun also believes that the lightweighting of machine tools, especially the lightweight design and application of moving parts, is a key technology for improving the energy efficiency of machine tools. one. It is reported that light weight technology is mainly carried out in two aspects: first, the use of lighter materials that can meet the same requirements, and second, structural optimization of machine tool components to reduce the use of materials.

“For example, using less dense plastics and aluminum alloys to replace steel materials in certain non-load-bearing parts, especially in the appearance of machine tools, it is easier to achieve better appearance results while satisfying the requirements. Some foreign machines Even using carbon fiber as a structural part greatly reduces overall machine weight.

It indicates a direction for the development of machine tools. According to Kong Lingyou of Shenyang Machine Tool, Kong Lingyou emphasized that the green design of the machine tool also has an easily overlooked aspect, that is, system upgradeability, which includes software and hardware. "In the design phase, we should consider using multi-function components and Modular components to assemble the product, the same type of machine tool can be unified component interface. When designing machine tools, you should also reserve space for functional expansion. Products with good scalability can avoid the waste of resources caused by users repurchasing devices. ”

At the time of manufacture, the machine tool industry should adopt more energy-efficient motors and variable frequency technologies. "The energy cost of a single motor accounts for more than 97% of its total life cycle cost. Therefore, an efficient motor product can be based on the original, through the optimization of electricity, magnetism, machinery and ventilation, and effectively reduce the loss of all aspects of the motor. , reduce the cost of operation and speed up the recovery of investment." For example, in the conventional transmission system, the energy generated by braking is often wasted in the form of heat energy, and the frequency converter through technological innovation has a function of regenerative energy feedback, which can put the motor The braking energy is fed back into the grid instead of being consumed in the braking resistor. For example, a certain brand of inverter can save up to 50% of energy by implementing intelligent regeneration energy feedback technology.

“Energy-efficient green machine tool technology has become a hot spot in the industry at home and abroad. The lightweight technology of moving parts not only reduces the material consumption of machine tools, but also improves the operating efficiency. The energy management technology strengthens the management of the energy consumption of the operating process. It is an important step towards greening; high-efficiency motors and frequency conversion technologies have improved the operating efficiency of the drive operation system; efficient cooling lubrication technology has enabled the efficient use of processing resources and improved efficiency.” Cao Huajun and other experts believe that improving the stability of the process Sex, reduction of processing energy consumption and material waste caused by processing scrap are also important aspects of energy saving; using high-precision forming technology instead of roughing or semi-finishing also has great potential for energy conservation.