Machinery manufacturing industry plays an important role in the development of the world economy as a basic industry. To this end, economists and entrepreneurs in various countries are constantly exploring various advanced manufacturing technologies and manufacturing development strategies under the new situation. The machine tool manufacturing industry, which is the core of the manufacturing industry, is the cornerstone of the pillars and is indispensable for any industry. I. Social and Economic Foundations of Production and Development Second, the choice of big modification plan Hydraudic Chuck Cnc Machine,Hydraulic Cnc Machine,Computer Digital Cnc Machine,Automatic Cnc Machine Shaoxing Sunfong Intelligent Equipment Inc. , https://www.zjsxsunfong.com
(1) China's existing and tens of thousands of obsolete and backward machine tools are the realistic basis for machine tool overhaul and numerical control transformation. China is a developing country, and its economic strength is too low due to the inadaptability of its own long-term mechanism. The backward technology and outdated equipment have greatly restricted the development of the national economy. In order to change the backwardness of China's machinery manufacturing industry as quickly as possible, we have actively introduced the world's advanced technology and equipment while we are struggling to develop the national machine tool manufacturing industry in the past two decades. On the one hand, it cooperates with the world's advanced machine tool manufacturers to continuously produce all types of machine tools with advanced world standards; on the other hand, it directly purchases a large number of various types of machine tools. All these have played a huge role in the rapid development of our national economy.
However, long-term operation of the machine tool and even overloaded use, while lack of serious maintenance and repair, resulting in serious wear and lack of accuracy of the machine tool; some machine tools are left idle for a long time due to changes in the company staff and product structure, or lack of technical force. Need to use it but found that it has been rusty, electronic control system can not start; due to the need for new product manufacturing, the original machine tool performance can no longer meet the requirements, an urgent need to update the upgrade; due to the rapid development of the world computer and network technology, resulting in CNC The system and drive system plant product update was speeded up. The original product was stopped prematurely, which caused certain difficulties in the replacement and maintenance of spare parts. In addition, the service life of the CNC system was generally 5 to 10 years, and most of the machine tools in China were in service. Many of these factors require the overhaul and numerical control of the machine tool.
(2) A large number of new and used machine tools have become catalysts for machine tool overhaul and numerical control transformation. Since the reform and opening up, many companies have introduced a large number of old machine tools that have been eliminated from abroad. Although some of them can still meet the requirements for use, most of them are due to lack of experience. Factors such as technology, data, and spare parts have created an embarrassing situation in which, although they are purchased cheaply, they cannot continue to function and become idle. Among them are many old machine tools and production lines introduced for use after transformation. Most of the used machines here have only a proper capital investment, and they can play a role after being modified.
(3) Significant economic benefit is the driving force behind the development of machine tool overhaul and numerical control transformation. For machine tool owners, the same use effect can be obtained for only 30% of the cost of purchasing the same new machine tool. According to the records of the international industry, even if the original machine tool's structural performance is completely transformed and upgraded, it only costs about 60% of the price to purchase new machine tools.
For large-scale machine tool manufacturers, this not only generates huge social and economic benefits for their service companies, but also is the fundamental driving force for their own survival and development.
(4) Advantages of machine overhaul and numerical control transformation are the advantages of the industry's survival and development Compared with the purchase of new machine tools, overhaul, refurbishment, and upgrade of old machine tools have the following advantages:
1 Short delivery time. Especially the advantages of large-scale machine tools and special-purpose machine tools are even more obvious.
2 more stable performance. The long-term aging of each basic part will hardly affect the accuracy due to stress and deformation; the functional parts will be worn over a long period of time. Functional stability and reliability.
3 The design risk is small. The risks of technology and solutions brought about in the design of new machine tools are almost non-existent in the process of major modification.
4 can fully reflect the user's wishes. Users and maintenance personnel can, in accordance with actual needs and long-term use of machine tools, put forward suggestions for improvement (including increase and change) in the performance, operation and maintenance of the machine tool, and have the right to choose electrical components such as mechanical parts and numerical control systems during major modifications. The specifications, models, performance, etc.
5 is more conducive to use and maintenance. Because users and maintenance personnel can not only directly participate in the formulation of the transformation plan, but also can participate in the entire process of transformation, they can directly obtain various technical information and master the structure and performance characteristics of the machine more deeply, thereby enhancing the active and useable ability of the machine.
6 Get the latest, more practical spare parts faster.
7 Save a lot of investment.
8 Reduce investment risks.
(5) The trend of socialization and specialization is the only way for machine tool overhaul and numerical control transformation. The transformation and refurbishment of old machine tools are not only necessary and important during the current economic transition period, but also a strategic measure for the long-term development of an enterprise.
At present, in the era of knowledge-based economy in the 21st century, most enterprises in China are facing enterprise restructuring, transition to market economy and rapid integration into international competition. This requires the leadership of our company to focus all its efforts on facing these challenges. A series of new technical theories, such as enterprise grouping and decentralized networking, autonomy, parallel work, new organization, production structure, agile manufacturing technology, virtual manufacturing technology, sustainable manufacturing technology, green manufacturing technology, etc., are all needed. Great force to study, to develop marketable products, to improve the ability to respond quickly to the market; focus on human, financial and material resources to improve the company's market competitiveness, give full play to their advantages to create as much as possible the fastest speed value. Therefore, the company itself can no longer have a large and complete maintenance team as in the past planned economic system. The socialization and professionalization of equipment maintenance and renovation will inevitably become a major trend.
The transformation and refurbishment of foreign machine tools is an emerging industry that has recently developed. In advanced countries, a certain scale and market have been formed. In China, this industry has only just emerged, and it still has a long way to go according to the conditions that must be met. However, people of insight in the industry are striving to shape themselves and improve themselves. It is believed that in the near future, a group of specialized enterprises with certain conditions and a certain scale of machine tool rebuilding and renovation will grow up.
If this work can win the technical support of the large-scale reorganization companies, it may be better and faster.
1. Preliminary preparation work
(1) The technical feasibility analysis mainly aims at the transformation target and the processing object, and conducts a comprehensive analysis of the technological status of the restructured machine tool such as structure, performance and precision. Including whether the original structural design of the machine tool is reasonable; whether the basic components and structural parts of the machine tool are still intact; the ordinary machine tool is changed to a numerical control machine tool; it is necessary to examine whether the mechanical transmission structure of the coordinate axes and the form of the guide rails are applicable; The accuracy is compared with the factory precision, whether there is a gap; comprehensive summary of all the current machine tool failures and history of major failures. In response to the above problems, the transformation task book is prepared against the transformation goals and typical artifacts, so that the machine tool after transformation can achieve certain advancedness and practicality.
(2) Economic Feasibility Analysis From the actual operability, several conditions should be listed: From the value of the machine tool itself, whether the investment needed to reach the transformation target is high or not; from the machine tool in the production of the unit product The status and importance of the company to analyze the value of transformation; from the input and output rate of the machine tool, whether it can quickly recover the investment, and then quickly produce better benefits; after the machine tool transformation to improve the accuracy of the machine tool, increase the function, whether it can make this Elevating the level of product per unit or can be beneficial to the development of new products, so as to obtain additional benefits. The source of the reform funds is reliable.
(3) Selecting a machine builder This is a key issue. If you choose a good one, you can successfully complete the transformation task and achieve the transformation goal. If the choice is not good, it is not only the failure of the machine tool transformation, but also a waste of funds and time, affecting production. The user can choose carefully according to the conditions that the machine tool should discuss later.
2. Preparation of technical solutions
(1) Mechanical and hydraulic systems As the end user of the machine tool, the factory must first confirm the condition of the machine's mechanical and hydraulic systems. Such as: the current machine tool accuracy, the status of the mechanical transmission chain, screw, rail conditions, whether there is a major fault, etc., to determine the machine tool is overhaul, repair items. If it is a non-CNC Machine tool to be changed to a Cnc Machine tool, first of all consider the feasibility of mechanical modification, the most important is the form of the guide rail and the installation of the ball screw. Then there is the transmission gap and transmission stiffness of mechanical transmission mechanism meet the requirements of CNC machine tools.
(2) Electrical system When doing the transformation project of CNC machine tools, the user can select the CNC system according to the machine state and process requirements. The first is the selection of CNC manufacturers. Currently, the world's performance and reputation are better: Siemens (Germany), Fanuc (Japan), Mitsubishi (Japan), NUM (France), FAGOR (Spain). Users can learn more about the characteristics of the above-mentioned manufacturer's numerical control system and performance cost ratios, and together with the engineering company that implements the transformation, choose a more suitable numerical control system. The second is to select the type of the corresponding control system according to the function requirements of the machine tool so that it can satisfy all the functional requirements of the machine tool without raising the standard.
We suggest that we should pay special attention to the selection of the CNC system: One must try to move closer to a famous manufacturer's model series. This will not only facilitate maintenance and management, but also facilitate the purchase of spare parts. Do not make the company's CNC system into a 10,000 card. Second, we must clear the status of the selected manufacturers in the domestic maintenance services in order to avoid future troubles.
After selecting the CNC system, the user decides whether to replace or not replace the drive system according to the actual conditions of the machine tool. If you do not replace it, you must confirm whether the old drive system and the numerical control system can match.
For the machine tool measuring system, the current requirement of the CNC system is the incremental pulse code input. Therefore, the measuring elements such as the induction synchronizing ruler or the resolver equipped with the old machine tool must be replaced with incremental pulse encoders and grating scales.
For peripheral circuits, there are two options for retrofitting: “Interface type retrofitâ€, which means that the peripheral relay circuit is reserved and only NC and PLC are modified. The new PLC does not participate in the peripheral circuit control and only processes the command signals required by the NC. This program has a smaller workload for retrofit design and commissioning. The other is "reinvention", in the case of complex relay logic, high failure rate, and the user can provide a clear logic diagram, the PLC can be used with the new NC to transform the peripheral circuit to simplify the peripheral circuit. Reasonable use of PLC control capabilities. This scheme can greatly simplify the hardware circuit and greatly improve the reliability, but the reconstruction design and debugging workload is large.
(3) The determination of each part of the installation form First, the installation of the control system is usually suspended, cabinet, desktop and so on. The selection of the installation method directly determines the cabling method and cable length of various connection cables, and also relates to the convenience of operation and maintenance. Second, the installation of the drive system, in principle, can only take the installation of the electrical cabinet this way, the factors that should be considered are ventilation and cooling, cable routing and length, and other electrical interference. Third, the installation of the motor, according to the actual machine tool, determine the motor mounting method: 1 flange type, 2 base type, 3 with base flange type, plus the shaft extension direction, the position of the motor terminal box, etc. The ordering auxiliary parameter of the motor is determined. Fourth, the installation of the measuring system, such as selecting the structure of the encoder built into the motor, is determined when the motor is installed; the external mounting requires flexible couplings, mounting clips, cable routing direction, and length. For grating ruler, the installation problem should be paid attention to. In addition to the feasibility of installation, the installation of fixed-foot, moving-foot ruler, installation accuracy, and temperature influence should all be considered.
Third, the implementation of the project
1. Selection of construction team
The design of a large-scale machine tool modification program is good or bad, and the major modification results in the pros and cons. In addition to economic factors, it largely depends on the quality of the construction team. This is a very important task. Companies participating in the project construction should meet the following requirements.
(1) The key to a complete and efficient technical support system is the human factor. The company should have an engineering team that includes all aspects of mechanical, electrical, hydraulic, process tooling, etc., with years of rich experience in design, manufacturing, assembly, and commissioning. At the same time, it should also have an on-site construction team that can fight hard. This mode of operation is a popular model under the economic conditions of today's market.
(2) The key to the management and management mode under the conditions of market economy is the human factor. Abandon all obstacles in enterprise management under the conditions of the planned economy, develop organizational forms and management methods for each person's enthusiasm, and establish a corporate structure that can quickly respond to market demands, and continuously improve and perfect the market economy, and at the same time, consider The company's size, funding status and many other factors.
2. Hardware orders
After all the above considerations, the construction team has been selected, the details of the technical plan are determined, and the order list can be listed. Users and engineering companies can use a mutual trust attitude to consider comprehensively from the aspects of cost reduction and reliability assurance, determine the order list at home and abroad, and sign a formal transformation contract. At the same time as the order is being carried out, the engineering personnel can begin to carry out system mechanical overhaul, repair and electrical software preparation, and laboratory debugging.
3. On-site commissioning
This is the key to the success of the transformation. At this stage, the engineering staff completes the work of machine and electric control, final adjustment of the numerical control system, and optimization of the parameters of the drive system, and prepares for acceptance.
4. Test processing acceptance
Usually there are two contents: trial cutting of standard samples. According to international standards, different types of machine tools have corresponding standard trial cutting procedures; the accuracy of machine tools is verified, and the corresponding measures are adopted according to the level of measurement of each factory, and the conditions are qualified. The user can use a laser interferometer to make measurements so that the machine position measurement system can use the resulting data to compensate for the machine's accuracy.
5. Information, training and warranty
After the completion of the acceptance work, technical data needs to be collated, archived, and provided to the user. Technical training and warranty work for the user are also required.
The transformation of old CNC machine tools is in the ascendant. Under the current situation in China, a large number of faulty machine tools, especially a large number of imported CNC machine tools, precision machine tools, and used equipment are being transformed and upgraded, and these devices will be used in economic development with a relatively small investment as soon as possible. Giving full play to effectiveness and creating benefits is indeed an important issue for many companies.