Promote full speed with innovation
In the same way as the continuous improvement of the precision of innovation, the aim of achieving high efficiency in the pursuit of high efficiency is to achieve the realization of a single high-speed cutting development to a full-speed. The requirement for innovation is not only to shorten the cutting time, but also to reduce the auxiliary time and technical preparation time. To this end, the spindle speed and feed rate should be increased to increase the fast-moving speed and the addition (decrease) speed, shorten the spindle starting and braking time, reduce the automatic tool exchange time and the workpiece tray automatic exchange time, thereby reducing the auxiliary time and Further shorten the technical preparation time through production information integration management and planning, and CAM.
According to the statistics of the use of existing CNC machine tools, the machine utilization rate (the ratio of effective cutting time to all working hours) is only 25-35%, and the remaining 75-65% are consumed in machine adjustment, program operation check, and idle travel. Auxiliary time such as brake dry running, workpiece loading and unloading, and waiting time (non-working time due to technical preparation and scheduling failure) and downtime. Therefore, it is necessary to improve the operation convenience and monitoring function of the numerical control system and enhance the information management by improving the fast-moving speed and the addition (decrease) speed of each axis, the angular addition (decrease) speed of the spindle shifting, and the automatic exchange speed of the tool (workpiece). It is possible to fully compress the auxiliary time and reduce the waiting time, so that the cutting time utilization rate of the CNC machine tool reaches 60%~80%.
In the process of innovation to promote the overall high-speed development of the manufacturing process, the following three technologies have played an important role:
(1) Electric spindle technology: It includes built-in motor structure, drive control and double-sided over-positioning tool holder structure to ensure high-speed and high-speed operation of the spindle.
(2) Direct drive technology: It includes the linear axis motion driven by the linear motor and the rotary shaft motion directly driven by the torque motor. Their frictionless, “zero intermediate transmission†improves the acceleration and smoothness of fast motion.
(3) High-speed and high-precision digital control technology: It is an advanced control technology for suppressing or eliminating the negative effects such as tracking error, thermal error and flutter caused by high speed.
Diversified innovations in composite machining machines
Multi-function composite machining machine is called ComplexMachineTool, or Multi-FunctionalMachining or CompleteMachining or EndtoEndMachining.
The meaning of a compound machine tool is to achieve or complete as much processing as possible from the blank to the finished product on one machine. Composite machine tools can be divided into the following two categories according to their structural characteristics:
(1) Composite machine tools across the processing category, such as turning and milling centers, milling centers, laser milling machines, etc.
(2) Multi-faceted multi-axis linkage machining of composite machine tools.
Innovatively increasing the composite machining function of CNC machine tools has an immediate effect on further increasing the concentration of the process. It not only reduces the loading and unloading time of multi-processed parts, but also avoids the increase of the time between the process and the waiting time of the parts on different machine tools, especially in the case of not forming an effective production line. The waiting time between the two will far exceed the working time of the part on the machine, thus extending the production cycle of the part.
The composite CNC machine tool has good process applicability, avoids the support and production of the product, and strongly supports the Just-In-Time Manufacturing (JIT). Therefore, its research and development has been given great attention. Therefore, composite CNC machine tools present a diverse and innovative structure.
Process applicability innovation
Through the innovation of machine layout and structure, it has the best processing applicability for different types of parts. Because the shape, size, and precision of parts and components vary with the performance optimization and weight reduction of mechanical products, it is difficult to optimally meet various process requirements with a few standard and general machine tool structures.
This "personalized" structure tends to have factors for product competition, but more importantly, it shows how to better adapt to the needs of users. Especially for some mass-produced parts, it is more desirable to have a specialized CNC machine tool with the best process suitability.
To solve the contradiction between variety and economy, this puts higher requirements on the modular design of machine tools. In recent years, research on parallel machine tools and hybrid machine tools and reconfigurable Machine Tools (RMT for short) The exploration of technology reflects the pursuit of more convenient and individualized and diversified development of manufacturing equipment.
Innovation to achieve an agile manufacturing system
Flexible Manufacturing System (FMS) and Flexible Manufacturing Unit (FMC), as a high-productivity multi-variety automated production system, were developed in the early 1970s and developed greatly in the 1980s. By the early 1990s, due to the acceleration of the mass production of manufacturing industries such as the automotive industry, there was a demand for multi-variety production, requiring automatic line flexibility, and the development of a flexible production line (FML) built with CNC machine tools, which also promoted the structure. The development of simple high-speed CNC machine tools.
Looking back at the innovation process of manufacturing systems in the past 10 years, basically follow the following two directions:
(1) Enhance the intelligent and autonomous management functions of the manufacturing system to improve the rapid response capability of the FMC/FMS.
(2) Develop a new reconfigurable manufacturing system (RMS) that combines flexibility, efficiency, low cost, and high quality with ease of functional reorganization.
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