Abstract As one of the most important equipments for industrial equipment processing and manufacturing, machine tools are constantly moving towards intelligence. Song Tianhu, chairman of the China Mechanical Engineering Society, said that in the next 20 years, China's intelligent manufacturing equipment industry should firmly grasp the strategic opportunity period of development, in the "...
Machine tools, as one of the most important equipments for industrial equipment manufacturing, are constantly moving toward intelligence. Song Tianhu, chairman of the China Mechanical Engineering Society, said recently that in the next 20 years, China's intelligent manufacturing equipment industry should firmly grasp the strategic opportunity period of development, with "innovation priority, key breakthroughs, technology integration, solid foundation, and diversified investment." The principle is to meet the needs of the transformation of traditional industries and the needs of strategic emerging industries, and integrate technologies such as advanced manufacturing, information and intelligence to achieve green, digital and intelligent manufacturing.
In order to further promote the pace of high-end equipment intelligence, the state has issued the "12th Five-Year" high-end equipment manufacturing industry development plan (hereinafter referred to as "plan") to transform the intelligent equipment development, satellite and application development projects have begun to implement, this It shows that the development plan of the high-end equipment manufacturing industry has entered the substantive operational level.
The data shows that the current industrial scale of smart equipment is about 300 billion yuan, the market is mostly monopolized by foreign manufacturers, the domestic market share of domestic manufacturers is low, the intelligent instrumentation and control system is 10%, the industrial robot and special equipment is 20%, and the mid-range CNC The machine tool is 20%, and the high-end CNC machine tool is 1%. The goal of the "Planning" is that by 2015, the sales revenue will reach 1 trillion yuan, and the domestic market share of high-end intelligent equipment and basic manufacturing equipment required by the national economy key industries. Up to 50%; sales revenue reached 2 trillion yuan in 2020, and the domestic market share reached 70%.
Intelligent manufacturing elements
In the past 20 years, the multi-disciplinary advancement of microelectronics, communications, computers, artificial intelligence, control and image processing has laid the foundation for the development of intelligent machines.
Song Tianhu pointed out that although the types of intelligent machines vary widely and the tasks are diverse, from the essence of science and technology, there are three basic elements, namely perception, decision-making and execution.
The perception function is mainly reflected in the information input of the intelligent machine, just like the five senses of the person is responsible for collecting the data of the work environment. Perceptual technology is mainly sensor technology and communication technology. The former is responsible for converting the physical characteristics of actual working conditions into digital quantities that can be understood by intelligent machines, while the latter is responsible for transmitting digital quantities to the decision-making layer of intelligent machines quickly and without error.
Decision-making is the performance of intelligent machines that can be intelligent, just as the human brain makes judgments about the perceived information and issues instructions for the next action. The decision-making technology is mainly artificial intelligence technology and intelligent control technology, which requires intelligent machines to process various working conditions in real time and closed loop, not just open loop execution according to the predetermined procedure.
The execution function is that the commands of the decision system must be executed, and the execution needs to be realized by a series of actions, just as the human motion system produces the actual actions under the command of the brain. The main technology for implementing the action function is the actuator technology, including so-called arms and claws, mobile platforms, drives, and also covers the actuators of the actuators, such as motor controllers, pressure controllers, etc.
Intelligent manufacturing technology features
Tracing back to the source, the technical characteristics of intelligent manufacturing mainly have the following four points:
First, intelligence is at the heart of smart manufacturing. Intelligent performance is the automatic identification and judgment of the working environment, and its work instructions are automatically generated based on the feedback information. Intelligence is also a difficult point in smart manufacturing technology. Although artificial intelligence technology has achieved great breakthroughs, the smartness of intelligent manufacturing technology is still very low compared with human intelligence. There is still a big gap.
Second, comprehensiveness is an integrated technology of intelligent manufacturing technology with a typical interdisciplinary nature. However, any breakthrough in a single technology can revolutionize smart manufacturing technology.
Again, smart manufacturing technology requires a quick response to real-life conditions. People can quickly respond to unpredictable unexpected situations in real time, which requires intelligent manufacturing technology to have this ability to ensure the completion of work tasks. At present, there is still a big gap in achieving this goal.
Finally, the interactivity of the technology is realized. Intelligent manufacturing technology must be able to understand people's intentions and ideas, and must communicate with people and society. For example, speech recognition technology and speech synthesis technology are designed to help people understand and understand human language when they are intelligently manufactured, and turn their own responses into speech "speak" for people to listen to. The essence of human-computer interaction technology is to make intelligent manufacturing technology have the ability to communicate with people, and the more natural the communication process is, the better.
Six major trends promote intelligent transformation of machine tools
The high-end CNC machine tools and basic manufacturing equipment "Technology Major Specialized Implementation Management Office", through profound research, systematically proposed six technical trends of machine tool intelligence:
The first is to monitor the intelligence of the working state of the machine tool.
In the monitoring of the working state of the machine tool, the intelligent progress of the spindle is most obvious. The height of the spindle is realized by the sensing system equipped with the temperature sensor and the load displacement sensor.
Here, the MEMS temperature sensor is used to monitor the lubrication condition of the bearing, prevent the bearing from sintering and correct the thermal displacement of the spindle. The load displacement sensor is used to detect the abnormal load in the machining, monitor the bearing load and infer its life, and avoid bearing damage. Because the spindle is close to the workpiece machining position, it is more suitable for accurately monitoring the machining state of the machine. However, installing the sensing system in the limited space of the spindle is not simple, and there are still many problems. For example, by installing an FBG sensor (strain sensor) in the structural material to detect the thermal displacement of the structure, the thermal displacement mode of the machine structure is judged and corrected, and the temperature distribution control of the main structure is performed to minimize thermal deformation.
In addition, the temperature and spindle operation information of several monitoring points in the machine structure are used, and the relative thermal deformation between the tool and the workpiece is corrected by the CNC command.
The second is to monitor the intelligence of the maintenance status. In order to reduce the load on the maintenance work, it is necessary to have a system to take countermeasures before a large failure occurs, so it is very important to perform regular monitoring of the maintenance status. Accumulating historical data of the working state of the machine tool and predicting the life based on this, and detecting the life in the working state, can be said to be a future issue.
The third is to ensure the security of security. The latest intelligent technology to ensure safety is a technology to avoid collisions. Interference checks can be performed through procedures, during exercise, and while preparing for work.
In addition, there are techniques for detecting the centrifugal force damage and critical safety speed of the tool, and some may sacrifice operability due to safety, which may also be solved by intelligence.
The fourth is to realize the intelligentization of energy conservation. The state in which the chips are discharged varies with the processing conditions, the processing materials, and the processing target. By detecting the change in the amount of chips and controlling the operation of the chip processing device, a good energy saving effect can be achieved.
This method is also suitable for the cooling lubricant supply system. By adjusting the cooling lubricant to meet the processing conditions, it will also achieve better energy saving effect.
The fifth is the intelligent decision-making of process conditions. The vibration during processing is detected, and a command to avoid such vibration is generated to form a system that automatically avoids vibration. In the turning process with slow spindle rotation speed, the fluctuation amplitude and fluctuation period of the spindle rotation speed can be calculated at any time to prevent the occurrence of regenerative vibration. In the milling process, by utilizing the periodic relationship between the spindle's speed of rotation and the vibration, it is possible to keep the spindle working in a specific area where there is no vibration.
As the choice of process conditions, it is not only the automatic determination of the processing conditions, but also the determination of whether the processing conditions selected by the user are reasonable, and the development of reasonable process conditions for achieving the necessary machining accuracy can further enhance the degree of intelligence. In development.
Sixth is the intelligence of the preparation work. Progress in the preparation of the homework is not yet obvious. When processing shaped materials such as cast parts and forged parts, it is difficult to process in high-speed rotation due to unbalanced mass and positional changes. Therefore, it is necessary to carry out processing while balancing, and the automatic balancing device is intended to solve this problem. In addition, there are no relevant examples. As for other intelligent systems for preparing for work, they are under development.
"The gradual liberation from physical strength to mental power, the continuous leap from traditional experience to scientific cognition, and the harmonious coexistence of man and nature, etc., have been and continue to profoundly change the production form of human society." Song Tianhu said.
Policy to support high-end equipment intelligence
At present, the technical level of the world's machine tools is based on the production of CNC machine bed machine, and the development in the next 20 years will be the same. On the basis of further improving accuracy, efficiency, automation, intelligence and networking, and gradually transitioning to processing units and cutting-edge flexible manufacturing systems, human intelligence and creativity will once again promote the integration of modern science and technology with higher density. .
However, in many industries such as construction machinery, electromechanical products, CNC machine tools, port equipment, shipbuilding, etc., although the manufacturing and sales volume of China's manufacturing has leapt to the forefront of the world, many sets of data show that the total economic output of China's equipment manufacturing has been ranked for four consecutive years. the first. However, “Made in China†all over the world has long been considered synonymous with low quality, low price, labor intensive, and low technology.
As an important part of the strategic emerging industry, the development strategy of the “Twelfth Five-Year Plan†for high-end equipment manufacturing industry is a key breakthrough from five major directions: aviation equipment, satellite and application, rail transit equipment, marine engineering equipment and intelligent manufacturing equipment. The goal of the "Planning" is that by 2015, the sales value of high-end equipment will account for more than 20% of the equipment manufacturing industry, and the annual sales value is expected to reach 6 trillion yuan.
The first funds to subsidize the manufacture of smart equipment have been released. The first batch of intelligent manufacturing equipment to implement subsidy funds has 19 projects, and the state subsidy fund of 950 million yuan has been officially launched. In particular, in order to support smart manufacturing equipment enterprises to expand the market, the state will allocate the first set of subsidy funds, the subsidy funds up to 25% to 50% of the product sales price.
According to relevant statistics, the "Plan" is expected to reach an annual sales value of more than 6 trillion yuan in the high-end equipment manufacturing industry by 2015. Nowadays, with the future industrial production will be highly automated or even intelligent production mode, China will continue to promote the development of the intelligent equipment industry.
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