國產(chǎn)高檔數(shù)控機床發(fā)展現(xiàn)狀—畢業(yè)論文.doc

國產(chǎn)高檔數(shù)控機床的發(fā)展現(xiàn)狀 摘要：近幾年來，國產(chǎn)的低端數(shù)控系統(tǒng)基本把國外競爭對手擠出了中國市場；而高端市場則正好相反，國產(chǎn)只占不到十分之一。高端數(shù)控系統(tǒng)市場基本上在法那科和西門子等廠家的掌握中。國外高檔數(shù)控系統(tǒng)，在高速和高精度表現(xiàn)上，以及在五軸加工和智能化方面比國內(nèi)產(chǎn)品表現(xiàn)都好，而且其平均無故障時間是國內(nèi)產(chǎn)品的4倍。除了數(shù)控系統(tǒng)水平的差距，關(guān)鍵零部件領(lǐng)域的薄弱也限制了國產(chǎn)機床的高度。關(guān)鍵字：高檔數(shù)控機床；現(xiàn)狀；數(shù)控系統(tǒng)the development present situation of domestic high-grade cnc machine toolabstract: in recent years, domestic low-end numerical control system the basic foreign competitors out of the china market; while the high-end market, by contrast, domestic only accounts for less than one over ten. high-end cnc system market largely in the hands and siemens, etc. foreign high-grade cnc system, performance in high speed and high precision, and in terms of five axis machining and intelligent than domestic products performance is good, and the mtbf is four times that of domestic products. in addition to the numerical control system level of gap, the key parts in the field of weak also limits the height of the domestic machine tool.key words: high-grade cnc machine tools; the status quo; numerical control system1.前言 數(shù)控機床是現(xiàn)代制造業(yè)的主流設(shè)備，是體現(xiàn)現(xiàn)代機床技術(shù)水平、現(xiàn)代機械制造業(yè)工藝水平的重要標志，是關(guān)系國計民生、國防尖端建設(shè)的戰(zhàn)略物資。 從2002年開始，中國已成為世界機床消費第一大國和機床進口第一大國，進出口逆差嚴重，中高檔、大型、精密、高速數(shù)控機床以及數(shù)控系統(tǒng)的進口依賴程度更加明顯。目前，中國進口高檔、大型、精密和高速數(shù)控機床的比例達80以上，中國汽車制造裝備70以上和汽車發(fā)動機生產(chǎn)線90以上依賴進口，而且?guī)缀醢俜种俚闹懈邫n國產(chǎn)數(shù)控機床采用的數(shù)控系統(tǒng)也都是依賴進口。 五軸聯(lián)動加工中心有高效率、高精度的特點，工件一次裝夾就可完成五面體的加工。如配置五軸聯(lián)動的高檔數(shù)控系統(tǒng)，還可以對復(fù)雜的空間曲面進行高精度加工，更能夠適合越來越復(fù)雜的高檔、先進模具的加工以及汽車零部件、飛機結(jié)構(gòu)件等精密、復(fù)雜零件的加工。眾所周知，發(fā)達國家直到現(xiàn)在還在限制五軸聯(lián)動數(shù)控系統(tǒng)和機床對中國的出口，如果用戶使用國外的數(shù)控系統(tǒng)，就必須簽署嚴格的定向使用協(xié)定，并接受檢查。2.五軸聯(lián)動數(shù)控加工中心的結(jié)構(gòu)五軸聯(lián)動加工中心大多是3+2的結(jié)構(gòu)，即x，y，z三個直線運動軸加上分別圍繞x,y,z軸旋轉(zhuǎn)的旋轉(zhuǎn)軸中的兩個旋轉(zhuǎn)軸組成。這樣，從大的方面分類，就有x-y-z-a-b、x-y-z-a-c、x-y-z-b-c三種形式；由二個旋轉(zhuǎn)軸的組合形式來分，大體上有雙轉(zhuǎn)臺式、轉(zhuǎn)臺加上擺頭式和雙擺頭式三種形式。 3. 國產(chǎn)高檔數(shù)控機床發(fā)展現(xiàn)狀在機床行業(yè)，一般以數(shù)控機床所控制的軸數(shù)為標準來劃分檔次，三軸以下的為低檔，三至五軸為中高檔，五軸以上為高檔。數(shù)控機床是機床工業(yè)的方向，其高精、高細、高速、柔性、智能，是現(xiàn)代機床工業(yè)的標志，現(xiàn)代裝備制造業(yè)正向極端制造方向發(fā)展，一是越來越高大，二是越來越細小，三是越來越復(fù)雜，生產(chǎn)工藝高度集成。在世界機床行業(yè)界，歐洲和日本的機床工業(yè)憑借其高度創(chuàng)新、多元化規(guī)模和精密級制造等產(chǎn)品優(yōu)勢，在世界高檔機床市場中多年來保持壟斷領(lǐng)先地位。那么我國高檔數(shù)控機床的發(fā)展狀況如何呢？3.1 國產(chǎn)高檔數(shù)控機床的應(yīng)用航空航天制造技術(shù)雜志期刊2009年曾經(jīng)針對數(shù)控機床及高檔數(shù)控機床進行應(yīng)用調(diào)查，調(diào)查顯示，國產(chǎn)數(shù)控裝置的配套滿足率可達 70%，但是國產(chǎn)數(shù)控系統(tǒng)幾乎有 80% 以上是用于中低端數(shù)控機床上，高端數(shù)控系統(tǒng)產(chǎn)品的差距仍然較大，雖然在核心技術(shù)上取得了突破，但總體技術(shù)與國外相比仍有較大差距，國外品牌占據(jù)我國高端數(shù)控系統(tǒng) 95% 以上的市場份額。目前中國高檔數(shù)控系統(tǒng)和功能部件仍然主要依靠進口，國內(nèi)高檔系統(tǒng)的自給率不到5%，約有95%依賴進口，其中日本成為主要的進口國，約占1/3；國產(chǎn)中高檔數(shù)控系統(tǒng)總和不到20%，因此發(fā)展國產(chǎn)高端數(shù)控系統(tǒng)勢在必行。3.2 與國際先進水平的差距高性能數(shù)控系統(tǒng)、電主軸、納米精度光柵等功能部件及整機設(shè)計制造的核心技術(shù)，是發(fā)展高端數(shù)控機床最關(guān)鍵的因素。近幾年來，國產(chǎn)的低端數(shù)控系統(tǒng)基本把國外競爭對手擠出了中國市場；而高端市場則正好相反，國產(chǎn)只占不到十分之一。高端數(shù)控系統(tǒng)市場基本上在發(fā)那科和西門子等廠家的掌握中。國外高檔數(shù)控系統(tǒng)，在高速和高精度表現(xiàn)上，以及在五軸加工和智能化方面比國內(nèi)產(chǎn)品表現(xiàn)都好，而且其平均無故障時間是國內(nèi)產(chǎn)品的4倍。除了數(shù)控系統(tǒng)水平的差距，關(guān)鍵零部件領(lǐng)域的薄弱也限制了國產(chǎn)機床的高度。在一些機床展會上，也能看到應(yīng)用法那科或西門子數(shù)控系統(tǒng)的國產(chǎn)高端機床，與國外裝配同樣“大腦”的機床相比，轉(zhuǎn)速只有國外的三分之一，誤差范圍是別人的5倍。3.2.1 各類數(shù)控機床主要技術(shù)性能的差距龍門式加工中心是一類產(chǎn)品規(guī)格大而且技術(shù)和利潤的附加值大的產(chǎn)品，工作臺移動式和龍門框架移動式或床身高架橫梁移動式，都是有技術(shù)實力和能力的廠家主要比拼的對象。此類機床技術(shù)含量較高，國內(nèi)龍門式加工中心的規(guī)格大多在工作臺寬度12005000毫米，x、y坐標軸的快移速度保持在20000毫米/分鐘左右，定位精度和重復(fù)定位精度保持在各坐標軸全行程上0.0150.035毫米和0.0080.025毫米。國外一般工作臺規(guī)格都在5000毫米以上，定位精度和重復(fù)定位精度比我們的值減少20%50%，體現(xiàn)了他們的技術(shù)獨樹一幟。3.2.2 國產(chǎn)數(shù)控系統(tǒng)與國外的差距 由于“東芝事件”的深遠影響，日本發(fā)那科在最近若干年內(nèi)五軸聯(lián)動的數(shù)控系統(tǒng)都是不可能賣給中國的。近年來，中國陸續(xù)推出五軸聯(lián)動機床的廠家(如沈陽、大連、北京、濟南、常州、桂林和齊齊哈爾等地的機床廠)越來越多，各式五軸聯(lián)動數(shù)控機床在北京、上海等國際機床展上不斷亮相。但是，這些五軸聯(lián)動機床一個共同特點就是所采用的數(shù)控系統(tǒng)基本上都是西門子的840d系統(tǒng)，而且，其中的功能大都是經(jīng)過適當裁減的。即使這樣，配上840d數(shù)控系統(tǒng)的五軸聯(lián)動機床的用戶也要接受他們的定向使用審查而受其限制。 國產(chǎn)數(shù)控系統(tǒng)主要有廣州數(shù)控，華中中數(shù)控，航天數(shù)控等系列，廣州數(shù)控系統(tǒng)是學(xué)習(xí)日本發(fā)那科系統(tǒng)的技術(shù)并消化吸收的成果，在國產(chǎn)數(shù)控中排行老大，華中數(shù)控有些仿德國西門子技術(shù)的意思，它的繪圖能力比較強大，在國內(nèi)數(shù)控系統(tǒng)中排行老二，是國家重點支持和發(fā)展的數(shù)控系統(tǒng)，因為由華中科技大學(xué)作為后盾，相信以后有很大的發(fā)展空間。國產(chǎn)數(shù)控系統(tǒng)正處在一個上升的成長期當中，與國外相比基本功能還是都有的，所差的部分有以下幾點：1、元件質(zhì)量，國產(chǎn)元件由于制作工藝、制作環(huán)境、原材料等一些軟性條件和硬性條件無法滿足、同時也被制造商忽視所以還無法與國際市場上最優(yōu)質(zhì)元件所比擬；2、控制精度實際取決于對電流、電壓、波形控制的精度，這里包含了信號的比較反饋、信號處理等，這主要還是靠軟件和硬件配合來完成的，國內(nèi)系統(tǒng)開發(fā)商好像對這兩個部門之間的配合還做得不是很好；3、國內(nèi)市場數(shù)控系統(tǒng)開發(fā)商的產(chǎn)品原型大多沒有形成真正的自己的思路，在復(fù)制過程中有些看似無用的，沒有真正理解其含義就匆匆省掉了；4、由于國內(nèi)市場數(shù)控系統(tǒng)開發(fā)商急于與國際市場接軌，低價競爭，導(dǎo)致在原材料采購中和在設(shè)計制造當中能省就省，這樣就導(dǎo)致差異擴大。 4. 國產(chǎn)高檔數(shù)控系統(tǒng)發(fā)展成果雖然國內(nèi)高檔數(shù)控機床與國際水平有差距，但是在國家政策的支持和研究人員的努力下，我國高檔數(shù)控機床取得了一定的成績。下面以華中控華中8型高檔數(shù)控系統(tǒng)為例子簡單介紹。我國高檔數(shù)控華中8型全數(shù)字高檔數(shù)控系統(tǒng)是我國自主研發(fā)的高端數(shù)控系統(tǒng)，具備全數(shù)字現(xiàn)場總線、多通道、多軸聯(lián)動、高速高精、使用方便、配套齊全等性能特點，是高檔數(shù)控機床與基礎(chǔ)制造裝備國家科技重大專項取得的重要成果。華中8型全數(shù)字高檔數(shù)控系統(tǒng)實現(xiàn)了從模擬接口、脈沖接口到總線控制、高速高精的技術(shù)跨越，對打破國外技術(shù)壟斷、提高國產(chǎn)高檔數(shù)控系統(tǒng)的市場占有率、維護我國產(chǎn)業(yè)、經(jīng)濟和國防安全都具有重要意義。華中8型全數(shù)字高檔數(shù)控系統(tǒng)2012年已在航空航天、能源、船舶、汽車等重點領(lǐng)域用戶實現(xiàn)了500多臺的實際應(yīng)用。華中8型數(shù)控系統(tǒng)還應(yīng)用于東方汽輪機公司的各類高檔機床，包括砂帶磨生產(chǎn)線9臺，高速木工龍門銑床1臺，五軸葉片銑床4臺。其中，五軸聯(lián)動龍門加工中心主要用于風(fēng)電漿葉等大型復(fù)雜整體結(jié)構(gòu)件的高速加工，突破了國外對我國高速龍門銑床方面的技術(shù)封鎖。5結(jié)論本文通過對國產(chǎn)高檔數(shù)控機床現(xiàn)狀及對策進行了探討，我深刻認識到我國高檔數(shù)控機床與先進國際水平差距較大，對國外高檔數(shù)控裝備的依賴程度依然很大。國內(nèi)的數(shù)控機床生產(chǎn)商更應(yīng)該認清差距，腳踏實地，有戰(zhàn)略規(guī)劃，有步驟的追趕國際先進水平，優(yōu)先發(fā)展與高檔數(shù)控裝備有關(guān)的精尖技術(shù) ，不斷縮小與國外先進水平的差距。參考文獻：1周延佑，陳長年新理念催生新結(jié)構(gòu)j制造技術(shù)與機床，2007(6)：55-594側(cè)衛(wèi),曉立.高端數(shù)控系統(tǒng)應(yīng)用調(diào)查報告j.航空制造技術(shù),2009（16）:5455.5熊永超,陶勇.國產(chǎn)數(shù)控機床現(xiàn)狀及發(fā)展趨勢j.煤礦機械,2006,（3）:3435.6宗合.機床突破需劍指高端n.中國船舶報,2009-07-24(007).7江仁潔,何建新.我國數(shù)控機床的現(xiàn)狀及發(fā)展趨勢j.湖南農(nóng)機,2007,(3).12杜玉湘，陸啟建，劉明燈五軸聯(lián)動數(shù)控機床的結(jié)構(gòu)和應(yīng)用機械制造與自動化，（）：15 周延佑.數(shù)控機床發(fā)展新趨勢與我國相應(yīng)的對策j.機械工藝師, 2001(2): 5-71.16 盛伯浩,唐華.數(shù)控機床技術(shù)發(fā)展淺析j.航空制造技術(shù),2002(6): 12-171.17 朱同興.國內(nèi)外數(shù)控技術(shù)發(fā)展動向j.數(shù)控技術(shù)與應(yīng)用, 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