Extreme manufacturing, to put it bluntly, can be "extremely large" or "extremely small". For example, an excavator successfully developed in China has a bucket capacity of 55 cubic meters, which is the largest bucket in the world and can accommodate one. The band played inside. How small is that small? Now the equipment used for integrated circuit plate making is nano-scale, only 90 nanometers. Extremely large and extremely small, is a comprehensive consideration of the strength of science and technology, then, how are these amazing extreme manufacturing, how to create it?
Liu Bingye, director of the Beijing New Machine Tool Research Institute, said that machining accuracy has always been an important indicator for measuring the development level of modern CNC machine tools, but the effect of machining accuracy is now not limited to dimensional accuracy, shape accuracy and surface roughness. Reflected in the processing technology of microstructure.
The development trend of processing technology can now be clearly perceived. On the one hand, the shape-scale features of local processing develop in the subtle direction, and on the other hand, the overall shape of the processing develops toward the large size.
In fact, driven by technological innovation, micro-structured parts are widely used, such as solar power generation components, mobile phone light guides, liquid crystal display brightness enhancement films, highway display panels, fly-eye lenses, diffraction gratings, sensor components, binary optics. Components, microlenses, etc.
“Many are inspired by the things around me.†Liu Bingye said, for example, someone found that water droplets on the lotus leaf always consciously present a specific shape, which is related to the miniature structure of the lotus leaf, so there are inventors trying to develop similar The platform, to carry out the corresponding application, requires the follow-up of processing technology.
Therefore, the processing of a large number of parts with microstructures has become an important task for the development of precision machine tools, and the emergence of microstructures has also made the processing of machine tools into new fields.
The advent of microstructures poses new challenges for machine tool processing because the size of microstructures varies from a few hundred microns to a few microns, and the size of the integral parts with microstructures ranges from millimeters to several meters. However, the quality of the microstructured surface is nanoscale. This has new requirements for the motion accuracy, smoothness and damping characteristics of the machine tool. In addition, new changes must be made in the machining process, machine tool and machine tool accessories.
New optical processing technologies such as fast knife servo (FTS), planing, chiseling, and deterministic grinding are also emerging in the development of micromachining technology. Nowadays, the micro-structured machine tools for processing large cylindrical surfaces, round end faces and planes have become the products of market competition, and the nano-imprint replication process technology has also been developed and applied accordingly.
According to Liu Bingye, in the field of micro-structured manufacturing equipment, Japan, Germany, and the United States have developed rapidly, and many new machine tool products have appeared. Typical companies include Toshiba Machine, FANUC, BIS, and Kugler.
He mentioned that micro-hole precision machining has also been rapidly developed during this period. The pyramid ultra-precision machine tool from Cohen, Germany, can process tens of thousands of micro-holes with a diameter of not more than 0.1 mm on the semiconductor ceramic material with the same tool. .
Intelligentization requires high reliability. Like the ultimate manufacturing, intelligent manufacturing has become a new trend in the international manufacturing field. Since the introduction of the “Fourth Industrial Revolution†(Industry 4.0) at the Hannover Fair in Germany in 2011, it has now entered the implementation phase.
Liu Bingye said that the goal of the "fourth industrial revolution" is the intelligence of the factory. In 2013, the United States began the re-industrialization of the intelligent era with the theme of manufacturing resurgence. On the basis of flexible manufacturing, Japan has formed a relatively mature intelligent manufacturing technology. China's current manufacturing labor costs are rising, and the “labor shortage†in some areas has also forced manufacturing companies to transform into intelligence.
The general trend of intelligent manufacturing technology requires that the machine tool must adapt to its application requirements. The most typical application feature is the high reliability of various configurations. As the most basic component of intelligent manufacturing, the reliability of machine tool equipment becomes the most important assessment. index.
He said that today's smart manufacturing technology can be seen as a technology developed on the basis of the previous two generations of flexible manufacturing technology. The first generation of flexible manufacturing systems was born in the 1980s. Its reliability is characterized by continuous operation for 24 hours. The second generation was produced in the 1990s and can run for 72 hours. Today's intelligent manufacturing systems require 720 hours of continuous operation. Therefore, machine tools that can operate for a long time without interruption and high reliability have become another development trend.
In the development of the three generations of intelligent manufacturing, the labor cost is declining, and the participation of people in intelligent manufacturing is rare, but the complexity of the robot is obviously improved. For example, in the second generation of development, robots can only carry in fixed path handling, but the third generation robot can not only perceive the disordered workpiece through the visual sensor, but also can sense the assembly process by judging the grasping action of different paths. The part is centered and matched with smart fixtures to replace work that could only be done by people in the past.
In addition, intelligent manufacturing also places demands on other aspects of machine tool adaptability, such as the ability to work with sensors with sensors and sensing alignment, and remote communication.
Liu Bingye said that although there are still many development trends of machine tools, such as multi-functional composite trend, reconfigurable trend, low energy consumption and environmental protection trends. However, the two major trends of extreme manufacturing and intelligent manufacturing have different technical characteristics. The main highlight of the first major trend is the cutting-edge and innovative nature of technology, with emphasis on the high-tech of technology; the second major trend is characterized by technology. The maturity reflects the foundation of a country's manufacturing industry.
"These two characteristics can fully reflect the strength of the national manufacturing industry. If the technology involved in the first major trend is lacking, one country will face the threat of monopoly; the second major trend tests and measures the manufacturing base of a country. The strengths and weaknesses and the quality of the issues involve a broader range of technologies."
Liu Bingye believes that in the face of the challenges of the first major trend, industry colleagues must develop technologies characterized by precision and scale to research and develop cutting-edge equipment and processes.
Among the three major objectives of the “Horizon 2020†research and innovation plan announced by the European Commission, “being an industry leaderâ€, the key development area is “nanotechnologyâ€, which also reflects the requirements of this development. In the field of precision manufacturing machine tools, we must pay close attention to the development of machine tools and ultra-precision machine tools in order to have a place in the country's high-tech fields.
In the face of the second trend, China's machine tool industry must meet the high reliability of the manufacturing field and other issues related to product quality and performance.
Because the biggest feature of intelligent manufacturing is integration, if the quality of components and components of intelligent manufacturing lines is problematic, the higher the integration, the bigger the problem.
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