Machine Tool Equipment Industry: Application and Practice of Design Process

Advanced Manufacturing Technology and Rapid Development of Chinese Machine Tool Industry

Machine tool industry is the foundation of modern manufacturing and modern industry. The development of machine tool industry has driven the development of manufacturing and industry. For a country, the local machine tool industry is closely linked to the local manufacturing industry and industry. A high level of local machine tool industry helps to raise the level of local manufacturing and industry. The United States, which had been the leader of the long-term automotive industry in the first half of the 20th century, was surpassed by Japan in 1980 because of backward manufacturing technology. In the 1980s, when the United States needed 214 people to produce a car, Japan needed only 133 people. Since the mid-late 1980s, the U.S. government began to support the machine tool industry, which affects industrial development and defense capabilities. The U.S. machine tool industry’s domestic sales increased from 1.883 billion U.S. dollars in 1986 to 4.35 billion U.S. dollars in 1994. In 1994, the production reached 12.265 million units, regaining the world’s No. 1 production position.

Due to the low level of equipment, China's manufacturing industry has shown labor productivity and low market competitiveness. In the third industrial census, among the important equipments of large and medium-sized enterprises in China's machinery industry, the gold-cutting machine tool accounted for 89% of the domestic general level and the domestic level, and only 1.5% of the international advanced level, which is the domestic advanced level. It also only accounts for 9%. As a result of the combination of information technology and machinery manufacturing technology, CNC machine tools represent the technological level and development trend of modern basic machinery and naturally become the focus of the revitalization of national equipment manufacturing industry. Since 2003, China has become the world's largest consumer of machine tools and the world's largest importer of CNC machine tools. Driven by strong market demand, China's CNC machine tool industry has developed rapidly. At present, there are nearly 100 CNC machine tools manufacturing plants. In terms of overall scale and key varieties, China has entered the top few in the world, and the output of CNC machine tools reached in 2006. More than 85,000 sets, up to more than 1,500 kinds of varieties, machine tool industry-wide industrial output value reached 150 billion yuan, output growth rate remained at about 15%.

In the next five years, under the traction of large-scale equipment manufacturing industries such as automobiles and parts, aerospace and defense industries, shipbuilding, and power station equipment, China's machine tool manufacturing industry will go with high precision, high efficiency, high reliability, personalization, and flexibility. The direction of development in the areas of chemical, intelligent, and green environmental protection has greatly changed the status quo of imports of large-scale, high-speed, and high-precision CNC machine tools, and ushered in the climax of national economic construction and technological transformation of manufacturing.

Machine tool industry product innovation and industrial upgrading usher in the era of popularization of PLM technology

With the development of individual needs in the machinery manufacturing industry, how the machine tool industry adapts to the development of the individual needs of the manufacturing industry and meets the individual needs of the manufacturing industry has become the never-ending driving force for product innovation of machine tool design and manufacturing enterprises; at the same time, with the automotive, aerospace, etc. The wide application of industrial light alloy materials, high-speed machining with the advantages of shortening processing time, improving processing accuracy and surface quality has become an important development trend of manufacturing technology; and the operation mode and lean production management of modern production organizations are also proposed for machine tool equipment. The requirements for reducing processing assistance time, compounding of processes to functional compounding, and flexibility are required to shorten the processing chain and auxiliary time, reduce the number of machine tools, simplify the material flow, increase the flexibility of production equipment, and minimize the total production area and investment. effective.

Under the situation of deteriorating market competition and the growing demand for personalized customers, the speed of upgrading machine tool equipment products will accelerate, and the reconfigurability of special machine tools and the reconfigurability of manufacturing systems will become increasingly important. Through the modularization of CNC machining units and functional components, the manufacturing system can be quickly reconfigured and configured to meet the production needs of variant products. The standardization and standardization of interfaces for mechanical, electrical and electronic, liquid and gas, and control software are key to achieving reconfigurability. The use of new design methods and tools based on computer-aided design systems accelerates the development of new products through 3D modeling and simulation, and gradually integrates CAD/CAPP/CAM/CAE/PDM to build enterprise-level product life. The cycle management (PLM) platform becomes an efficient multiplier for rapid reorganization and configuration of machine tool companies using existing product knowledge resources to speed up the development of new machine tools and improve product quality. Driven by PLM technology, the traditional manufacturing model will be transformed from "product = raw material + manufacturing process" to modern manufacturing model with product innovation as the core "product = knowledge + raw material + manufacturing process + service", the value-added of machine tool manufacturing Mainly reflected in product design, software development, market development and recycling and other links.

In addition, CNC machine tools are complex electromechanical products. Their complex product structure and variety of specifications require various functional components to be provided by a highly technical supply chain. Therefore, the machine tool industry enhances the ability of independent innovation. Whether it is the machine tool manufacturer itself, or the upstream and downstream industries such as cutting tools, cutting fluids, numerical control systems, and functional components, it must take product innovation as a guide to gain core competitive advantages over the next decade. thought. At present, China's machine tool industry chain has not yet formed a tie-based supporting relationship like the automotive industry. Its production methods are large, complete, small and complete. No matter how large-scale machine tool manufacturers, they must directly purchase and manage thousands of components at the same time. As many as 400 to 500 suppliers, as well as specialized, large-scale capacity is not enough. With the popularization and application of network and information technology, the company's operational strategy is also changing from domestic to global, internal collaboration, external supply chain collaboration, and price war to product innovation. The machine tool manufacturers who have successfully built an enterprise-wide product life cycle management platform will organically integrate product design process management and manufacturing process management. From the original producer-oriented, low-volume, high-volume production model, to the customer Leading multi-variety, small-batch, and short-delivery production model transformations have become lean, agile, informational, and networked digital factories that meet market demand with less resources and production capacity.

application solution

CNC machine tools are generally designed and manufactured according to customer orders, including various functional components such as mechanical, electrical, hydraulic, and automatic control. The technical difficulty is high, and the design and manufacturing cycle are relatively long. For the sales department, the biggest problem is the inability to deliver on time in accordance with the requirements of the customers. For the design department, due to the rapid development of the business, product types, specifications and models are very complicated, and customer needs change frequently, resulting in a large amount of design work. Project management and change management are not effectively controlled; for the production and materials management departments, there are many types of machine tool product parts and the manufacturing process is complex. The types of machine equipment and fixtures required for the manufacturing process are also numerous. For MTS, MTO, ETO, and ATO coexistence, single-piece, small-batch, batch, and project-type production are the same, and the biggest headaches are Overly rapid change and scientific scheduling in the event of frequent changes in design changes and changes in the plan will not only control the cost, but also deliver the goods on schedule and in good quality.

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Figure 1 CAXA Design Process Integration PLM Application for Machine Tool Industry

The design process management solution and manufacturing process management solution provided by CAXA (Figure 1) adopts a unified data platform, and the design, process, and production data can be used for subsequent business processes once they are entered, avoiding duplication of data. Entry to reduce errors due to manual re-entry. At the same time, due to the adoption of a unified service platform, all segments of the business can support inter-departmental and cross-enterprise collaboration under the support of a workflow engine. All data is shared and updated under the platform's security control mechanism. Enterprises can also use the data. The customization capabilities of the platform continue to optimize business processes, achieve continuous improvement of business operations, and continuously enhance competitiveness.

Application features

1. Seamlessly integrates CAXA electronic charts with the largest installed base of genuine CAD in China, specifically tailored to the characteristics of product drawings in the machine tool industry, and supports the “in place” labeling habits for product drawings in the machine tool industry; and provides standard parts and common parts. Gallery, standardize product design management, improve product and component standardization;

2. Provides material information integration for product design CAD tools and PDM systems, embedded deep integration of foreign 3D or 2D CAD design tools (SolidWorks, Pro/E, CATIA, UG NX, Solidedge, AutoCAD), product design and drawing The link realizes the integration with the company's material information and enhances the design and reuse capabilities of the company's parts and components.

3. To adapt to the complex structure of machine products, variety of specifications, and long process routes, to provide process life cycle management solutions, including machining, stamping, welding, assembly, painting and other professional process preparation, process route preparation, materials Quota preparation and management, process task management, tooling business management, process information management, assembly assembly detail management, process knowledge management, and process resource management, etc., effectively shortening the production technology preparation cycle

4. Product design process, process design process and product data, process data management architecture on a unified PDM basic platform, product BOM information configured and maintained in accordance with different business views, greatly reducing the repetitive entry of material information, can be timely for the ERP system Provide a unique and accurate product bill of materials, effectively shorten the order delivery cycle.

Successful application

Beijing No.2 Machine Tool Works Co., Ltd. (hereinafter referred to as “Bei Er”) was founded in 1953 and is one of the backbone enterprises in the Chinese machine tool industry (“Eighteen Arhat Factory”). Its “North II” brand high-precision outer circle Grinding machines, CNC cylindrical grinding machines, precision machining equipment and other precision products are the key equipment for precision manufacturing in China's auto, aerospace, home appliances, machinery and equipment industries. They are sold throughout the country and sold to more than 30 countries and regions in the world.

Beibei Information Technology started earlier, but with the rapid increase in the number of orders that meet the needs of individual customers in recent years, the unit system (CAD system, shop floor management system) has been difficult to support the development of the enterprise, and can not achieve internal product data The effective management and mobility have restricted the efficiency of enterprise-level product development. In order to build a distinctive, differentiated and differentiated product competitive advantage for Beier II in the mid-to-high-end market segment, Bei Er established the Leading Group for Enterprise Informatization, and General Manager Mao Yufeng personally took the lead. With Mao Zedong's high level of attention and direct concern, the PLM project team has meticulously examined more than one year's experience of many domestic and foreign PLM suppliers after determining the idea that enterprise informatization should first build an enterprise-level collaborative working platform through PLM. After the product selection activity, CAXA unanimously recognized CAXA's professional accumulation and long-term sustainability support service capabilities for more than a decade, as well as CAXA's complete PLM function and extensibility, and finally selected CAXA as the PLM solution provider. And the implementation of service providers has promoted the company's overall transformation strategy with product research and development as the core.

Prior to the implementation of PLM projects in Beier II, the problems in product development process management mainly included:

1. Product structure management and configuration

In the North two, product structure management mainly relies on four kinds of schedules, which are the component parts list, parts list, standard parts list and purchased parts list. The component parts list records the large parts of the product and indicates the borrowing and new design; the parts list records all the parts (except standard parts and purchased parts) of the product. The standard parts and purchased parts information are separately represented by their respective schedules. This product structure management approach brings about the following aspects: The internal relationship between a large number of schedules is not clear, and it is difficult for engineers and technicians to understand the product structure of a complete, orderly, and intuitive product; it is difficult to carry out the borrowing of parts and components. Statistics also make it difficult to clearly understand the borrowing scope of parts and components; it takes a lot of time to set up various schedules to repeatedly input the attributes of parts and components such as purchased parts.

2. Document Management

Each department of the company manages the documents used by the department, and the electronic documents are stored on the server. The electronic documents mainly depend on the resource manager provided by the server operating system, and the documents approved by the organization are stored in accordance with the product organization. Paper documents are the only legal circulation documents within an enterprise. However, due to the low retrieval efficiency, it is difficult to obtain all the required data quickly when borrowing. At the same time, due to the limited number of paper documents, technicians who need to borrow cannot obtain timely information. Reference electronic documents, but electronic documents are not accurate. The documents in the storage catalog cannot be guaranteed to be the final version. It is difficult to see the past status of the documents and trace back the historical information. Some electronic documents have been modified and directly covered. When data needs to be reviewed, the data has been lost.

3. Coding management

The company originally had no corresponding codes for internally used standard parts, purchased parts and materials, and the description of relevant parts or materials was not uniform. Therefore, there was a difference in the description of the same purchased parts when the designer purchased the purchased parts. Confusion.

4. Process preparation

Originally, the company used Word, Excel, and other general-purpose software for process planning. Therefore, the following difficulties existed in process establishment: The number of process tasks is large, and the amount of work for repeated work depends on the familiarity of the process designer with respect to the typical processes of a typical process; the process file is not Sharing on the server, the retrieval efficiency is low, historical results are difficult to borrow; the input of special symbols for the process is difficult, the craftsman can only use the text description method, so the standardization degree of the process document is not high; it is difficult to draw the drawings in the process preparation. Less efficient; Process calculations in process design lack effective tool support, such as machining allowances.

5. Project Management

The project management of enterprise product R&D is mainly for business executives to formulate technical preparation schedules. It is only necessary to manually monitor and coordinate the parallel projects. The execution and supervision of the processes mainly rely on manual work and internal forms. The problems in this traditional project management approach are mainly due to the lack of sharing of project information. The senior leadership and design supervisors of the enterprise cannot perform comprehensive and real-time monitoring of the implementation status of each project. For design managers who participate in multiple projects, they must obtain timely information. The progress of each project, the project team members of the task saturation is more difficult; designers can not understand the overall situation of the project, it is difficult to achieve effective coordination; in the product development project management, the history of the process process is more difficult In retrospect, related records do not have a relationship with the product.

The above problems directly affect the efficiency of product design, and engineers and technicians spend a lot of time and energy on finding drawings, entering product information, outputting and maintaining various kinds of value lists and other worthless duplication of labor. As a result, product development and design workload is heavy and the development cycle is long. The time when valuable human resources are actually used for product technological innovation cannot be guaranteed.

In order to solve the above problems of product development management, with the help of CAXA's senior consultants, the North 2 PLM project team chose to implement the corresponding functional modules of CAXA V5, as shown in the following table.

North II CAXA V5 Implementation Scope

department

Modules

Planning and Development Department

Technical Department

Function Description

Project management

þ

þ

Perform task decomposition, project schedule management, task tracking, information transfer, and integrated resource management. Workflow management

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Automatically realize the flow of work, the flow of tasks, and the flow of documents within the company, while providing powerful management and tracking capabilities, speeding up the approval process and change process. Engineering Change Management

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Provides complete changes to the process control and quality template files. The change results are automatically deployed in the system; changes are automatically recorded (version information, change records, etc.). authority management

þ

þ

The role-oriented, workgroup, and personnel rights setting functions can set permissions for different operations at different stages on each type of object in the system. Template Library Management

þ

þ

Define various template files, such as paper template and quality template. When a project is started, different quality template files can be called at each control point, and the information of this project can be directly input to standardize the quality management process. Coding management

þ

þ

Encoding management includes four major categories of management: coding rules, classification codes, attribute codes, and stream codes. The user can create multiple sets of coding rules and select one set as the default value. When the user receives the code number, the system will automatically pick the number according to the set coding rule. Graph Document Management

þ

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Establish a connection with CAXA V5 in the product design environment (CAXA electronic board) to automatically submit document drawings. The drawings will enter the PLM system and will be automatically organized according to the assembly relationship. The attribute information of the drawings will also be automatically generated by the PLM system. Extract from CAD system. Product Structure Management

þ

Define product views at different stages of the product's entire life cycle, such as design BOM, production BOM, assembly BOM, and so on. Changes to the product structure in the view, such as adding parts, deleting parts, etc., do not affect the product's real structure. Product multi-view technology allows users to manage product configuration. Product structure management provides various functions such as BOM maintenance, BOM comparison, BOM packaging, BOM consolidation, and BOM synchronization. Product Configuration Management

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When designing a new product, a reference design is obtained through an efficient query function provided by the system. On the basis of the reference design, a variety of configuration methods provided by CAXA V5 are used for rapid new product design. Standard parts library management

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The custom-designed mechanical standard parts management for North 2 include nuts, washers, pins, screws, springs, etc.; electronic components management includes resistors, capacitors, and integrated circuits. Through the data modeler, you can also quickly customize other standards that companies need to manage. Universal Library Management

þ

þ

According to the general classification of machine tools, parts that pass the approval process of common parts are stored. When designing, the designer can search through the common parts library to find the necessary parts through the query function provided by the system, and directly use the existing design results through the common parts application process to shorten the design cycle. Process Resource Management

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Management of basic manufacturing resource data related to process design includes materials, components, tooling, tools, equipment, etc., so that they can be invoked during process design. Process Card Template Management

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A card format editor is provided to create a process card template according to the standardization of a company's process, and a cell, a column, and a table can be defined, a font therein, an associated process knowledge base, and fields corresponding to data storage can be set. Process summary customization

þ

Customize the template for the supporting tables of the North 2 product R&D technical documents, and use the product structure management to automatically summarize the “Outsourced Parts Summary Sheet”, “Standard Parts Summary Sheet”, “Special Parts Summary Sheet”, and “Self-made Special Tooling Schedule” 》And other 25 statistical summary. Process design environment

þ

The "What You See Is What You Get" interface is used to drive the integration of process data and documents using an information model-driven mechanism. At the same time, an excellent 2D graphics platform is embedded to effectively support quick rendering of process diagrams and integration of other CAD systems. Engineering drawings information.

Figure 2 Drawings from MAGIC CAD Unified Conversion to CAXA Electronic Drawings

Figure 3 Components marked on the drawing are selected from PDM's corporate general parts library

Figure 4 Statistical summary schedule automatically generated according to a customized template

CAXA has achieved the goals set by the North Two PLM project, and the system is stable and reliable. It effectively solves the issues of project management, product structure and configuration management, figure document management, code management, process establishment, and statistical summary of the product R&D process management. Successfully built an enterprise product R&D collaborative work platform with integrated design and process. By unifying the original MAGIC CAD into the CAXA electronic drawing board (see Figure 2), the massive technical drawing assets accumulated in the history of the enterprise are inherited and protected, and the efficiency of drawing of the retrofit design of the industrial product is greatly improved; the product design process is greatly improved. The CAD tool is tightly integrated with PDM, and the parts and components marked on the drawings are selected from the PDM's corporate general parts library, which effectively guarantees the uniqueness of the material code and the consistency of the part information; a large number of statistical summary tables follow the customized template. Automatically generated (as in Figure 3), reducing the process designer. The successful deployment of CAXA V5 enables Bei'er's product R&D process management to be effectively controlled from the creation, modification, review, release, maintenance, and reuse of data, and it will be a strategic development strategy for Beier II. Lay a solid foundation.

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