The development of flexible automation in the world's forging industry continues to accelerate. Stamping equipment is widely used in automobiles, aviation, electronics, home appliances and other industrial fields. Among them, the automobile industry, as one of the symbols to measure a country's industrial level, is listed as a pillar industry of the national economy by major industrialized countries and emerging industrial countries in the world today. Its development has dominated the development of forging technology and equipment. The development and progress of forging technology basically revolves around the development of the automobile industry. Fierce market competition has significantly accelerated the speed of automobile upgrading, and further shortened the market life cycle of products; at the same time, the number of automobile variants is increasing day by day, and modern automobile industry production is increasingly showing production scale, personalized vehicle models, small batch sizes, and small vehicle models. It is characterized by rapid changes, multi-model line production, and large-scale integration of body panels. The traditional rigid production line that processes a single variety is obviously no longer suitable for this characteristic and the requirements of the development of the market situation. Its upgraded products have automated forging equipment with high flexibility and high efficiency, which has become the main trend in the development of stamping technology and equipment in the world.
The current situation and development strategies of my country's forging industry
In terms of stamping, currently about 90% of the stamping lines of my country's major automobile manufacturers use a double-action stretching press (or more Connecting rod single-action stretching press) and 4-6 single-action presses form a stamping assembly line. Manual loading and unloading completes the stamping production of large cover parts. The production efficiency is low, and the maximum production cycle is only 3-5 times/min; personal safety and the workpiece environment is poor; during the manual loading and unloading and transfer of workpieces, defects such as scratches on the workpiece are easily caused, and the quality of stamped parts is poor; the entire stamping line is about 60 meters long, requires about 20-24 operators, and covers an area of Large, labor costs are high, and the manufacturing cost of stamping parts is 2-3 times higher than that of foreign countries. This is one of the important factors why my country's automobile industry seriously lacks market competitiveness. There are 90% of stamping lines in my country using manual loading and unloading, and another 10% of stamping lines have realized single-machine online automation, with a maximum production cycle of 6-8 times/min. And the large multi-station presses that represent the international level of today's stamping technology, Its application in my country's automobile industry is still blank. This is also the main gap between my country's stamping industry and Western developed countries, which to a large extent restricts the development of my country's automobile industry.
In terms of hot forging, large-scale free forging equipment has excess capacity, equipment layout is scattered, utilization rate is extremely low, mechanization and automation are low, forging processing margins are large, workers' working conditions are poor, and labor intensity is high. Three 800T dual-machine linkage fast forging units have been designed and manufactured domestically, but the degree of automation is not high; the domestic metallurgical industry has introduced a small number of fast forging units and precision forging production lines; in terms of automation of large automotive die forgings, only a few large companies such as FAW and Second Automobile Works have The company has imported hot die forging press automatic lines from abroad, and most of them still use a combination of evaporated die forging hammers and press die forging, with a low degree of automation. For die forging of small and medium-sized parts, die forging hammers still account for the majority, basically The above is manual operation, hammer die forging manipulators are rarely used in practice, and high-speed automatic hot forging machines mainly rely on imports.
With the development of my country's industrial technology level, especially the rapid development of the automobile industry represented by cars, the output and quality of automobile parts have been continuously improved. However, we must be clearly aware that there is still a big gap between China and the international advanced level. With China's accession to the WTO, major international automobile companies will inevitably have a serious impact on the Chinese automobile industry, and competition among domestic peers will also become increasingly fierce. The development of China's automobile industry cannot be separated from the strong support of the equipment industry. The forging equipment manufacturing industry must meet the mass production requirements of the automobile industry and develop in the direction of automation and high efficiency.
Large-scale free forging is developing toward CNC, high-precision, and specialization; precision forging and cold-temperature extrusion are gradually replacing small and medium-sized free forgings.
Vigorously develop press hot die forging automatic line technology.
Automotive body panel stamping is developing towards single-machine in-line automation, especially large-scale multi-station presses. According to foreign experience, companies with an automobile output of more than 150,000 vehicles must use large-scale multi-station presses for continuous automatic stamping to reduce the cost of stamped parts.
It can be believed that whoever masters and uses large-scale multi-station automatic presses first will have a competitive advantage in terms of automobile output, quality, cost, etc. China's forging industry must improve its core competitiveness and technical level, adhere to "Chinese equipment, equip China", develop large-scale multi-station presses with first-class technology, first-class quality, and domestic prices to support the development of the automobile industry and improve the international reputation of the automobile industry. competitiveness and revitalize national industry.
IV. Overview of Jinan No.2 Machine Tool Group Co., Ltd. and the development level of forging equipment
Our Jinan No.2 Machine Tool Group Co., Ltd. was founded in 1937. In the 1950s, we developed China’s first machinery Presses and gantry planers, heavy-duty forging equipment mainly mechanical presses, and metal cutting machine tools represented by milling planers and CNC gantry boring and milling machines have a domestic market share of more than 80% and are exported to more than 40 countries and regions around the world. , known as China’s “King of Forging and Longmen Family”. Now it is one of the 520 key enterprises in the country and a leader in China's forging industry. It has developed six categories of products: forging equipment, CNC machine tools, automation products, casting equipment, environmental protection machinery, and building materials machinery. The company covers an area of ??1.01 million square meters, has 11 production plants, 8 wholly-owned subsidiaries, more than 4,700 employees, including nearly 800 engineering and technical personnel, and total assets of more than 1.1 billion yuan.
Establish a technological innovation mechanism, implement the product development strategy of "automation of forging equipment and CNC metal cutting machine tools", and form and continuously develop core technologies and core products. In order to master the world's advanced forging equipment development and manufacturing technology as soon as possible, we implement high-tech grafting and expand cooperative production and production with nine companies in the United States, Germany, France, Japan, Sweden and other countries, as well as more than ten domestic universities and scientific research institutes. The cooperation between industry, academia and research institutes has accelerated the development of "industrialization" of products, rapidly developed and improved high-tech products such as CNC forging equipment, CNC metal cutting machine tools, and automation equipment, and promoted the diversified development of products. At the same time, we strengthen the construction of national enterprise technology centers and continuously improve our independent technological innovation and development capabilities. We develop and develop forty to fifty new products every year, 90% of which reach the international or domestic advanced level. The output value of technologically advanced products accounts for more than 70% of the new industrial output value. In 2000, it ranked among the top 50 in the comprehensive evaluation of nationally recognized enterprise technology centers. The company was also selected as the first "Top Ten Outstanding Enterprises in China's Machinery Industry" and the "Top Thirty Core Competencies in China's Machinery Industry".
After the introduction of the mechanical press design and manufacturing technology of the American VERSON Company in the 1980s, the stamping automation technology of the American ISI Robot Company was introduced in the 1990s. From 1996 to 2001, it cooperated with Japan's Komatsu Company and Japan's Komatsu Company respectively. Germany's Muller Weingarten Company cooperates to produce large-scale stamping lines, further developing the core technology and core competitiveness of forging equipment, consolidating its dominant position in domestic technology and market, and its products have entered international markets such as Europe and the United States. We also undertook the completion of the national key scientific and technological research plan - "Development of key equipment for stamping automation of large panel parts for cars - loading and unloading machinery", and cooperated in the design of more than 20 single-machine in-line stamping automation production lines such as Shanghai General Motors. Manufacturing, and has achieved a series of results in several key technical fields such as fully automatic mold change technology and fieldbus. The single-machine line automation technology has reached today's international level. Our company also introduced the technical data of the large-scale multi-station press from VERSON Company in the United States, and cooperated with the German Muller Weingarten Company to produce two 2000T multi-station presses and exported them to the North American market. It has developed, designed and manufactured The technical level and capabilities of large multi-station presses. At present, a series of forging equipment and automated auxiliary machines of large, medium and small, medium, high and low-end, various sizes and models have been formed, including: single-acting, double-acting and single-point, double-point and four-point closed mechanical presses, and their compositions Various stamping production lines; fully automatic stamping lines, large multi-station presses; open presses, CNC sheet metal bending machines, CNC shearing machines; cold extrusion machines, multi-station cold extrusion machines, precision pressing machine; stand-alone automatic and connected automatic stamping devices, automatic uncoiling blanking line, turret punch press. At the same time, it has also rapidly developed more than 30 series and more than 100 varieties of CNC machine tools, forming the ability to provide "high-tech CNC packages" and a complete set of equipment for automated stamping workshops.
Implement high-starting transformation and build world-class forging equipment manufacturing capabilities. After the "Seventh Five-Year Plan", "Eighth Five-Year Plan" and "Double Plus Plan" and other technological transformations, more than 300 million yuan has been invested in technological transformation, and the construction of a national-level enterprise technology center has been strengthened, with complete scientific research, design, processing and testing methods. More than 300 pieces (sets) of key equipment and instruments such as large-scale MAAG gear shaping machines and large-scale CNC machine tools have been added, and more than 1,200 pieces of major production equipment have been added. It has 3 press product factories including a world-class heavy-duty press manufacturer, 3 CNC machine tool product factories including a domestic first-class CNC machine tool manufacturer, 3 blank factories including a metal structural parts model factory for the Chinese machine tool industry, and 1 automation The equipment factory and a specialized processing plant have built a strong manufacturing system with an annual production capacity of 570 standard units of various machine tools. It can manufacture super-heavy mechanical presses and heavy-duty metal cutting machine tools with the largest nominal power in the world, becoming a One of the enterprises with the strongest equipment and manufacturing capabilities in the same industry in China.
Promote management innovation and improve the ability to meet market demand. We will deepen human resources management, strengthen political and professional training for cadres and employees, establish a performance-based wage system, and improve the competition and incentive mechanism. Implementing "life engineering" and "quality engineering", establishing and operating a strict quality assurance system, and passing DNV ISO9001 international quality certification, product quality has reached the international advanced level. Implement "Concurrent Engineering" and "Agile Manufacturing Engineering", introduce MRPII, and establish a rapid response mechanism for production. Strengthen product target cost control and quality and price comparison procurement to improve corporate quality. The enterprise's management level and comprehensive strength rank at the forefront of the national machine tool industry, providing reliable management guarantee for manufacturing high-quality and high-level forging equipment.
Relying on core technology and core capabilities, it has provided a large amount of advanced equipment to the domestic market. In recent years, our domestic market share of large and heavy mechanical presses has increased to 90%, and we have introduced to the market high-level forging equipment such as the first fully automatic stamping production line in China and an intelligently controlled first-level precision heavy-duty stamping production line. Since 1997, we have successfully provided 7 high-level heavy-duty stamping lines for General Motors Corporation of the United States and its branches in the United Kingdom, Canada, Thailand, and Shanghai, China through cooperation, pioneering the export of domestic large and heavy-duty forging equipment lines. precedent. In 1998, the presses were exported to the African market in batches. In 2000, we cooperated with the German Muller Weingarten Company and won orders for the third stamping line of Shanghai General Motors Company, two heavy-duty stamping lines of General Motors Company of the United States, and two large multi-station presses in Mexico; Self-operated exports also achieved major breakthroughs. We signed export contracts with German agents for 17 mechanical presses. SC2 series presses began to enter the international market in batches. In particular, the independently designed and manufactured 2,000-ton heavy-duty mechanical presses successfully entered the US market. Marking a major breakthrough in international marketing. In 2000, the total amount of CNC machine tool contracts increased by 350 RMB compared with the previous year. The order amount of large CNC gantry boring and milling machines ranked first in the national machine tool industry. In 2001, the market share further increased. After heavy forging equipment, it became an emerging leading product and won the bid in Shanghai. Maglev trains and other national key engineering projects.
China's accession to the WTO will definitely bring huge opportunities and challenges to China's forging industry and user industries such as automobiles, home appliances, aerospace and aviation, and promote the structural upgrading and development of forging technology, equipment and markets. It is foreseeable that in the near future, automated forging technology will dominate the competitive landscape of China's forging equipment market. Relying on the core capabilities of the enterprise, we have the confidence and determination to work with our social peers to take automation, numerical control, and flexibility as the development direction, use information technology to transform traditional industries, promote the development and upgrading of my country's forging technology and equipment, and strengthen ourselves. While maintaining international competitiveness, it also strongly supports the development of China’s national industries such as automobiles