Someone’s main concern is, can we produce high-precision machine tools now? The answer is, yes, definitely! But this is under the premise of not too much cost.
As for the development of the industry, the gap with foreign countries, and the problems existing in the industry, we have not paid much attention to it. And it is precisely these problems that are affecting the development direction of this industry.
You’re welcome to say that the overall level of our machine tools is far worse than that of foreign countries. Our common view is that it is about 50 years behind Germany.
Among them, the major gaps that currently appear to be unsolvable in a short period of time mainly include seals, bearings, materials, servo motors, controllers, systems, etc.
In fact, I don’t think these are the main problems in the industry at present and in the future. The reason why this industry is relatively pessimistic now, personally feel that there are mainly the following aspects.
The country does not pay enough attention
Although most of us know that the machine tool industry is the basic industry of all industries, it was removed from the Ministry of Machinery and Electromechanics n years ago. At that time, more than n enterprises became childless children and died off.
why?
The machine tool industry is a large-cycle product. From the design, production, installation, commissioning, acceptance and normal use of a machine tool product, no one will not come in three years (this is a non-standard product).
This is especially true of high-precision machine tools. In the modern market that seeks to maximize profits, it is difficult to do fine work, mainly because companies cannot afford it.
That is to say, even if an enterprise can do a good job in its ability to do fine work, it should not regard it as the highest goal of organizational production, but maximize profit as its highest goal.
The brain drain is serious, because the industry’s treatment is very low
How low is it? The salaries of designers, craftsmen, and technicians are definitely no better than those of a sales lady or a car seller. Most of the salaries of the chief engineer are not as good as those of pharmacies.
However, this industry is a deadly job. There are too many dead brain cells, various diseases such as lumbar discs, rheumatoid arthritis, mouse hands, high blood pressure, and the risks are still great. You think that the machine tool can be accepted. ? Check how many inspection items of a qualified machine tool under the national standard?
Therefore, those who graduated with me or participated in work have started earlier. The sales of resale, the sales of business, the management of business, and the management of technology are still basic. Why? It’s too difficult to make ends meet.
We are designing, but the design is different from the design. The design of the machinery industry, if you have peers, you can express your thoughts.
This is definitely not an easy job. You need enough professional knowledge. You need to make drawings and know the standards. Draw and paint on the black computer screen all day long. The complexity of mechanical drawings is not imaginable by ordinary people, especially machine tools.
However, mechanical design is not valuable. For the same design work, the salary of mechanical design can never be higher than advertising design, animation design, architectural design, and even higher than the design of business cards.
In this state of affairs, younger people have room for maneuver, and no one will be a designer for a lifetime.
Because of the hard work of the older generation of the company, they saw it. When a 50-year-old engineer took a reading glasses to examine the plan, he would never be more comfortable than the 50-year-old demolition farmer who traveled abroad.
Employees who are not above the middle level, but they are old enough to pay more than 5K, just support their families. The social value of doing design work is not much.
A real example:
A female colleague of the company (the machine tool industry generally does not want to see female workers), has been designing for three to four thousand yuan in the company for many years, but later felt that there was no development, went out to sell insurance, less than three years, the monthly salary is already close to 30,000 yuan Do mechanical design, even if you are designing aircraft tanks, the monthly salary is not expected to have these.
The salary determines your social value. Such a salary has decided that no high-end people can live on the cold bench.
The above are social factors.
And in a company, design is not a tall job. Although, as far as products are concerned, design is the source. Without good design, there will be no good products, which everyone knows.
But the reality is that no matter which company, the design is also stepped on the lowest level, the salary is not at the bottom, but it certainly cannot be achieved in the sales, procurement, outsourcing and other departments, and the design is a clean water department, unlike the first three departments. Rebates are leaking out.
What do leaders see? Sales performance is what they care about most, and spending less money is what they care about most. This indirectly led to the loss of design talent within the company.
The unit recruits people every year, the lowest degree of graduate students, of course, the highest is also a graduate student, doctoral students can not recruit, in addition to foreign languages wow wow good, other basically messed up.
Most of the students who have cultivated slightly complicated drawings for more than a year do not understand it (or they don’t want to understand it, because there are few people who do design in Anfen), and they have not been able to undertake projects independently for more than three years… Shaking his head and sighing, the university has learned everything.
They may not know, which subject is not mainly English training now? Professional courses? Just pass it! When looking for a job, you don’t look at your professional courses. Whether the level 4 or 6 is the company’s most concerned.
In addition, many of them have been engaged in design work for a few years. At first glance, there is no future for design work (money), and they will either change jobs or change departments.
In addition, I have participated in several projects in cooperation with colleges and universities. Looking at the Jiebao schemes from those colleges and universities, I can’t help but laugh, but the scheme is not ridiculous and it is not important. The key is to have a national red ticket, colleges have money.
User (market) choice
The machine tool industry is a more pragmatic industry. Without high costs, it is impossible to produce good things.
This is different from the electronics industry or the luxury industry. A fruit phone can cost 8,000 yuan for a mobile phone at a cost of only 2,000 yuan, but the machine tool does not work. You have to meet the accuracy and performance requirements of 2 million machine tools. No matter who does it, you can’t do it. With a cost of only 200,000.
What does that mean?
For example, if a machine tool costs 2 million in Germany and sells 3 million, then the same precision and performance products made by the Chinese must also cost 2 million, and due to various technical limitations, the cost may be much higher To 2 million.
This is what I said at the beginning. It may be able to do it, but it does not care about the cost.
But the question is coming, if the performance accuracy of the two machine tools is basically the same, the price of Germany and China is the same, which one will the user choose? This is like a mobile phone. If Apple sells the same price as Xiaomi, who would you choose?
The boss is not stupid, and the purpose of making money is, “I don’t buy it anyway when I’m done. I’m so good and useful?”
This has been the case for many years, but it has not been difficult to do so at such low quality and low price for the past two years.
why? Because non-native products, such as Wanwan, Bangzai, and Asan’s, in recent years, the prices have been getting lower and lower, and the quality is acceptable. The market share of domestic manufacturers is getting smaller and smaller, so they have to upgrade their industries.
But it’s not clear if you go up or down.
R & D without power
Now calling Industry 4.0, well, what can we do with a robot? The servo motor can’t do well, the rv reducer can’t do it, the cylinder seal can’t do it, system? Don’t think about it, to sell you is to give you face.
I don’t know in this industry, but I can tell you that the machine tool is composed of these seemingly ordinary things, but it is these seemingly ordinary things that we have not done well.
The cylinder is more simple, but a cylinder with a guide rail of 150 strokes in Taiwan costs 2,000 yuan.
The skf seal ring is a big plastic ring at a glance, and the size of 800 is more than 3000.
Fag bearings, with 90 inner diameter, dare to ask for more than 4,000, and they are also available in limited supply.
Sometimes I look angry at these things. Is such a XX thing worth my monthly salary? But there is no way, no need.
What I am pessimistic about is that we do not pay enough attention to these seemingly ordinary things. Will the state pay for professional institutions to engage in plastic circles? I didn’t hear it anyway.
There is a Luo Research Institute for bearings, but the bearings can be used for civilian purposes. Ordinary machine tools are also acceptable. We don’t dare to use Havalo anyway.
Screws, guide rails, servo motor systems, dd motors are specialized institutions, generally colleges and universities, but colleges and universities are mainly for the purpose of writing papers and funding, whether things are good or not, who knows if there is any progress. Anyway, there is no such thing at the moment.
So, this industry is a bit weird now, like these things, such as high-performance bearings, do it yourself, the cost is not as good as foreign use, do not do it yourself, and you are afraid of being strangled by the foreign country, neither enter nor retreat No.
The country also recognizes this, but has not seen a corresponding policy.
Small companies will not have this responsibility. Whoever loves research and development will go, regardless of our business.
For large companies, R&D also costs money, and it is likely to be a bottomless hole, or everything is made, the cost is higher than the selling price of others abroad, so it is also entangled.
Speaking of which, I have to say the fact that our industry, at some level, is not as good as it was before the 1980s. The company’s archives room, full of drawings on the ground floor, had the honour to go through it a few times, that level… not admirable.
Imagine that there was no computer at that time, nor the design software, analysis software, and imitation software that are so good now. All of them were drawn by hand, and they could make such an excellent product.
As we all know, the current machine tool is a typical mechatronics product, and it has been going in and out of electricity, such as a lathe. Now the bedside is basically a servo motor and a power spindle. The old machine tool only changes the headboard speed. The pile of gears and shifting mechanism in the box makes people very big.
From this point of view, China does not lack talents in this area, but for various reasons, talents in this area are no longer bothered to do this boring business.
Therefore, how to develop the Chinese machine tool industry and how to change the status quo is a very worthy question.
Someone misunderstood my intention
I am very confident in the wisdom of our nation. There are indeed problems in this industry, and this is also an objective fact. Some people who raise bar or are not in this industry, it is difficult to explain to you.
To be honest, I have worked in this industry for 15 years, and the feelings for this industry are not comparable to yours. It is because I love this industry that I pay more attention to and worry about the development of this industry.
If I have the mentality of “controlling my farts,” I won’t waste time here.
I always think that it is all kinds of machinery that liberate mankind from the heavy work for survival. The machinery industry is the foundation of all industries, and the machine tool industry is the foundation of the machinery industry.
Think about when we were young, in the 1980s, when the farmers were harvesting in autumn or summer, there was no one month of busy work that could not be completed, but now, you only need to stand by the field and watch the combine harvester. The family is busy for half a month. , The machine can be done in less than an hour.
Now, all of our clothing, food, housing and transportation industries are completed by all kinds of machinery. But in China, the machinery industry is by no means a tall job. It is hard and tiring. It is not decent, and the wages are still low.
Moreover, this trend has intensified in recent years, and it is difficult for companies to recruit people who can concentrate on researching technology. In fact, there is no way for everyone to put it a decade ago and say that you are a senior engineer, but still feel very face-saving. Put it on now and just smile.
It’s not that all people who engage in technology are power eyes. There are also many people like me who still insist on this industry. On the one hand, they like this industry, on the other hand, they like to engage in machinery.
But it can’t be said that there is no idea. Ten years ago, the average salary of engineers was not the highest, but they could eat an average. What about now? The low wage level in this industry is a common phenomenon, not an exception.
Based on the above reasons, there will be a terrible consequence, that is, elite talents rarely or no longer flow into this industry. For an enterprise, it doesn’t matter, if it is enlarged to the whole country?
Such examples have already happened.
A colleague of mine, graduated from graduate school, joined the work in 2008, is definitely a genius of machinery, young man theory is great, computational analysis and simulation are all excellent, clever and clever, many ideas, every colleague is optimistic about him, think he is in this The industry is definitely promising.
But in 15 years, he proposed to resign and went to a copywriting job, because the salary paid by that company was more than double that.
For individuals, it doesn’t matter, earn more money; but for the industry, a talent is lost; for society, training a mechanical graduate to do writing work is not a great waste of social resources ?
Just like the colleague who is going to do insurance, I already knew how to sell insurance, why did you go to university? Four years of wasted time plus four years of tuition fees!
Another example is this year’s college entrance examination for a colleague’s child with a high score. However, when applying for a major, machinery-related majors are not considered at all, because colleagues feel that there is no future in machinery. I believe this is not a minority.
This invisibly blocked the inflow of talent to this industry. If this is a social phenomenon, please think about the development prospects of this industry?
In addition, some people talk about artificial intelligence and 3D printing, I can briefly talk about my personal views, and I will have time to add them in detail.
Mechanical design, so-called design, is because this is a creative work, that is to say, as long as the computer does not have creative thinking, it is basically impossible to complete, at least at this stage, there is no hope.
If you imagine that one day, I will tell the computer what kind of product I need and what kind of functions it needs to meet, then the computer will complete the design work by itself. It is estimated that it will wait until the quantum computer comes out.
3D printing, it is possible to meet the requirements in the future, but not yet.
Because in machinery, the mechanical properties of different parts are different. For example, some parts are tensile, some are compressive, some are shear, some are wear-resistant, and some are fatigue-resistant. Wait.
Some parts even require that the same part does not have different mechanical properties. For example, the most common gears generally require the tooth surface to be very hard, to achieve Rockwell above 58 degrees, because it needs to be wear-resistant, but the root and core Toughness, otherwise it will hit teeth when there is impact.
To know that hardness and toughness are contradictory, so to achieve this requirement must be achieved through reasonable material selection and reasonable heat treatment.
At present, it is still difficult for metal 3D printing to accurately meet the requirements of geometric dimensions (surface roughness and geometric tolerances). At the same time, it is necessary to take into account the material grade and the mechanical properties of parts.
This article does not intend to cause any controversy, and I did not expect to write such a long, just sentimental personal opinion, which is more subjective and is the personal experience of the individual in this industry.
However, from the point of view of reply, many people are not experts, and they are blindly spraying for spraying, which is actually unnecessary.
Because the development of the country is powerful, everyone can see it. We do not deny the great achievements that the country has made, but the problem exists is that it exists, or we feel that it exists because everyone has a different perspective and sees different problems.
In the past ten years, I think the development of the white goods and automobile industries is commendable, especially in the white goods industry. At present, domestic products have absolute advantages, good quality and reasonable prices.
But why is there a dilemma for the machine tool industry as an industrial foundation?
I think this is a matter of industry differences. In the following, I will give you a simple comparison and try not to involve professional terminology. The ability to organize text is not good. I hope I can speak clearly.
Still taking the bearing as an example, it is also conditional to say that domestic bearings are not good. That is for our industry.
Bearings, everyone thinks the structure is very simple, the inner sleeve jacket plus rolling elements, but if I tell you that only deep groove ball bearings (a type of bearing, the most widely used, the industry called 6 series bearings, because the code of these bearings are all If the raceway design starts with 6) can be written as a book, do you think it is simple?
I explained from two applications, one is ordinary car, and the other is ordinary machine tool. Everyone knows that cars currently do not need to be overhauled at 200,000 kilometers, and the bearings do not need to be replaced. Do you think the bearings are very NB?
If we calculate that the car runs 200,000 kilometers, and the average speed of 50km/h is calculated within these 200,000 kilometers (the actual may be much larger than this number), then the life of the bearing can be checked according to 2e5/50=0.4e4= 4000 hours to calculate.
What is the concept of 4000 hours?
If it is placed in the machine tool industry, it means that a machine tool is designed for 8 hours of work per day and has a service life of less than 2 years. Who will design the machine tool in less than 2 years? I’m afraid it’s even difficult to pass.
In fact, the lifespan falls second, and domestic bearings are no problem. The most important ones are the three indicators of accuracy, accuracy retention and reliability.
For the most common lathes, the beating requirement of the spindle of a qualified product will not exceed 2 wires (wire, length unit, 1 wire = 0.01 mm, some places are also called 1 track or 1 dimension, different regions, different statements, a little bit like In other words, 1 silk is approximately equal to one tenth of the diameter of the hair).
Of course, even with such high accuracy, domestically produced Havalo (Haxel, tile, and Luoxu, representing the highest comprehensive level of domestic bearings) can meet the needs.
However, the machine tool also requires that this accuracy be maintained for a long time, either one year or three years. A good machine tool can not change its accuracy even for 10 years. This is challenging for bearings. At present, domestic bearings have to meet these three indicators at the same time, and it seems that there are indeed difficulties.
In addition, for a better machine tool, the spindle’s runout is less than 1 wire, such as an ordinary grinder, which generally requires three thousandths to five thousandths of a millimeter. This is difficult for people outside the industry to have a concept.
In addition, the selection of bearings must also consider the indicators of tolerance consistency, interchangeability, accuracy consistency and other aspects. If the accuracy of a single bearing does not meet the standard, because the machine tool spindle uses a combined shaft system (the spindle has a pile of various Various bearings), if the accuracy of each bearing is up to standard, but the consistency is not good, it will not work.
Speaking of which, do you not understand if we have to purchase foreign bearings at a high price? The scrap bearings that may be removed from the machine tool parts and then installed in the car (if it can be installed) can still be used for 10 years, but the machine tool does not work.
The machine tool’s assessment of the bearing is not a life assessment but a precision assessment. As long as the accuracy of the bearing fails, it means that the function of the machine tool fails.
In the same way, the reducer is also the same. The general energy reducer basically does not check its transmission accuracy, transmission stability, backlash (commonly known as backlash) and other indicators, but it is used on the machine tool, which must be checked, but also Examine the pile of indicators such as accuracy retention and interchangeability. In this way, domestically-made ones are facing challenges again.
Let’s talk about it again, the machinery industry, especially the machine tool industry, is a pragmatic industry that can’t be achieved by shouting slogans.
Moreover, the machine tool is a relatively comprehensive industry, involving the fields of metallurgy, materials, physics, chemistry, electrical, processing, technology, heat treatment, microelectronics, numerical control technology, etc. Problems in any link will affect the overall performance.