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Improve the level of equipment to help the gear industry realize the dream of a strong country

Improve the level of equipment to help the gear industry realize the dream of a strong country

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  • Time of issue:2021-09-16
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(Summary description)    In recent years, my country's key industries and key construction projects, such as power generation, high-speed locomotives, mining machinery, large construction machinery, large ships, drilling platforms and aerospace, have increasingly demanded major equipment Gears and their gearboxes also make more and newer demands. After more than 20 years of rapid development, my country has truly become a big country in gear production, but it is still far from the goal of becoming a powerful country. At present, my country's gear industry can not fully meet the supporting requirements of key industries and key projects, and the overall technical level of the industry is only equivalent to the level of developed countries in the late 1990s. Therefore, the manufacture of gears and gearboxes has become a bottleneck restricting the development of a series of major equipment in my country.

During the "Twelfth Five-Year Plan" period, gears and transmissions are listed as development priorities. This is also a critical period for my country to change from a big gear country to a gear power country. The gear industry includes three aspects: industrial gear, vehicle gear and gear equipment manufacturing. The symbol of a gear power country includes not only the first-class gear technology and gear quality, but also the world level of gear manufacturing equipment. In the process of my country's transformation from a gear power country to a gear power country, the level of gear manufacturing equipment is in a key position.

The difference is the driving force

The processing of gears can use a variety of technology from milling, hobbing, gear shaping to grinding. Therefore, we can analyze the current status of my country's gear processing technology and equipment from the perspective of technology, as well as the gap with foreign countries.

Machine tools: --- Milling machine tools. Gear milling machines are rarely used in the processing of small and medium-modulus cylindrical gears because of their low efficiency, but they have been used to a certain extent in the processing of large cylindrical gears, especially the processing of internal gear rings. Due to the small number of extra-large gears, milling is the main method. There are many domestic enterprises producing such machine tools. At present, the gap between domestic gear milling machines and foreign countries is relatively small.

——Gear hobbing machine. Gear hobbing is the main method of cylindrical gear processing, which is used for roughing and semi-finishing, and is suitable for processing various straight and helical gears. The hobbing of large ring gears also shows good prospects. At present, there is a big gap between domestic high-speed gear hobbing machines and large-scale gear hobbing machines and foreign advanced gear hobbing machines.

——Gear shaper. Its efficiency is lower than that of gear hobbing machines, and it is mainly used for the processing of ring gears, double or multiple gears. At present, there is a big gap between the domestic gear shaper level and the world's advanced level.

——Gear grinding machine. Profile grinding and worm grinding are the main ways of finishing medium-module gears; profile grinding is the main form of finishing large cylindrical gears, although 1.2-meter worm grinding machines have appeared. Modern CNC gear grinding machines can realize any three-dimensional topological modification of the tooth surface. The domestic large-scale gear grinding machine market is almost occupied by internationally renowned companies such as Hofler, Niles and Gleason. At present, the gap between domestic medium-modulus gear grinding machines and foreign countries is not large, but the level of large-scale gear grinding machines is far behind that of foreign countries.

Tool: Gear tool consists of three elements: geometric design, material and coating. In general, the domestic gear cutting tool enterprises are still good in the macro design of the cutting tool, but there is a big gap with foreign countries in the detailed design such as modification. Coating is a key element of tool life, and most of the gear tool coating equipment still relies on imports. In addition, more efforts in innovation are required for gear cutters to reach the world's advanced level.

Measuring instruments: foreign countries: the measurement technology of small and medium-sized modulus gears based on the electronic generation method has matured, and the typical instrument CNC gear measurement center has been widely used. Gear measuring center and three-coordinate measuring machine, the measurable gear diameter has reached 6 meters; the gear on-machine measuring system integrated on the gear machine tool has become an integral part of the machine tool (especially the large gear grinding machine); coupled on the gear production line, combined with The rapid sorting and measuring machine for gears with automatic loading and unloading by manipulators has become

Improve the level of equipment to help the gear industry realize the dream of a strong country

(Summary description)    In recent years, my country's key industries and key construction projects, such as power generation, high-speed locomotives, mining machinery, large construction machinery, large ships, drilling platforms and aerospace, have increasingly demanded major equipment Gears and their gearboxes also make more and newer demands. After more than 20 years of rapid development, my country has truly become a big country in gear production, but it is still far from the goal of becoming a powerful country. At present, my country's gear industry can not fully meet the supporting requirements of key industries and key projects, and the overall technical level of the industry is only equivalent to the level of developed countries in the late 1990s. Therefore, the manufacture of gears and gearboxes has become a bottleneck restricting the development of a series of major equipment in my country.

During the "Twelfth Five-Year Plan" period, gears and transmissions are listed as development priorities. This is also a critical period for my country to change from a big gear country to a gear power country. The gear industry includes three aspects: industrial gear, vehicle gear and gear equipment manufacturing. The symbol of a gear power country includes not only the first-class gear technology and gear quality, but also the world level of gear manufacturing equipment. In the process of my country's transformation from a gear power country to a gear power country, the level of gear manufacturing equipment is in a key position.

The difference is the driving force

The processing of gears can use a variety of technology from milling, hobbing, gear shaping to grinding. Therefore, we can analyze the current status of my country's gear processing technology and equipment from the perspective of technology, as well as the gap with foreign countries.

Machine tools: --- Milling machine tools. Gear milling machines are rarely used in the processing of small and medium-modulus cylindrical gears because of their low efficiency, but they have been used to a certain extent in the processing of large cylindrical gears, especially the processing of internal gear rings. Due to the small number of extra-large gears, milling is the main method. There are many domestic enterprises producing such machine tools. At present, the gap between domestic gear milling machines and foreign countries is relatively small.

——Gear hobbing machine. Gear hobbing is the main method of cylindrical gear processing, which is used for roughing and semi-finishing, and is suitable for processing various straight and helical gears. The hobbing of large ring gears also shows good prospects. At present, there is a big gap between domestic high-speed gear hobbing machines and large-scale gear hobbing machines and foreign advanced gear hobbing machines.

——Gear shaper. Its efficiency is lower than that of gear hobbing machines, and it is mainly used for the processing of ring gears, double or multiple gears. At present, there is a big gap between the domestic gear shaper level and the world's advanced level.

——Gear grinding machine. Profile grinding and worm grinding are the main ways of finishing medium-module gears; profile grinding is the main form of finishing large cylindrical gears, although 1.2-meter worm grinding machines have appeared. Modern CNC gear grinding machines can realize any three-dimensional topological modification of the tooth surface. The domestic large-scale gear grinding machine market is almost occupied by internationally renowned companies such as Hofler, Niles and Gleason. At present, the gap between domestic medium-modulus gear grinding machines and foreign countries is not large, but the level of large-scale gear grinding machines is far behind that of foreign countries.

Tool: Gear tool consists of three elements: geometric design, material and coating. In general, the domestic gear cutting tool enterprises are still good in the macro design of the cutting tool, but there is a big gap with foreign countries in the detailed design such as modification. Coating is a key element of tool life, and most of the gear tool coating equipment still relies on imports. In addition, more efforts in innovation are required for gear cutters to reach the world's advanced level.

Measuring instruments: foreign countries: the measurement technology of small and medium-sized modulus gears based on the electronic generation method has matured, and the typical instrument CNC gear measurement center has been widely used. Gear measuring center and three-coordinate measuring machine, the measurable gear diameter has reached 6 meters; the gear on-machine measuring system integrated on the gear machine tool has become an integral part of the machine tool (especially the large gear grinding machine); coupled on the gear production line, combined with The rapid sorting and measuring machine for gears with automatic loading and unloading by manipulators has become

  • Categories:news
  • Author:
  • Origin:
  • Time of issue:2021-09-16
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Information

    In recent years, my country's key industries and key construction projects, such as power generation, high-speed locomotives, mining machinery, large construction machinery, large ships, drilling platforms and aerospace, have increasingly demanded major equipment Gears and their gearboxes also make more and newer demands. After more than 20 years of rapid development, my country has truly become a big country in gear production, but it is still far from the goal of becoming a powerful country. At present, my country's gear industry can not fully meet the supporting requirements of key industries and key projects, and the overall technical level of the industry is only equivalent to the level of developed countries in the late 1990s. Therefore, the manufacture of gears and gearboxes has become a bottleneck restricting the development of a series of major equipment in my country.

During the "Twelfth Five-Year Plan" period, gears and transmissions are listed as development priorities. This is also a critical period for my country to change from a big gear country to a gear power country. The gear industry includes three aspects: industrial gear, vehicle gear and gear equipment manufacturing. The symbol of a gear power country includes not only the first-class gear technology and gear quality, but also the world level of gear manufacturing equipment. In the process of my country's transformation from a gear power country to a gear power country, the level of gear manufacturing equipment is in a key position.

The difference is the driving force

The processing of gears can use a variety of technology from milling, hobbing, gear shaping to grinding. Therefore, we can analyze the current status of my country's gear processing technology and equipment from the perspective of technology, as well as the gap with foreign countries.

Machine tools: --- Milling machine tools. Gear milling machines are rarely used in the processing of small and medium-modulus cylindrical gears because of their low efficiency, but they have been used to a certain extent in the processing of large cylindrical gears, especially the processing of internal gear rings. Due to the small number of extra-large gears, milling is the main method. There are many domestic enterprises producing such machine tools. At present, the gap between domestic gear milling machines and foreign countries is relatively small.

——Gear hobbing machine. Gear hobbing is the main method of cylindrical gear processing, which is used for roughing and semi-finishing, and is suitable for processing various straight and helical gears. The hobbing of large ring gears also shows good prospects. At present, there is a big gap between domestic high-speed gear hobbing machines and large-scale gear hobbing machines and foreign advanced gear hobbing machines.

——Gear shaper. Its efficiency is lower than that of gear hobbing machines, and it is mainly used for the processing of ring gears, double or multiple gears. At present, there is a big gap between the domestic gear shaper level and the world's advanced level.

——Gear grinding machine. Profile grinding and worm grinding are the main ways of finishing medium-module gears; profile grinding is the main form of finishing large cylindrical gears, although 1.2-meter worm grinding machines have appeared. Modern CNC gear grinding machines can realize any three-dimensional topological modification of the tooth surface. The domestic large-scale gear grinding machine market is almost occupied by internationally renowned companies such as Hofler, Niles and Gleason. At present, the gap between domestic medium-modulus gear grinding machines and foreign countries is not large, but the level of large-scale gear grinding machines is far behind that of foreign countries.

Tool: Gear tool consists of three elements: geometric design, material and coating. In general, the domestic gear cutting tool enterprises are still good in the macro design of the cutting tool, but there is a big gap with foreign countries in the detailed design such as modification. Coating is a key element of tool life, and most of the gear tool coating equipment still relies on imports. In addition, more efforts in innovation are required for gear cutters to reach the world's advanced level.

Measuring instruments: foreign countries: the measurement technology of small and medium-sized modulus gears based on the electronic generation method has matured, and the typical instrument CNC gear measurement center has been widely used. Gear measuring center and three-coordinate measuring machine, the measurable gear diameter has reached 6 meters; the gear on-machine measuring system integrated on the gear machine tool has become an integral part of the machine tool (especially the large gear grinding machine); coupled on the gear production line, combined with The rapid sorting and measuring machine for gears with automatic loading and unloading by manipulators has become the leading equipment for on-site measurement of vehicle gears.

Domestic: The middle modulus gear measurement center is relatively mature, the measurement accuracy is stable at level 4, and some projects can reach level 3; the measurable gear diameter of the largest gear measurement center is 2 meters; the integrated on-machine measurement system is in the research and development stage; coupling The gear quick sorting and measuring machine on the vehicle gear production line has been put into production; my country's original gear overall error measuring instrument has not been developed for nearly 20 years, and its traditional application market is constantly shrinking; there is no coordinate measuring machine that meets gear measurement, and small molds Almost all gear measuring instruments and large gear measuring instruments are imported.

The measurement of micro gears and extra large gears (more than 6 meters in diameter) is a technical problem at home and abroad, and is being explored. The transmission of large gear values ​​is a worldwide problem.

The stronger the equipment, the stronger the gear

At present, my country's complete sets of gear processing equipment have made great progress in terms of appearance, specifications, and main functions, and successfully solved the problem of starting from scratch; especially the major national science and technology projects ("High-end CNC machine tools and basic manufacturing equipment"). ”) support for gear manufacturing equipment has narrowed the gap between the level of some gear equipment in my country and the world’s top products. However, there are still gaps in some gear manufacturing equipment in our country, and the existing equipment still has a big gap in reliability, stability, precision retention, processing efficiency, intelligence level and other aspects. Systematic process research and technological innovation need to be carried out at multiple levels.

In view of the existing gap and the demand for key process equipment for future gear product manufacturing, my country's "Gear Engineering Technology Roadmap" lists the development goals of key process equipment for gear processing:

Develop high-precision, high-efficiency, large-scale CNC cylindrical gear grinding machines and bevel gear grinding machines to change the situation that large and high-end gear grinding machines in my country rely on imports.

Develop dry hobbing machine and hard tooth surface hobbing machine, and develop special milling machine tools such as large bevel gear milling machine.

Develop high-efficiency gear hobbing tools, develop tool coating materials and technologies, and expand the application of carbide and CBN tools; develop gear grinding wheels with high material removal rate, long service life and low dressing frequency.

Develop high-end CNC induction hardening machine tools, and develop new intelligent, high-efficiency, low-consumption, environmentally friendly gear carburizing, nitriding and other heat treatment equipment.

Develop a super-large gear in-situ measurement system based on laser tracking measurement technology and indoor lidar technology, develop a micro-gear measuring machine based on optical fiber probes, and develop a combination of robotic loading and unloading. machine etc.

Cooperation from top to bottom to promote common development

After hard work in the future, breaking through high-end product technology, making my country's gear product quality reach the international level, completing the transformation from a gear manufacturing country to a gear power country, and then making my country a major exporter of gear products in the world, this is the strategy of China's gear industry. Task.

In order to complete this arduous task, support and efforts from the government, industry and enterprises are needed, and the gear industry and enterprises themselves need to continue to innovate independently. Specifically include the following aspects:

Advocate a collaborative innovation model of "government-industry-university-research application" combined with enterprises as the mainstay, and organize joint research, and establish an industry-university-research alliance. my country's gear industry should form a basic research, product development, process and equipment development system under the conditions of a market economy.

Accelerate the formulation of gear standards and form a system.

Establish a common technical service platform for the gear industry, accelerate the promotion and application of new technologies, new processes, and advanced standards, and improve the industry's innovation capabilities.

Establish a gear product testing and reliability service platform.

Implement brand strategy. This is an important means to establish a corporate image, and it is also the only way for China's gear industry to become stronger and go global.

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