1、數控技術和裝備發展趨勢及對策裝備工業的技術水平和現代化程度決定著整個國民經濟的水平和現代化程度，數控技術及裝備是發展新興高新技術產業和尖端工業（如信息技術及其產業、生物技術及其產業、航空、航天等國防工業產業）的使能技術和最基本的裝備。馬克思曾經說過“各種經濟時代的區別，不在于生產什么，而在于怎樣生產，用什么勞動資料生產”。制造技術和裝備就是人類生產活動的最基本的生產資料，而數控技術又是當今先進制造技術和裝備最為核心的技術。當今世界各國制造業廣泛采用數控技術，以提高制造能力和水平，提高對動態多變市場的適應能力和競爭能力。此外，世界上各工業發達國家還將數控技術及數控裝備列為國家的戰略物資，不僅采取

2、重大措施來發展自己的數控技術及其產業，而且在“高精尖”數控關鍵技術和裝備方面對我國實行封鎖和限制政策。總之，大力發展以數控技術為核心的先進制造技術已成為世界各發達國家加速經濟發展、提高綜合國力和國家地位的重要途徑。數控技術是用數字信息對機械運動和工作過程進行控制的技術，數控裝備是以數控技術為代表的新技術對傳統制造產業和新興制造業的滲透形成的機電一體化產品，即所謂的數字化裝備，其技術范圍覆蓋很多領域：(1)機械制造技術；(2)信息處理、加工、傳輸技術；(3)自動控制技術；(4)伺服驅動技術；(5)傳感器技術；(6)軟件技術等。1 數控技術的發展趨勢數控技術的應用不但給傳統制造業帶來了革命性的變化

3、，使制造業成為工業化的象征，而且隨著數控技術的不斷發展和應用領域的擴大，他對國計民生的一些重要行業（it、汽車、輕工、醫療等）的發展起著越來越重要的作用，因為這些行業所需裝備的數字化已是現代發展的大趨勢。從目前世界上數控技術及其裝備發展的趨勢來看，其主要研究熱點有以下幾個方面14。1.1 高速、高精加工技術及裝備的新趨勢效率、質量是先進制造技術的主體。高速、高精加工技術可極大地提高效率，提高產品的質量和檔次，縮短生產周期和提高市場競爭能力。為此日本先端技術研究會將其列為5大現代制造技術之一，國際生產工程學會（cirp）將其確定為21世紀的中心研究方向之一。在轎車工業領域，年產30萬輛的生產節拍

4、是40秒/輛，而且多品種加工是轎車裝備必須解決的重點問題之一；在航空和宇航工業領域，其加工的零部件多為薄壁和薄筋，剛度很差，材料為鋁或鋁合金，只有在高切削速度和切削力很小的情況下，才能對這些筋、壁進行加工。近來采用大型整體鋁合金坯料“掏空”的方法來制造機翼、機身等大型零件來替代多個零件通過眾多的鉚釘、螺釘和其他聯結方式拼裝，使構件的強度、剛度和可靠性得到提高。這些都對加工裝備提出了高速、高精和高柔性的要求。從emo2001展會情況來看，高速加工中心進給速度可達80m/min，甚至更高，空運行速度可達100m/min左右。目前世界上許多汽車廠，包括我國的上海通用汽車公司，已經采用以高速加工中心組

5、成的生產線部分替代組合機床。美國cincinnati公司的hypermach機床進給速度最大達60m/min，快速為100m/min，加速度達2g，主軸轉速已達60 000r/min。加工一個薄壁飛機零件，只用30min，而同樣的零件在一般高速銑床加工需3h，在普通銑床加工需8h；德國dmg公司的雙主軸車床的主軸速度及加速度分別達120000r/mm和1g。在加工精度方面，近10年來，普通級數控機床的加工精度已由10m提高到5m，精密級加工中心則從35m，提高到11.5m，并且超精密加工精度已開始進入納米級(0.01m)。在可靠性方面，國外數控裝置的mtbf值已達6 000h以上，伺服系統的m

6、tbf值達到30000h以上，表現出非常高的可靠性。為了實現高速、高精加工，與之配套的功能部件如電主軸、直線電機得到了快速的發展，應用領域進一步擴大。1.2 五軸聯動加工和復合加工機床快速發展采用5軸聯動對三維曲面零件的加工，可用刀具最佳幾何形狀進行切削，不僅光潔度高，而且效率也大幅度提高。一般認為，1臺5軸聯動機床的效率可以等于2臺3軸聯動機床，特別是使用立方氮化硼等超硬材料銑刀進行高速銑削淬硬鋼零件時，5軸聯動加工可比3軸聯動加工發揮更高的效益。但過去因5軸聯動數控系統、主機結構復雜等原因，其價格要比3軸聯動數控機床高出數倍，加之編程技術難度較大，制約了5軸聯動機床的發展。當前由于電主軸的

7、出現，使得實現5軸聯動加工的復合主軸頭結構大為簡化，其制造難度和成本大幅度降低，數控系統的價格差距縮小。因此促進了復合主軸頭類型5軸聯動機床和復合加工機床（含5面加工機床）的發展。在emo2001展會上，新日本工機的5面加工機床采用復合主軸頭，可實現4個垂直平面的加工和任意角度的加工，使得5面加工和5軸加工可在同一臺機床上實現，還可實現傾斜面和倒錐孔的加工。德國dmg公司展出dmuvoution系列加工中心，可在一次裝夾下實現5面加工和5軸聯動加工，可由cnc系統控制或cad/cam直接或間接控制。1.3 智能化、開放式、網絡化成為當代數控系統發展的主要趨勢21世紀的數控裝備將是具有一定智能化

8、的系統，智能化的內容包括在數控系統中的各個方面：為追求加工效率和加工質量方面的智能化，如加工過程的自適應控制，工藝參數自動生成；為提高驅動性能及使用連接方便的智能化，如前饋控制、電機參數的自適應運算、自動識別負載自動選定模型、自整定等；簡化編程、簡化操作方面的智能化，如智能化的自動編程、智能化的人機界面等；還有智能診斷、智能監控方面的內容、方便系統的診斷及維修等。為解決傳統的數控系統封閉性和數控應用軟件的產業化生產存在的問題。目前許多國家對開放式數控系統進行研究，如美國的ngc(the next generation work-station/machine control)、歐共體的osac

9、a(open system architecture for control within automation systems)、日本的osec(open system environment for controller)，中國的onc(open numerical control system)等。數控系統開放化已經成為數控系統的未來之路。所謂開放式數控系統就是數控系統的開發可以在統一的運行平臺上，面向機床廠家和最終用戶，通過改變、增加或剪裁結構對象（數控功能），形成系列化，并可方便地將用戶的特殊應用和技術訣竅集成到控制系統中，快速實現不同品種、不同檔次的開放式數控系統，形成具有鮮明個性

10、的名牌產品。目前開放式數控系統的體系結構規范、通信規范、配置規范、運行平臺、數控系統功能庫以及數控系統功能軟件開發工具等是當前研究的核心。網絡化數控裝備是近兩年國際著名機床博覽會的一個新亮點。數控裝備的網絡化將極大地滿足生產線、制造系統、制造企業對信息集成的需求，也是實現新的制造模式如敏捷制造、虛擬企業、全球制造的基礎單元。國內外一些著名數控機床和數控系統制造公司都在近兩年推出了相關的新概念和樣機，如在emo2001展中，日本山崎馬扎克（mazak)公司展出的“cyberproduction center”（智能生產控制中心，簡稱cpc)；日本大隈（okuma）機床公司展出“it plaza”

11、（信息技術廣場，簡稱it廣場)；德國西門子(siemens)公司展出的open manufacturing environment（開放制造環境，簡稱ome）等，反映了數控機床加工向網絡化方向發展的趨勢。1.4 重視新技術標準、規范的建立1.4.1 關于數控系統設計開發規范如前所述，開放式數控系統有更好的通用性、柔性、適應性、擴展性，美國、歐共體和日本等國紛紛實施戰略發展計劃，并進行開放式體系結構數控系統規范(omac、osaca、osec)的研究和制定，世界3個最大的經濟體在短期內進行了幾乎相同的科學計劃和規范的制定，預示了數控技術的一個新的變革時期的來臨。我國在2000年也開始進行中國的o

12、nc數控系統的規范框架的研究和制定。1.4.2 關于數控標準數控標準是制造業信息化發展的一種趨勢。數控技術誕生后的50年間的信息交換都是基于iso6983標準，即采用g，m代碼描述如何（how）加工，其本質特征是面向加工過程，顯然，他已越來越不能滿足現代數控技術高速發展的需要。為此，國際上正在研究和制定一種新的cnc系統標準iso14649（stepnc)，其目的是提供一種不依賴于具體系統的中性機制，能夠描述產品整個生命周期內的統一數據模型，從而實現整個制造過程，乃至各個工業領域產品信息的標準化。step-nc的出現可能是數控技術領域的一次革命，對于數控技術的發展乃至整個制造業，將產生深遠的影

13、響。首先，step-nc提出一種嶄新的制造理念，傳統的制造理念中，nc加工程序都集中在單個計算機上。而在新標準下，nc程序可以分散在互聯網上，這正是數控技術開放式、網絡化發展的方向。其次，step-nc數控系統還可大大減少加工圖紙（約75）、加工程序編制時間（約35）和加工時間（約50）。目前，歐美國家非常重視step-nc的研究，歐洲發起了step-nc的ims計劃(1999.1.12001.12.31)。參加這項計劃的有來自歐洲和日本的20個cad/cam/capp/cnc用戶、廠商和學術機構。美國的step tools公司是全球范圍內制造業數據交換軟件的開發者，他已經開發了用作數控機床加

14、工信息交換的超級模型(super model)，其目標是用統一的規范描述所有加工過程。目前這種新的數據交換格式已經在配備了siemens、fidia以及歐洲osaca-nc數控系統的原型樣機上進行了驗證。2 對我國數控技術及其產業發展的基本估計我國數控技術起步于1958年，近50年的發展歷程大致可分為3個階段：第一階段從1958年到1979年，即封閉式發展階段。在此階段，由于國外的技術封鎖和我國的基礎條件的限制，數控技術的發展較為緩慢。第二階段是在國家的“六五”、“七五”期間以及“八五”的前期，即引進技術，消化吸收，初步建立起國產化體系階段。在此階段，由于改革開放和國家的重視，以及研究開發環境

15、和國際環境的改善，我國數控技術的研究、開發以及在產品的國產化方面都取得了長足的進步。第三階段是在國家的“八五”的后期和“九五”期間，即實施產業化的研究，進入市場競爭階段。在此階段，我國國產數控裝備的產業化取得了實質性進步。在“九五”末期，國產數控機床的國內市場占有率達50，配國產數控系統（普及型）也達到了10。縱觀我國數控技術近50年的發展歷程，特別是經過4個5年計劃的攻關，總體來看取得了以下成績。a. 奠定了數控技術發展的基礎，基本掌握了現代數控技術。我國現在已基本掌握了從數控系統、伺服驅動、數控主機、專機及其配套件的基礎技術，其中大部分技術已具備進行商品化開發的基礎，部分技術已商品化、產業

16、化。b. 初步形成了數控產業基地。在攻關成果和部分技術商品化的基礎上，建立了諸如華中數控、航天數控等具有批量生產能力的數控系統生產廠。蘭州電機廠、華中數控等一批伺服系統和伺服電機生產廠以及北京第一機床廠、濟南第一機床廠等若干數控主機生產廠。這些生產廠基本形成了我國的數控產業基地。c. 建立了一支數控研究、開發、管理人才的基本隊伍。雖然在數控技術的研究開發以及產業化方面取得了長足的進步，但我們也要清醒地認識到，我國高端數控技術的研究開發，尤其是在產業化方面的技術水平現狀與我國的現實需求還有較大的差距。雖然從縱向看我國的發展速度很快，但橫向比（與國外對比）不僅技術水平有差距，在某些方面發展速度也有

17、差距，即一些高精尖的數控裝備的技術水平差距有擴大趨勢。從國際上來看，對我國數控技術水平和產業化水平估計大致如下。a. 技術水平上，與國外先進水平大約落后1015年，在高精尖技術方面則更大。b. 產業化水平上，市場占有率低，品種覆蓋率小，還沒有形成規模生產；功能部件專業化生產水平及成套能力較低；外觀質量相對差；可靠性不高，商品化程度不足；國產數控系統尚未建立自己的品牌效應，用戶信心不足。c. 可持續發展的能力上，對競爭前數控技術的研究開發、工程化能力較弱；數控技術應用領域拓展力度不強；相關標準規范的研究、制定滯后。分析存在上述差距的主要原因有以下幾個方面。a. 認識方面。對國產數控產業進程艱巨性

18、、復雜性和長期性的特點認識不足；對市場的不規范、國外的封鎖加扼殺、體制等困難估計不足；對我國數控技術應用水平及能力分析不夠。b. 體系方面。從技術的角度關注數控產業化問題的時候多，從系統的、產業鏈的角度綜合考慮數控產業化問題的時候少；沒有建立完整的高質量的配套體系、完善的培訓、服務網絡等支撐體系。c. 機制方面。不良機制造成人才流失，又制約了技術及技術路線創新、產品創新，且制約了規劃的有效實施，往往規劃理想，實施困難。d. 技術方面。企業在技術方面自主創新能力不強，核心技術的工程化能力不強。機床標準落后，水平較低，數控系統新標準研究不夠。3 對我國數控技術和產業化發展的戰略思考3.1 戰略考慮

19、我國是制造大國，在世界產業轉移中要盡量接受前端而不是后端的轉移，即要掌握先進制造核心技術，否則在新一輪國際產業結構調整中，我國制造業將進一步“空芯”。我們以資源、環境、市場為代價，交換得到的可能僅僅是世界新經濟格局中的國際“加工中心”和“組裝中心”，而非掌握核心技術的制造中心的地位，這樣將會嚴重影響我國現代制造業的發展進程。我們應站在國家安全戰略的高度來重視數控技術和產業問題，首先從社會安全看，因為制造業是我國就業人口最多的行業，制造業發展不僅可提高人民的生活水平，而且還可緩解我國就業的壓力，保障社會的穩定；其次從國防安全看，西方發達國家把高精尖數控產品都列為國家的戰略物質，對我國實現禁運和限

20、制，“東芝事件”和“考克斯報告”就是最好的例證。3.2 發展策略從我國基本國情的角度出發，以國家的戰略需求和國民經濟的市場需求為導向，以提高我國制造裝備業綜合競爭能力和產業化水平為目標，用系統的方法，選擇能夠主導21世紀初期我國制造裝備業發展升級的關鍵技術以及支持產業化發展的支撐技術、配套技術作為研究開發的內容，實現制造裝備業的跨躍式發展。強調市場需求為導向，即以數控終端產品為主，以整機（如量大面廣的數控車床、銑床、高速高精高性能數控機床、典型數字化機械、重點行業關鍵設備等）帶動數控產業的發展。重點解決數控系統和相關功能部件（數字化伺服系統與電機、高速電主軸系統和新型裝備的附件等）的可靠性和生

21、產規模問題。沒有規模就不會有高可靠性的產品；沒有規模就不會有價格低廉而富有競爭力的產品；當然，沒有規模中國的數控裝備最終難以有出頭之日。在高精尖裝備研發方面，要強調產、學、研以及最終用戶的緊密結合，以“做得出、用得上、賣得掉”為目標，按國家意志實施攻關，以解決國家之急需。在競爭前數控技術方面，強調創新，強調研究開發具有自主知識產權的技術和產品，為我國數控產業、裝備制造業乃至整個制造業的可持續發展奠定基礎。numerical control technology and equipping development trend and countermeasure equip the engine

22、ering levelnumerical control technology and equipping development trend and countermeasureequip the engineering level, level of determining the whole national economy of the modernized degree and modernized degree of industry, numerical control technology is it develop new developing new high-tech i

23、ndustry and most advanced industry to equip (such as information technology and his industry, biotechnology and his industry, aviation, spaceflight, etc. national defense industry) last technology and getting more basic most equipment. marx has ever said the differences of different economic times,

24、do not lie in what is produced, and lie in how to produce, produce with some means of labor . manufacturing technology and equipping the most basic means of production that are that the mankind produced the activity, and numerical control technology is nowadays advanced manufacturing technology and

25、equips the most central technology. nowadays the manufacturing industry all around the world adopts numerical control technology extensively, in order to improve manufacturing capacity and level, improve the adaptive capacity and competitive power to the changeable market of the trends. in addition

26、every industrially developed country in the world also classifies the technology and numerical control equipment of numerical control as the strategic materials of the country, not merely take the great measure to develop ones own numerical control technology and industry, and implement blockading a

27、nd restrictive policy to our country in view of high-grade, precision and advanced key technology of numerical control and equipping. in a word, develop the advanced manufacturing technology taking numerical control technology as the core and already become every world developed country and accelera

28、te economic development in a more cost-effective manner, important way to improve the overall national strength and national position. numerical control technology is the technology controlled to mechanical movement and working course with digital information, integrated products of electromechanics

29、 that the numerical control equipment is the new technology represented by numerical control technology forms to the manufacture industry of the tradition and infiltration of the new developing manufacturing industry, namely the so-called digitization is equipped, its technological range covers a lo

30、t of fields: (1)mechanical manufacturing technology; (2)information processing, processing, transmission technology; (3)automatic control technology; (4)servo drive technology; (5)technology of the sensor; (6)software engineering ,etc. development trend of a numerical control technologythe applicati

31、on of numerical control technology has not only brought the revolutionary change to manufacturing industry of the tradition, make the manufacturing industry become the industrialized symbol , and with the constant development of numerical control technology and enlargement of the application, the de

32、velopment of some important trades (it , automobile , light industry , medical treatment ,etc. ) to the national economy and the peoples livelihood of his plays a more and more important role, because the digitization that these trades needed to equip has already been the main trend of modern develo

33、pment. numerical control technology in the world at present and equipping the development trend to see, there is the following several respect 1- in its main research focus. 1 a high-speed, high finish machining technology and new trend equippedthe efficiency, quality are subjavanufacturing technolo

34、gy. high-speed, high finish machining technology can raise the efficiency greatly , improve the quality and grade of the products, shorten production cycle and improve the market competitive power. japan carries the technological research association first to classify it as one of the 5 great modern

35、 manufacturing technologies for this, learn (cirp) to confirm it as the centre in the 21st century and study one of the directions in international production engineering. in the field of car industry, produce one second when beat such as production of 300,000 / vehicle per year, and many variety pr

36、ocess it is car that equip key problem that must be solved one of; in the fields of aviation and aerospace industry, spare parts of its processing are mostly the thin wall and thin muscle, rigidity is very bad, the material is aluminium or aluminium alloy, only in a situation that cut the speed and

37、cut strength very small high, could process these muscles, walls. adopt large-scale whole aluminium alloy method that blank pay empty make the wing recently, such large-scale parts as the fuselage ,etc. come to substitute a lot of parts to assemble through numerous rivet , screw and other connection

38、 way, make the intensity , rigidity and dependability of the component improved. all these, to processing and equipping the demand which has proposed high-speed, high precise and high flexibility. according to emo2001 exhibition situation, high-speed machining center is it give speed can reach 80m/m

39、in is even high , air transport competent speed can up to 100m/min to be about to enter. a lot of automobile factories in the world at present, including shanghai general motors corporation of our country, have already adopted and substituted and made the lathe up with the production line part that

40、the high-speed machining center makes up. hypermach lathe of u.s.a. cincinnati company enters to nearly biggest 60m/min of speed, it is 100m/min to be fast, the acceleration reaches 2g, the rotational speed of the main shaft has already reached 60 000r/min. processing a thin wall of plane parts, spe

41、nd 30min only, and same part general at a high speed milling machine process and take 3h, the ordinary milling machine is being processed to need 8h; the speed and acceleration of main shaft of dual main shaft lathes of germany dmg company are up to 120000r/mm and 1g. in machining accuracy, the past

42、 10 years, ordinary progression accuse of machining accuracy of lathe bring 5m up to from 10m already, accurate grades of machining center from 35m, rise to 11.5m, and ultraprecision machining accuracy is it enter nanometer grade to begin already (0.01m). in dependability, mtbf value of the foreign

43、numerical control device has already reached above 6 000h, mtbf value of the servo system reaches above 30000h, demonstrate very high dependability . in order to realize high-speed, high finish machining, if the part of function related to it is electric main shaft, straight line electrical machiner

44、y get fast development, the application is expanded further . 1.2 link and process and compound to process the fast development of the lathe in 5 axes adopt 5 axles to link the processing of the three-dimensional curved surface part, can cut with the best geometry form of the cutter , not only highl

45、y polished, but also efficiency improves by a large margin . it is generally acknowledged, the efficiency of an 5 axle gear beds can equal 2 3 axle gear beds, is it wait for to use the cubic nitrogen boron the milling cutter of ultra hard material is milled and pared at a high speed while quenching

46、the hard steel part, 5 axles link and process 3 constant axles to link and process and give play to higher benefit. because such reasons as complicated that 5 axles link the numerical control system , host computer structure that but go over, it is several times higher that its price links the numer

47、ical control lathe than 3 axles , in addition the technological degree of difficulty of programming is relatively great, have restricted the development of 5 axle gear beds. at present because of electric appearance of main shaft, is it realize 5 axle complex main shaft hair structure processed to l

48、ink greatly simplify to make, it makes degree of difficulty and reducing by a large margin of the cost, the price disparity of the numerical control system shrinks. so promoted 5 axle gear beds of head of complex main shaft and compound to process the development of the lathe (process the lathe incl

49、uding 5). at emo2001 exhibition, new japanese 5 of worker machine process lathe adopt complex main shaft hair, can realize the processing of 4 vertical planes and processing of the wanton angle, make 5 times process and 5 axles are processed and can be realized on the same lathe, can also realize th

50、e inclined plane and pour the processing of the hole of awls. germany dmg company exhibits the dmuvoution series machining center, but put and insert and put processing and 5 axles 5 times to link and process in once, can be controlled by cnc system or cad/cam is controlled directly or indirectly. 1

51、.3 become the main trend of systematic development of contemporary numerical control intelligently, openly, networkedly.the numerical control equipment in the 21st century will be sure the intelligent system, the intelligent content includes all respects in the numerical control system: it is intell

52、igent in order to pursue the efficiency of processing and process quality, control such as the self-adaptation of the processing course, the craft parameter is produced automatically; join the convenient one in order to improve the performance of urging and use intelligently, if feedforward control

53、, adaptive operation , electrical machinery of parameter , discern load select models , since exactly makes etc. automatically; the ones that simplified programming , simplified operating aspect are intelligent, for instance intelligent automatic programming , intelligent man-machine interface ,etc.

54、; there are content of intelligence diagnose , intelligent monitoring , diagnosis convenient to be systematic and maintaining ,etc.produce the existing problem for the industrialization of solving the traditional numerical control system sealing and numerical control application software. a lot of c

55、ountries carry on research to the open numerical control system at present, such as ngc of u.s.a. (the next generation work-station/machine control), osaca of european community (open system architecture for control within automation systems), osec (open system environment for controller) of japan,

56、onc (open numerical control system) of china, etc. the numerical control system melts to become the future way of the numerical control system open. the so-called open numerical control system is the development of the numerical control system can be on unified operation platform, face the lathe pro

57、ducer and end user, through changing, increasing or cutting out the structure target(numerical control function), form the serration, and can use users specially conveniently and the technical know-how is integrated in the control system, realize the open numerical control system of different variet

58、y , different grade fast, form leading brand products with distinct distinction. system structure norm of the open numerical control system at present, communication norm , disposing norm , operation platform , numerical control systematic function storehouse and numerical control systematic functio

59、n software development ,etc. are the core of present research. the networked numerical control equipment is a new light spot of the fair of the internationally famous lathe in the past two years. meeting production line , manufacture system , demand for the information integration of manufacturing company networkedly greatly of numerical control equipment, realize new manufacture mode such as quick make ,