Abstract 1. The challenge of intelligentization of basic manufacturing technology 1. The development status of basic manufacturing technology (casting, forging, welding, heat treatment) Industrial characteristics: The process is more and more complex, the material strength is getting higher and higher; China's production scale ranks first in the world. Main gap: quality...
Intelligentization is an important symbol of upgrading the manufacturing industry In 2009, the Chinese Academy of Sciences released the 2050 scientific development roadmap: "Intelligent Manufacturing System Based on Ubiquitous Information"
In 2011, China Mechanical Engineering Society released "China Mechanical Engineering Technology Roadmap": Intelligent Manufacturing
In 2012, the Chinese Academy of Engineering launched a strategic emerging industry planning study, and intelligent manufacturing equipment was listed as one of the 18 key strategic industries.
In 2013, the Chinese Academy of Engineering undertook the State Council's Consultation Report on Manufacturing Powers, and made intelligence a major strategy for manufacturing power.
First, the challenge of intelligentization of basic manufacturing technology
1. Development status of basic manufacturing technology (casting, forging, welding, heat treatment)
Industrial characteristics: the process is more and more complex, the material strength is getting higher and higher; China's production scale ranks first in the world;
The main gaps: poor quality stability, large material waste, high energy consumption, and serious pollution.
The urgent need for basic manufacturing technology jumps: many processes still rely on experience, and energy consumption is a serious phenomenon. Casting: The energy consumption of castings is 1.5~2 times that of similar technology in developed countries; the total pollution emission per ton of castings is 3~5 times that of developed countries; the qualification rate of single-crystal blades for aerospace engines is <30%, and 80% for foreign countries. Technology is lagging behind the international advanced level 1~1.5 generations; forging: large forging material utilization rate 30%~55%, Korea 60%~65%, Japan up to 70%~75%; forging automatic line: US 5085, Japan 9000 6,130 in Germany, 300 in China; welding: the proportion of automated welding equipment is 45~50%, the United States is more than 80%, Japan has reached 90%; heat treatment: efficient, high quality, energy saving, environmentally friendly controlled atmosphere furnace and The proportion of total heat treatment equipment such as vacuum furnaces is less than 20%; more than 80% in advanced industrial countries.
Development goal: Through digitalization and intelligence, the precision of parts manufacturing has been greatly improved; by 2020, it has reached the same level as developed countries in terms of energy consumption and material utilization.
2. The technical challenge of basic manufacturing intelligence
Large-scale structure: resulting in increased process parameters in the workspace;
Process compounding: lead to multi-energy field manufacturing process parameters coupling, variable strength hot stamping boron steel forming (heating, coating, controlled cooling, in-mold stamping quenching);
Flexibility of equipment: difficulties in system coordination control of the manufacturing process, multi-point stretch forming machine, single-point incremental forming machine;
High material strengthening: QP steel, DP steel >1000Mpa, rolling unequal thick plate or tailor welded plate results in non-uniform thickness, material forming rules are complex;
The structure is complicated: the structure function is enhanced, the shape is complex, and the processing difficulty is greatly increased;
Shape integration: High-end manufacturing requires comprehensive control of the shape and performance of components, which improves the difficulty of process design.
3. The connotation of intelligent basic manufacturing technology
Integrate sensors and intelligent decision-making software with equipment to realize perception, analysis, reasoning, decision-making, and control functions, so that the process can adapt to changes in the manufacturing environment. Among them, the sensing detection should reach the equipment operation monitoring and manufacturing quality inspection; the process design should reach: process intelligent creation, real-time process planning; control execution should be achieved: equipment automatic control, equipment flexible operation.
Second, the understanding of the basic manufacturing intelligence
Definition of intelligent manufacturing: Intelligent manufacturing is a comprehensive technology that studies information perception and analysis, knowledge expression and learning, and intelligent decision-making and execution in manufacturing activities. It mainly includes three aspects: intelligent manufacturing equipment, intelligent manufacturing system, and intelligent manufacturing service. Its goal is to improve manufacturing efficiency and quality and reduce manufacturing costs. Intelligent manufacturing is the main content of German Industry 4.0.
The research focus of basic manufacturing intelligent technology : the basic manufacturing process is complex, there are many uncontrollable links, the process design relies on experience accumulation, and it is necessary to study the evolutionary process knowledge base model to achieve reasonable reasoning and decision making; the basic manufacturing working conditions are harsh, the process In the process, the shape and performance parameters lack real-time detection means, and online information collection is particularly difficult, and special sensing equipment (high temperature resistance) needs to be studied.
Research layout of key core technologies for basic intelligent manufacturing : Sensing detection of manufacturing processes: lack of real-time and in-situ measurement methods for key control information; process planning and decision-making: lack of online real-time process planning capability for time-varying processes; adaptive control execution : Closed-loop control of shape accuracy and physical properties.
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