348 8英寸鋼管熱浸鍍鋅自動(dòng)生產(chǎn)線設(shè)計(jì)
348 8英寸鋼管熱浸鍍鋅自動(dòng)生產(chǎn)線設(shè)計(jì),英寸,鋼管,鍍鋅,自動(dòng)生產(chǎn)線,設(shè)計(jì)
天津科技大學(xué) 2007 屆本科生畢業(yè)設(shè)計(jì)摘 要本次設(shè)計(jì)的題目是 8 英寸鋼管熱浸鍍鋅自動(dòng)生產(chǎn)線設(shè)計(jì)。它是根據(jù)熱鍍鋅工藝的要求而設(shè)計(jì)的。包括工件運(yùn)輸、工件檢驗(yàn)、酸洗、清水洗、涂溶劑、烘干、熱浸鍍、引出外吹、內(nèi)吹、冷卻、鈍化、打印、包裝等工序。其中熱浸鍍、鈍化是特殊工序；酸洗、涂溶劑是關(guān)鍵工序。本次設(shè)計(jì)中，我具體負(fù)責(zé)鍍鋅機(jī)橫移機(jī)的設(shè)計(jì)。在說(shuō)明書(shū)中，我詳細(xì)介紹了鋼管熱浸鍍鋅自動(dòng)生產(chǎn)線設(shè)備設(shè)計(jì)，以及橫移機(jī)的相關(guān)計(jì)算，如軸的校核，螺紋聯(lián)接的強(qiáng)度計(jì)算等，來(lái)滿足保證設(shè)計(jì)要求。同時(shí)在說(shuō)明書(shū)中也附有大量的圖示以展示重要機(jī)構(gòu)，說(shuō)明其具體結(jié)構(gòu)和它們之間的裝配關(guān)系。說(shuō)明書(shū)中還介紹了關(guān)于這臺(tái)設(shè)備所要注意的環(huán)境保護(hù)等方面的問(wèn)題。關(guān)鍵詞： 鋼管； 熱鍍鋅； 自動(dòng)生產(chǎn)線； 橫移機(jī) 天津科技大學(xué) 2007 屆本科生畢業(yè)設(shè)計(jì)ABSTRACTThe paper is written on the topic of design for steel pipe of hot zinc plating automatic product equipment. It is base on the hot zinc plating technics including workpiece , transportation ,work inspection, pickling, washing ,making inpregnent,, drying, hot plating, draw out, postartum mastitis ,passivation, cooling, printing, packaging. The hot zinc plating and passivation, are the special working procedure, pickling and making inpregnent are pretty crucial work procedure. I take charge of the traverse motion machine designing. Steel pipe of hot zinc plating automatic product equipment is introduced in detail in the paper. The important framework are exemplified to show their interaction and we also concentrate on the environment protecting.Keywords: Steel pipe; Hot galvanizing; Automatic product equipment; Traverse motion machine天津科技大學(xué)實(shí)習(xí)報(bào)告1實(shí) 習(xí) 報(bào) 告今天我們開(kāi)始了 07 屆畢業(yè)生專業(yè)實(shí)習(xí)參觀，早上 8 點(diǎn)我們坐上車首先來(lái)到了天津北星汽車廠。該廠外表不大但是給人的感覺(jué)很干凈很氣派，幾座大大的倉(cāng)庫(kù)式廠房。進(jìn)入了該廠后幾排整齊的奔馳轎車給人感覺(jué)更是氣派。該廠主要致力于為東北、華北地區(qū)的奔馳汽車經(jīng)銷商以及擁護(hù)提供零配件后備支持、車輛維修服務(wù)、整車售前檢測(cè)以及整車銷售服務(wù)。 北京北星行汽車銷售中心是專門從事奔馳汽車銷售咨詢、銷售服務(wù)的專業(yè)公司。公司系北星（天津）汽車有限公司的附屬機(jī)構(gòu)，是德國(guó)奔馳公司在中國(guó)長(zhǎng)江以北地區(qū)唯一授權(quán)代理銷售奔馳汽車全線車型的公司。我們致力于把奔馳汽車及其國(guó)際化標(biāo)準(zhǔn)的銷售服務(wù)理念引入中國(guó)。公司總部位于燕莎商圈。第一分部燕莎展廳毗鄰豪華飯店、使館區(qū)，悠久的歷史，便捷的交通，專業(yè)的銷售人員、力求為顧客提供最優(yōu)質(zhì)的服務(wù)。剛剛建成開(kāi)業(yè)的盈科展廳是目前中國(guó)最大的奔馳汽車展示中心，整體造型及內(nèi)部裝飾均采用德國(guó)奔馳的設(shè)計(jì)風(fēng)格，集展示、洽談、精品收藏等多種功能。格調(diào)高雅、充滿現(xiàn)代感，是一座代表國(guó)際最新汽車服務(wù)方式的展示和銷售場(chǎng)所。公司采用立體的經(jīng)營(yíng)管理模式，配備高素質(zhì)、專業(yè)化和國(guó)際化的人才隊(duì)伍，以完善客戶服務(wù)為首要目標(biāo)，為客戶提供"售前、售中、售后"一站式全程貴賓服務(wù)。我們進(jìn)入了廠房車車間后，更是眼前一亮這里就是奔馳汽車的檢測(cè)車間，奔馳汽車是模塊化設(shè)計(jì)，工人師傅們用電腦連接各個(gè)模塊后電腦自動(dòng)監(jiān)測(cè)各個(gè)模塊的運(yùn)行情況然后返回?cái)?shù)據(jù)，有問(wèn)題的數(shù)據(jù)都會(huì)用問(wèn)號(hào)來(lái)表示。不禁使我感覺(jué)到現(xiàn)代化生產(chǎn)的強(qiáng)大，同時(shí)也為國(guó)外汽車強(qiáng)大的研發(fā)能力感嘆。還有一項(xiàng)檢測(cè)就是左右論壇距離的測(cè)量，把汽車開(kāi)到檢測(cè)機(jī)器上然后使汽車的輪胎運(yùn)行，儀器表上的指針就是很清楚的表示出各個(gè)論壇的運(yùn)行情況跟兩個(gè)輪胎的間距是天津科技大學(xué)實(shí)習(xí)報(bào)告2否合格。當(dāng)工人師傅為我們演示奔馳汽車的性能時(shí)，我突然覺(jué)得我們國(guó)家的汽車比起外國(guó)還是有一定的差距。首先當(dāng) V12 發(fā)動(dòng)器啟動(dòng)的時(shí)候我?guī)缀趼?tīng)不到什么聲音，而且汽車做到了全自動(dòng)化比如安裝了 GPS,電視，音響，全自動(dòng)儀表，全新的檔位設(shè)計(jì)更加合理，夜間行車更是方便，幾乎可以從小電視中看清所有路況免除了汽車道上復(fù)雜的夜間情況，舒適的座椅不但可以前后移動(dòng)更可以上下全方位移動(dòng)，我想坐上此車感覺(jué)肯定舒適無(wú)比。參觀完汽車后我們又看了一些北星汽車的文化他們的文化底蘊(yùn)繼承了奔馳汽車的高貴傳統(tǒng)他們代表了先進(jìn)。離開(kāi)了北星（天津）汽車，我戀戀不舍，此廠帶給我的不僅是視覺(jué)的享受，更是機(jī)械汽車行業(yè)前進(jìn)的方向那就是現(xiàn)代化，高科技。為了對(duì)熱浸鍍鋅有更深的認(rèn)識(shí)，我們又學(xué)習(xí)了很多關(guān)于鍍鋅的知識(shí)。熱鍍鋅板作為深加工產(chǎn)品，具有抗腐蝕性能強(qiáng)、使用壽命長(zhǎng)、外觀美觀的特點(diǎn)，在汽車、輕工、建筑、家居等行業(yè)具有廣泛的應(yīng)用前景，是十余年來(lái)發(fā)展最快的鋼材品種之一。1995年世界鍍鋅板產(chǎn)量己超過(guò)5000萬(wàn)噸，從世界鋼材品種結(jié)構(gòu)看，鍍鋅板約占鋼材總產(chǎn)量7%-8%，發(fā)達(dá)國(guó)家占15%以上，而我國(guó)2002年鍍鋅板產(chǎn)量卻僅占鋼材總產(chǎn)量的1.3%。世界發(fā)達(dá)國(guó)家鍍鋅板的生產(chǎn)量占到冷軋產(chǎn)品的60%左右，而我國(guó)只有30%。到目前為止，我國(guó)己建成15條鍍鋅機(jī)組生產(chǎn)線，我國(guó)2002年鍍鋅板產(chǎn)量為227萬(wàn)噸，而2001年國(guó)內(nèi)鍍鋅板的表觀消費(fèi)量達(dá)到了428萬(wàn)噸(2000年為374萬(wàn)噸)，隨著我國(guó)國(guó)民經(jīng)濟(jì)的不斷發(fā)展和人民生活水平的不斷提高，市場(chǎng)對(duì)鍍鋅產(chǎn)品的需求和要求也越來(lái)越高。盡管我國(guó)熱鍍鋅產(chǎn)品市場(chǎng)容量及前景較為可觀，但是，目前中國(guó)國(guó)內(nèi)己建有多條熱鍍鋅機(jī)組，正在籌建和上馬的熱鍍鋅機(jī)組也己超過(guò)10條。根據(jù)近年鋼材消費(fèi)趨勢(shì)預(yù)測(cè)，2005年我國(guó)鍍鋅板表觀消費(fèi)量將超過(guò)500萬(wàn)噸，考慮到國(guó)內(nèi)鋼鐵企業(yè)新建項(xiàng)目的達(dá)產(chǎn)情況及設(shè)備開(kāi)工率情況，預(yù)計(jì)“十五”末期，國(guó)內(nèi)鍍鋅板產(chǎn)量將達(dá)到460萬(wàn)噸左右。在鍍鋅產(chǎn)品領(lǐng)域，國(guó)外鋼鐵企業(yè)全方位領(lǐng)先我們，進(jìn)口產(chǎn)品始終占據(jù)著中國(guó)鍍鋅產(chǎn)品市場(chǎng)的半壁江山(我國(guó)鍍鋅板的自給率僅為45%右)。隨著國(guó)內(nèi)鍍鋅產(chǎn)品產(chǎn)量的急劇增長(zhǎng)和國(guó)外產(chǎn)品的大量涌入，未來(lái)中國(guó)鍍鋅板產(chǎn)品的市場(chǎng)競(jìng)爭(zhēng)將會(huì)非常激烈。在生產(chǎn)實(shí)踐中向鋅液中投入定量的鋁會(huì)明顯的改善鋅層的附著性，鋅液中含有一定量的鋁會(huì)明顯改善鍍鋅層的結(jié)構(gòu)，F(xiàn)e5ZnZ:合金層減少，在溫度、鍍鋅時(shí)間的綜合影響下，會(huì)優(yōu)先在鋼基表面上形成Fe,Al。中間層。均質(zhì)的Fe,Al。中間層牢固地附著在鋼基表面，作為粘附鍍層的媒介，對(duì)提高鋅層附著性起著至關(guān)重要的作用。連續(xù)熱鍍鋅生產(chǎn)工藝的流程為：開(kāi)卷，焊接，連續(xù)退火，熱鍍鋅，鍍后處理，卷取或切版。熱鍍鋅板卷是冷軋主要產(chǎn)品之一，由于該產(chǎn)品抗腐蝕性能好，外觀美觀等天津科技大學(xué)實(shí)習(xí)報(bào)告3眾多優(yōu)點(diǎn)，在國(guó)內(nèi)、外各行業(yè)中得到廣泛的應(yīng)用。近年來(lái)，隨著國(guó)內(nèi)熱鍍鋅機(jī)組的陸續(xù)建成、投產(chǎn)，國(guó)外鍍鋅產(chǎn)品的打入，使國(guó)內(nèi)鍍鋅產(chǎn)品市場(chǎng)競(jìng)爭(zhēng)日益激化，這種競(jìng)爭(zhēng)的特點(diǎn)主要表現(xiàn)為五個(gè)特點(diǎn):其一，競(jìng)爭(zhēng)己無(wú)國(guó)界概念;其二，產(chǎn)品質(zhì)量不斷提高、價(jià)格下降;其三，產(chǎn)品系列化及新產(chǎn)品不斷推出;其四，隨著技術(shù)發(fā)展，產(chǎn)品實(shí)物質(zhì)量己普遍得到大幅度的提高;其五，消費(fèi)者日益成熟，消費(fèi)觀念日益更新。這種形勢(shì)迫使每一個(gè)生產(chǎn)廠家不但要有自己的拳頭產(chǎn)品，同時(shí)還要不斷研發(fā)市場(chǎng)需要的新產(chǎn)品。主要結(jié)論為：通過(guò)對(duì)于國(guó)內(nèi)外熱鍍鋅生產(chǎn)線的研究，鍍鋅生產(chǎn)線上的深入討論以及在實(shí)驗(yàn)室中對(duì)于熱軋板工藝的模擬，得出以下結(jié)論:(1)現(xiàn)在最流行的板帶熱鍍鋅工藝是森吉米爾法和美鋼聯(lián)法。它們的主要區(qū)別是美鋼聯(lián)法用一個(gè)堿性電解槽代替氧化爐的脫脂作用，其余工序和森吉米爾法基本相同，它特別適用于生產(chǎn)表面油脂較多的冷軋板。而現(xiàn)在森吉米爾法也經(jīng)常在加熱爐前使用堿洗設(shè)備，所以熱軋板熱鍍鋅生產(chǎn)線應(yīng)采用森吉米爾法，它具有優(yōu)質(zhì)，高效，安全等特點(diǎn)。(2)在森吉米爾法工藝條件下，經(jīng)實(shí)驗(yàn)室研究證明熱軋板的鍍層結(jié)構(gòu)與冷軋板沒(méi)有明顯區(qū)別，熱軋板鍍鋅時(shí)間的增加不會(huì)造成有害的鐵鋅合金層的產(chǎn)生。這使得熱軋板有充分的時(shí)間生成良好的鐵鋁合金層。(3)由于熱軋板一般比冷軋板較厚，熱軋板鍍鋅線設(shè)備除了強(qiáng)度較大外，還應(yīng)注意:焊機(jī)應(yīng)具有焊接厚鋼板的能力;活套和加熱爐應(yīng)采用臥式;由于熱軋板一般不用退火，所以熱軋板生產(chǎn)線可以采用不帶冷卻段的加熱系統(tǒng)。(4)目前板帶熱鍍鋅的一些先進(jìn)設(shè)備有液壓式開(kāi)卷機(jī)和卷取機(jī)，堿洗系統(tǒng)，預(yù)熱爐，帶弧性的氣刀，四輥濕式平整機(jī)，拉矯機(jī)等。通過(guò)本次實(shí)習(xí)不僅使我對(duì)鍍鋅工藝有了更具體的了解與認(rèn)識(shí)，更使我看到目前機(jī)械行業(yè)對(duì)人才和先進(jìn)設(shè)備的需求，這也就更加深了我畢業(yè)后投身機(jī)械行業(yè)的信心與決心。畢業(yè)實(shí)習(xí)報(bào)告專 業(yè)：機(jī)械設(shè)計(jì)制造及自動(dòng)化姓 名：王景凱指導(dǎo)教師姓名：申請(qǐng)學(xué)位級(jí)別：學(xué) 士報(bào)告提交日期：2007 年 月 日學(xué)位授予單位：天津科技大學(xué) 天津科技大學(xué)本科生畢業(yè)設(shè)計(jì)（論文）開(kāi)題報(bào)告學(xué) 院 天津科技大學(xué)機(jī)械工程學(xué)院 專 業(yè) 機(jī)械設(shè)計(jì)制造及自動(dòng)化 題 目 8 英寸鋼管熱浸鍍鋅自動(dòng)生產(chǎn)線設(shè)計(jì) （子題目：鋼管熱浸鍍鋅生產(chǎn)線機(jī)橫移機(jī)設(shè)計(jì)）姓 名 王景凱 指 導(dǎo) 教 師 （ 簽名） 2007 年 3 月 18 日擬選題目 8 英寸鋼管熱浸鍍鋅自動(dòng)生產(chǎn)線設(shè)計(jì)——鍍鋅鋼管橫移機(jī)設(shè)計(jì)選題依據(jù)及研究意義：熱鍍鋅是鋼鐵最經(jīng)濟(jì)、最基本、應(yīng)用最普遍的防腐方法之一，廣泛應(yīng)用于經(jīng)濟(jì)建設(shè)中的各個(gè)領(lǐng)域，如絲、管、板、帶，鋼結(jié)構(gòu)件等。近年來(lái)，隨著基礎(chǔ)建設(shè)的加速，鍍鋅鋼板、高速公路鍍鋅護(hù)欄和鍍鋅郵電鐵塔的發(fā)展勢(shì)頭強(qiáng)勁。這些行業(yè)的發(fā)展大大推動(dòng)了熱鍍鋅行業(yè)的發(fā)展。但是，目前我國(guó)的熱鍍鋅工藝水平較低，鋅耗高、產(chǎn)品質(zhì)量差、環(huán)境污染嚴(yán)重。本項(xiàng)目全面優(yōu)化熱鍍鋅工藝，可大大提高我國(guó)的熱鍍鋅水平，使之接近目前國(guó)際水平。鋅耗由目前噸產(chǎn)品的 7%降至 5%，產(chǎn)品質(zhì)量大幅度提高，環(huán)境污染減輕?？梢?jiàn)，研究與解決金屬腐蝕問(wèn)題在發(fā)展經(jīng)濟(jì)、節(jié)約能源、防止污染、保證人與自然協(xié)調(diào)共存等方面都有十分重要的意義和作用。因此，本課程設(shè)計(jì)符合市場(chǎng)及技術(shù)經(jīng)濟(jì)的需求，對(duì)我國(guó)工業(yè)的發(fā)展有著重要的意義。鍍鋅鋼板廣泛地用于輕工、家電、汽車和建筑行業(yè)。在汽車工業(yè)中，用于汽車車體、外殼、內(nèi)板、底板等；在家電和輕工方面，用于各類家用電器的外殼和底板；在建筑業(yè)中，用于各類工業(yè)及民用建筑的輕鋼龍骨、建筑層面板、瓦楞板、卷簾門等。長(zhǎng)期以來(lái)中國(guó)鍍鋅板一直屬于短線產(chǎn)品，1988-2002年，中國(guó)鍍鋅板生產(chǎn)及表觀消費(fèi)量，多年來(lái)中國(guó)鍍鋅板的自給率約為50％，每年需要大量進(jìn)口。鋼管熱鍍鋅生產(chǎn)線的設(shè)計(jì)作為畢業(yè)設(shè)計(jì)課題，其覆蓋面較廣，涉及到機(jī)、電、氣、制冷等一體化技術(shù)以及專業(yè)課程等知識(shí)，在這個(gè)過(guò)程中，我們不但提高了自己的繪圖能力，也提高了我們的分析能力和解決實(shí)際問(wèn)題的能力。文獻(xiàn)綜述（對(duì)已有相關(guān)代表性研究成果的綜合介紹與評(píng)價(jià)）：經(jīng)過(guò)三周的文獻(xiàn)檢索，展覽會(huì)的參觀，我對(duì)金屬熱鍍鋅的生產(chǎn)有了進(jìn)一步的了解。金屬材料在工農(nóng)業(yè)上用的最多的是鋼鐵材料。但鋼鐵材料耐腐蝕性能比較差。熱鍍鋅是防止鋼鐵生銹的一種方法，是公認(rèn)的高性價(jià)比鋼鐵制品防護(hù)方法。焊接鋼管的熱鍍鋅技術(shù)國(guó)外在六、七十年代已經(jīng)得到比較廣泛的應(yīng)用。由于鋅層能夠保護(hù)鋼基體不受腐蝕，鍍鋅管比未鍍鋅的黑管壽命可延長(zhǎng)十幾倍，因而，已廣泛用于鋼鐵的保護(hù)。如用于建筑、石油、化工、造船和電力等領(lǐng)域。焊接鋼管的熱鍍鋅技術(shù)國(guó)外在六、七十年代已經(jīng)得到比較廣泛的應(yīng)用。由于鋅層能夠保護(hù)鋼基體不受腐蝕，鍍鋅管比未鍍鋅的黑管壽命可延長(zhǎng)十幾倍，因而，被廣泛用于建筑、石油、化工、造船和電力等領(lǐng)域。為了改善鋼管熱浸鍍鋅生產(chǎn)環(huán)境，提高鍍鋅鋼管質(zhì)量，我國(guó)開(kāi)始了研發(fā)鋼管熱浸鍍鋅生產(chǎn)線。該生產(chǎn)線采用新穎的液壓機(jī)械手浸鍍，以取代傳統(tǒng)的結(jié)構(gòu)龐大的轉(zhuǎn)耙式與螺旋式鍍鋅機(jī)構(gòu)，不僅簡(jiǎn)化了熱鍍鋅管生產(chǎn)機(jī)構(gòu)，改進(jìn)了鍍鋅工藝，而且提高了鍍鋅管質(zhì)量，降低了生產(chǎn)成本。目前，美、日大規(guī)模生產(chǎn)熱軋帶鋼鍍鋅板，并已與冷軋鍍鋅板平分天下?？梢韵嘈牛捎跓彳堝冧\板的低成本，其市場(chǎng)前景非常廣闊。研究?jī)?nèi)容（包括基本思路、框架、主要研究方式、方法等）：鍍鋅設(shè)備為 SDX 雙線鍍鋅機(jī)組，本機(jī)采用微機(jī)全自動(dòng)控制。工藝流程：工件運(yùn)輸、檢驗(yàn)、酸洗、清水洗、涂溶劑、烘干、熱浸鋅、引出外吹、內(nèi)吹、冷卻、鈍化、檢驗(yàn)、打印、包裝、入庫(kù)。其中，關(guān)鍵工序?yàn)椋核嵯?、涂溶劑；特殊工序?yàn)椋簾峤\、鈍化。1．鋼管酸洗：（1）采用鹽酸酸洗：配置含量為 15-18﹪濃度的酸洗液（或濃度為 100-170 克的稀鹽酸） 。首先將清水放入酸洗槽中，然后加入足量的鹽酸；往水中放入鹽酸時(shí)，一定要把放酸的膠管插入水中，防止鹽酸氣體的發(fā)揮，污染空氣。（2）當(dāng)酸液中鹽酸的含量低于 100 克/升時(shí)，可加入新鹽酸進(jìn)行調(diào)配，以保證酸洗速度。（3）酸洗液的溫度應(yīng)保持在 8℃-35℃，鹽酸不宜加溫縮短酸洗時(shí)間，而宜增加其濃度提高酸洗速度。（4）酸洗時(shí)間可根據(jù)鋼管的銹蝕程度、酸液濃度、溫度等情況決定。（5）酸液中氯化鐵（鐵鹽）含量最多不得超過(guò) 200 克/升，當(dāng)鐵鹽含量大于 150克/升小于 200 克/升時(shí)，應(yīng)停止往酸洗槽中加入新酸。（6）當(dāng)鐵鹽超過(guò) 200 克/升濃度低于 20 克/升時(shí)應(yīng)排放，重新配置新的酸液。（7）雨季或空氣濕度大時(shí)，會(huì)產(chǎn)生酸霧，惡化空氣環(huán)境，要加入酸霧抑制劑，抑制酸霧或使用萘磺酸甲醛縮合物封閉酸液面。（8）為防止鋼管局部欠酸洗，增加酸洗速度，要在酸洗期間勤翻動(dòng)鋼管，使之產(chǎn)生摩擦，多接觸酸液，酸洗后的鋼管表面應(yīng)呈銀亮色。2. 涂溶劑涂溶劑的目的是：防止在烘干過(guò)程中鐵基體接觸空氣而再次氧化生銹；清除掉鋼管表面上殘留的鐵鹽及其他污物；使鋼管表面的鐵基體于鋅液更快的形成合金。鋼管鍍鋅烘干后的鋼管經(jīng)過(guò)鍍鋅機(jī)自動(dòng)運(yùn)轉(zhuǎn)，進(jìn)入鋅液，鋼管在鋅液中排放管內(nèi)的氣體，經(jīng)過(guò)浸鋅，形成牢固的鋅鐵合金層，再經(jīng)過(guò)提升、引出就完成了鋼管鍍鋅。在正常情況下鋅液溫度范圍應(yīng)保持在 450℃（+5℃或-5℃）為改善鋅層韌性極鋅液流動(dòng)性和光潔度，鋅液中的含鋅量應(yīng)保持在 0.2-0.3﹪之間。鋅液中加鋁要以鋅鋁合金方式加入。內(nèi)吹時(shí)，必須使鋼管內(nèi)壁吹凈不得有余鋅。往鋅液中加鋅塊時(shí)，要分多次添加，不要一次集中添加，一次不得超過(guò) 15 塊，以保證鋅液的溫度和設(shè)備的正常運(yùn)轉(zhuǎn)，同時(shí)保證正常鋅液面高。對(duì)于往鋅液中投放鋅鋁合金，一般是每下一噸鋅就要投相配量的鋅鋁合金，以保證鋅液的含鋁量在 0.2-0.3﹪之間。鍍鋅生產(chǎn)過(guò)程中，在鋅液面產(chǎn)生的鋅灰，不要產(chǎn)生很多時(shí)再清除。研究進(jìn)程安排：3.5 —3.14 收集相關(guān)論文資料和參考文獻(xiàn)，完成翻譯工作。3.15 —3.30 完城實(shí)習(xí)報(bào)告和開(kāi)題報(bào)告。4.1 —5.10 進(jìn)行零件，部件，總裝的草圖。 5.11 —5.25 完成結(jié)構(gòu)設(shè)計(jì)圖紙。5.26 —6.5 整理完成設(shè)計(jì)說(shuō)明書(shū)。6.6 —6.25 準(zhǔn)備并參加答辯。主要參閱文獻(xiàn)：[1]王義生．國(guó)外鋼管熱鍍鋅生產(chǎn)[M]．冶金工業(yè)出版社．[2]楊廷力．機(jī)械系統(tǒng)基本理論一結(jié)構(gòu)學(xué)、運(yùn)動(dòng)學(xué)、動(dòng)力學(xué)．北京：機(jī)械工業(yè)出版社，1996[2]陳厚載．熱鍍鋅技術(shù) 1000 例[M]．上海交大出版社．[3]吳作明等．熱鍍鋅、電鍍鋅及鋅合金創(chuàng)新生產(chǎn)工藝實(shí)用全書(shū)．北方工業(yè)出版社，2OOO(16)[4]李九齡 帶鋼連續(xù)熱鍍鋅（第 2 版） ．冶金工業(yè)出版社，2002(14)[5]凌全偉，劉建秋．熱鍍鋅技術(shù)的現(xiàn)狀及發(fā)展[J] ．鞍鋼技術(shù)，2004(2)[6]孔綱，盧錦堂，陳錦紅等．熱浸鋅浴中少量鋁對(duì)鍍層的影響[J]．材料保護(hù)，2002(35)[7]朱立．鋼材熱鍍鋅：化學(xué)工業(yè)出版社，1996其它說(shuō)明：市場(chǎng)前景:全國(guó)每年大約有 1000 萬(wàn)噸鍍鋅產(chǎn)品，如果每噸產(chǎn)品節(jié)鋅 2%，每年可節(jié)鋅 20 萬(wàn)噸，價(jià)值 20 億元。加之由于提高產(chǎn)品質(zhì)量，降低環(huán)境污染帶來(lái)的效益，這個(gè)市場(chǎng)更加巨大。指導(dǎo)教師是否同意開(kāi)題簽名: 年 月 日系（教研室）教學(xué)負(fù)責(zé)人簽署簽名: 年 月 日說(shuō)明：1、開(kāi)題報(bào)告工作從第七學(xué)期學(xué)生確定畢業(yè)設(shè)計(jì)（論文）題目后開(kāi)始，在教師指導(dǎo)下，學(xué)生通過(guò)調(diào)研、收資后，于第八學(xué)期第四周前完成。2、紙張?zhí)顚懖粔蚩闪砑痈巾?yè)。天津科技大學(xué)外文資料翻譯1數(shù)控技術(shù)和裝備發(fā)展趨勢(shì)及對(duì)策 裝備工業(yè)的技術(shù)水平和現(xiàn)代化程度決定著整個(gè)國(guó)民經(jīng)濟(jì)的水平和現(xiàn)代化程度，數(shù)控技術(shù)及裝備是發(fā)展新興高新技術(shù)產(chǎn)業(yè)和尖端工業(yè)（如信息技術(shù)及其產(chǎn)業(yè)、生物技術(shù)及其產(chǎn)業(yè)、航空、航天等國(guó)防工業(yè)產(chǎn)業(yè)）的使能技術(shù)和最基本的裝備。馬克思曾經(jīng)說(shuō)過(guò)“各種經(jīng)濟(jì)時(shí)代的區(qū)別，不在于生產(chǎn)什么，而在于怎樣生產(chǎn)，用什么勞動(dòng)資料生產(chǎn)” 。制造技術(shù)和裝備就是人類生產(chǎn)活動(dòng)的最基本的生產(chǎn)資料，而數(shù)控技術(shù)又是當(dāng)今先進(jìn)制造技術(shù)和裝備最核心的技術(shù)。 當(dāng)今世界各國(guó)制造業(yè)廣泛采用數(shù)控技術(shù)，以提高制造能力和水平，提高對(duì)動(dòng)態(tài)多變市場(chǎng)的適 應(yīng)能力和競(jìng)爭(zhēng)能力。此外世界上各工業(yè)發(fā)達(dá)國(guó)家還將數(shù)控技術(shù)及數(shù)控裝備列為國(guó)家的戰(zhàn)略物資，不僅采取重大措施來(lái)發(fā)展自己的數(shù)控技術(shù)及其產(chǎn)業(yè)，而且在“高精尖”數(shù)控關(guān)鍵技術(shù)和裝備方面對(duì)我國(guó)實(shí)行封鎖和限制政策。總之，大力發(fā)展以數(shù)控技術(shù)為核心的先進(jìn)制造技術(shù)已成為世界各發(fā)達(dá)國(guó)家加速經(jīng)濟(jì)發(fā)展、提高綜合國(guó)力和國(guó)家地位的重要途徑。數(shù)控技術(shù)是用數(shù)字信息對(duì)機(jī)械運(yùn)動(dòng)和工作過(guò)程進(jìn)行控制的技術(shù)，數(shù)控裝備是以數(shù)控技術(shù)為代表的新技術(shù)對(duì)傳統(tǒng)制造產(chǎn)業(yè)和新興制造業(yè)的滲透形成的機(jī)電一體化產(chǎn)品，即所謂的數(shù)字化裝備，其技術(shù)范圍覆蓋很多領(lǐng)域：(1)機(jī)械制造技術(shù)；(2)信息處理、加工、傳輸技術(shù)；(3)自動(dòng)控制技術(shù)；(4)伺服驅(qū)動(dòng)技術(shù)；(5)傳感器技術(shù)；(6)軟件技術(shù)等。1 數(shù)控技術(shù)的發(fā)展趨勢(shì)數(shù)控技術(shù)的應(yīng)用不但給傳統(tǒng)制造業(yè)帶來(lái)了革命性的變化，使制造業(yè)成為工業(yè)化的象征，而且隨著數(shù)控技術(shù)的不斷發(fā)展和應(yīng)用領(lǐng)域的擴(kuò)大，他對(duì)國(guó)計(jì)民生的一些重要行業(yè)（IT、汽車、輕工、醫(yī)療等）的發(fā)展起著越來(lái)越重要的作用，因?yàn)檫@些行業(yè)所需裝備的數(shù)字化已是現(xiàn)代發(fā)展的大趨勢(shì)。從目前世界上數(shù)控技術(shù)及其裝備發(fā)展的趨勢(shì)來(lái)看，其主要研究熱點(diǎn)有以下幾個(gè)方面［1～4］ 。1．1 高速、高精加工技術(shù)及裝備的新趨勢(shì)效率、質(zhì)量是先進(jìn)制造技術(shù)的主體。高速、高精加工技術(shù)可極大地提高效率，提高產(chǎn)品的質(zhì)量和檔次，縮短生產(chǎn)周期和提高市場(chǎng)競(jìng)爭(zhēng)能力。為此日本先端技術(shù)研究會(huì)將其列為 5 大現(xiàn)代制造技術(shù)之一，國(guó)際生產(chǎn)工程學(xué)會(huì)（CIRP）將其確定為 21 世紀(jì)的中心研究方向之一。在轎車工業(yè)領(lǐng)域，年產(chǎn) 30 萬(wàn)輛的生產(chǎn)節(jié)拍是 40 秒/輛，而且多品種加工是轎車裝備必須解決的重點(diǎn)問(wèn)題之一；在航空和宇航工業(yè)領(lǐng)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(duì)這些筋、壁進(jìn)行加工。近來(lái)采用大型整體鋁合金坯料“掏空”的方法來(lái)制造機(jī)翼、機(jī)身等大型零件來(lái)替代多個(gè)零件通過(guò)眾多的鉚釘、天津科技大學(xué)外文資料翻譯2螺釘和其他聯(lián)結(jié)方式拼裝，使構(gòu)件的強(qiáng)度、剛度和可靠性得到提高。這些都對(duì)加工裝備提出了高速、高精和高柔性的要求。從 EMO2001 展會(huì)情況來(lái)看，高速加工中心進(jìn)給速度可達(dá) 80m/min，甚至更高，空運(yùn)行速度可達(dá) 100m/min 左右。目前世界上許多汽車廠，包括我國(guó)的上海通用汽車公司，已經(jīng)采用以高速加工中心組成的生產(chǎn)線部分替代組合機(jī)床。美國(guó) CINCINNATI 公司的 HyperMach 機(jī)床進(jìn)給速度最大達(dá) 60m/min，快速為100m/min，加速度達(dá) 2g，主軸轉(zhuǎn)速已達(dá) 60 000r/min。加工一薄壁飛機(jī)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(guó) DMG 公司的雙主軸車床的主軸速度及加速度分別達(dá) 12*!000r/mm 和 1g。在加工精度方面，近 10 年來(lái)，普通級(jí)數(shù)控機(jī)床的加工精度已由 10μm 提高到 5μm，精密級(jí)加工中心則從 3～5μm，提高到 1～1.5μm，并且超精密加工精度已開(kāi)始進(jìn)入納米級(jí)(0.01μm)。在可靠性方面，國(guó)外數(shù)控裝置的 MTBF 值已達(dá) 6 000h 以上，伺服系統(tǒng)的MTBF 值達(dá)到 30000h 以上，表現(xiàn)出非常高的可靠性。為了實(shí)現(xiàn)高速、高精加工，與之配套的功能部件如電主軸、直線電機(jī)得到了快速的發(fā)展，應(yīng)用領(lǐng)域進(jìn)一步擴(kuò)大。1.2 5 軸聯(lián)動(dòng)加工和復(fù)合加工機(jī)床快速發(fā)展采用 5 軸聯(lián)動(dòng)對(duì)三維曲面零件的加工，可用刀具最佳幾何形狀進(jìn)行切削，不僅光潔度高，而且效率也大幅度提高。一般認(rèn)為，1 臺(tái) 5 軸聯(lián)動(dòng)機(jī)床的效率可以等于 2 臺(tái) 3 軸聯(lián)動(dòng)機(jī)床，特別是使用立方氮化硼等超硬材料銑刀進(jìn)行高速銑削淬硬鋼零件時(shí)，5 軸聯(lián)動(dòng)加工可比 3 軸聯(lián)動(dòng)加工發(fā)揮更高的效益。但過(guò)去因 5 軸聯(lián)動(dòng)數(shù)控系統(tǒng)、主機(jī)結(jié)構(gòu)復(fù)雜等原因，其價(jià)格要比 3 軸聯(lián)動(dòng)數(shù)控機(jī)床高出數(shù)倍，加之編程技術(shù)難度較大，制約了 5 軸聯(lián)動(dòng)機(jī)床的發(fā)展。當(dāng)前由于電主軸的出現(xiàn)，使得實(shí)現(xiàn) 5 軸聯(lián)動(dòng)加工的復(fù)合主軸頭結(jié)構(gòu)大為簡(jiǎn)化，其制造難度和成本大幅度降低，數(shù)控系統(tǒng)的價(jià)格差距縮小。因此促進(jìn)了復(fù)合主軸頭類型 5 軸聯(lián)動(dòng)機(jī)床和復(fù)合加工機(jī)床（含 5 面加工機(jī)床）的發(fā)展。在 EMO2001 展會(huì)上，新日本工機(jī)的 5 面加工機(jī)床采用復(fù)合主軸頭，可實(shí)現(xiàn)4 個(gè)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(tái)機(jī)床上實(shí)現(xiàn)，還可實(shí)現(xiàn)傾斜面和倒錐孔的加工。德國(guó) DMG 公司展出 DMUVoution系列加工中心，可在一次裝夾下 5 面加工和 5 軸聯(lián)動(dòng)加工，可由 CNC 系統(tǒng)控制或 CAD/CAM 直接或間接控制。1.3 智能化、開(kāi)放式、網(wǎng)絡(luò)化成為當(dāng)代數(shù)控系統(tǒng)發(fā)展的主要趨勢(shì)21 世紀(jì)的數(shù)控裝備將是具有一定智能化的系統(tǒng)，智能化的內(nèi)容包括在數(shù)控系統(tǒng)中的各個(gè)方面：為追求加工效率和加工質(zhì)量方面的智能化，如加工過(guò)程的自適應(yīng)控制，工藝參數(shù)自動(dòng)生成；為提高驅(qū)動(dòng)性能及使用連接方便的智能化，天津科技大學(xué)外文資料翻譯3如前饋控制、電機(jī)參數(shù)的自適應(yīng)運(yùn)算、自動(dòng)識(shí)別負(fù)載自動(dòng)選定模型、自整定等；簡(jiǎn)化編程、簡(jiǎn)化操作方面的智能化，如智能化的自動(dòng)編程、智能化的人機(jī)界面等；還有智能診斷、智能監(jiān)控方面的內(nèi)容、方便系統(tǒng)的診斷及維修等。為解決傳統(tǒng)的數(shù)控系統(tǒng)封閉性和數(shù)控應(yīng)用軟件的產(chǎn)業(yè)化生產(chǎn)存在的問(wèn)題。目前許多國(guó)家對(duì)開(kāi)放式數(shù)控系統(tǒng)進(jìn)行研究，如美國(guó)的 NGC(The Next Generation Work-Station/Machine Control)、歐共體的 OSACA(Open System Architecture for Control within Automation Systems)、日本的 OSEC(Open System Environment for Controller)，中國(guó)的 ONC(Open Numerical Control System)等。數(shù)控系統(tǒng)開(kāi)放化已經(jīng)成為數(shù)控系統(tǒng)的未來(lái)之路。所謂開(kāi)放式數(shù)控系統(tǒng)就是數(shù)控系統(tǒng)的開(kāi)發(fā)可以在統(tǒng)一的運(yùn)行平臺(tái)上，面向機(jī)床廠家和最終用戶，通過(guò)改變、增加或剪裁結(jié)構(gòu)對(duì)象（數(shù)控功能） ，形成系列化，并可方便地將用戶的特殊應(yīng)用和技術(shù)訣竅集成到控制系統(tǒng)中，快速實(shí)現(xiàn)不同品種、不同檔次的開(kāi)放式數(shù)控系統(tǒng)，形成具有鮮明個(gè)性的名牌產(chǎn)品。目前開(kāi)放式數(shù)控系統(tǒng)的體系結(jié)構(gòu)規(guī)范、通信規(guī)范、配置規(guī)范、運(yùn)行平臺(tái)、數(shù)控系統(tǒng)功能庫(kù)以及數(shù)控系統(tǒng)功能軟件開(kāi)發(fā)工具等是當(dāng)前研究的核心。網(wǎng)絡(luò)化數(shù)控裝備是近兩年國(guó)際著名機(jī)床博覽會(huì)的一個(gè)新亮點(diǎn)。數(shù)控裝備的網(wǎng)絡(luò)化將極大地滿足生產(chǎn)線、制造系統(tǒng)、制造企業(yè)對(duì)信息集成的需求，也是實(shí)現(xiàn)新的制造模式如敏捷制造、虛擬企業(yè)、全球制造的基礎(chǔ)單元。國(guó)內(nèi)外一些著名數(shù)控機(jī)床和數(shù)控系統(tǒng)制造公司都在近兩年推出了相關(guān)的新概念和樣機(jī)，如在EMO2001 展中，日本山崎馬扎克（Mazak)公司展出的“CyberProduction Center”（智能生產(chǎn)控制中心，簡(jiǎn)稱 CPC)；日本大隈（Okuma）機(jī)床公司展出“IT plaza”（信息技術(shù)廣場(chǎng)，簡(jiǎn)稱 IT 廣場(chǎng))；德國(guó)西門子(Siemens)公司展出的 Open Manufacturing Environment（開(kāi)放制造環(huán)境，簡(jiǎn)稱 OME）等，反映了數(shù)控機(jī)床加工向網(wǎng)絡(luò)化方向發(fā)展的趨勢(shì)。1.4 重視新技術(shù)標(biāo)準(zhǔn)、規(guī)范的建立1.4.1 關(guān)于數(shù)控系統(tǒng)設(shè)計(jì)開(kāi)發(fā)規(guī)范如前所述，開(kāi)放式數(shù)控系統(tǒng)有更好的通用性、柔性、適應(yīng)性、擴(kuò)展性，美國(guó)、歐共體和日本等國(guó)紛紛實(shí)施戰(zhàn)略發(fā)展計(jì)劃，并進(jìn)行開(kāi)放式體系結(jié)構(gòu)數(shù)控系統(tǒng)規(guī)范(OMAC、OSACA、OSEC)的研究和制定，世界 3 個(gè)最大的經(jīng)濟(jì)體在短期內(nèi)進(jìn)行了幾乎相同的科學(xué)計(jì)劃和規(guī)范的制定，預(yù)示了數(shù)控技術(shù)的一個(gè)新的變革時(shí)期的來(lái)臨。我國(guó)在 2000 年也開(kāi)始進(jìn)行中國(guó)的 ONC 數(shù)控系統(tǒng)的規(guī)范框架的研究和制定。1.4.2 關(guān)于數(shù)控標(biāo)準(zhǔn)數(shù)控標(biāo)準(zhǔn)是制造業(yè)信息化發(fā)展的一種趨勢(shì)。數(shù)控技術(shù)誕生后的 50 年間的信息交換都是基于 ISO6983 標(biāo)準(zhǔn)，即采用 G，M 代碼描述如何（how）加工，其本天津科技大學(xué)外文資料翻譯4質(zhì)特征是面向加工過(guò)程，顯然，他已越來(lái)越不能滿足現(xiàn)代數(shù)控技術(shù)高速發(fā)展的需要。為此，國(guó)際上正在研究和制定一種新的 CNC 系統(tǒng)標(biāo)準(zhǔn)ISO14649（STEP－NC)，其目的是提供一種不依賴于具體系統(tǒng)的中性機(jī)制，能夠描述產(chǎn)品整個(gè)生命周期內(nèi)的統(tǒng)一數(shù)據(jù)模型，從而實(shí)現(xiàn)整個(gè)制造過(guò)程，乃至各個(gè)工業(yè)領(lǐng)域產(chǎn)品信息的標(biāo)準(zhǔn)化。STEP-NC 的出現(xiàn)可能是數(shù)控技術(shù)領(lǐng)域的一次革命，對(duì)于數(shù)控技術(shù)的發(fā)展乃至整個(gè)制造業(yè)，將產(chǎn)生深遠(yuǎn)的影響。首先，STEP-NC 提出一種嶄新的制造理念，傳統(tǒng)的制造理念中，NC 加工程序都集中在單個(gè)計(jì)算機(jī)上。而在新標(biāo)準(zhǔn)下，NC 程序可以分散在互聯(lián)網(wǎng)上，這正是數(shù)控技術(shù)開(kāi)放式、網(wǎng)絡(luò)化發(fā)展的方向。其次，STEP-NC 數(shù)控系統(tǒng)還可大大減少加工圖紙（約 75％） 、加工程序編制時(shí)間（約35％）和加工時(shí)間（約 50％） 。目前，歐美國(guó)家非常重視 STEP-NC 的研究，歐洲發(fā)起了 STEP-NC 的 IMS 計(jì)劃(1999.1.1～2001.12.31)。參加這項(xiàng)計(jì)劃的有來(lái)自歐洲和日本的 20 個(gè)CAD/CAM/CAPP/CNC 用戶、廠商和學(xué)術(shù)機(jī)構(gòu)。美國(guó)的 STEP Tools 公司是全球范圍內(nèi)制造業(yè)數(shù)據(jù)交換軟件的開(kāi)發(fā)者，他已經(jīng)開(kāi)發(fā)了用作數(shù)控機(jī)床加工信息交換的超級(jí)模型(Super Model)，其目標(biāo)是用統(tǒng)一的規(guī)范描述所有加工過(guò)程。目前這種新的數(shù)據(jù)交換格式已經(jīng)在配備了 SIEMENS、FIDIA 以及歐洲 OSACA-NC 數(shù)控系統(tǒng)的原型樣機(jī)上進(jìn)行了驗(yàn)證。2 對(duì)我國(guó)數(shù)控技術(shù)及其產(chǎn)業(yè)發(fā)展的基本估計(jì)我國(guó)數(shù)控技術(shù)起步于 1958 年，近 50 年的發(fā)展歷程大致可分為 3 個(gè)階段：第一階段從 1958 年到 1979 年，即封閉式發(fā)展階段。在此階段，由于國(guó)外的技術(shù)封鎖和我國(guó)的基礎(chǔ)條件的限制，數(shù)控技術(shù)的發(fā)展較為緩慢。第二階段是在國(guó)家的“六五” 、 “七五”期間以及“八五”的前期，即引進(jìn)技術(shù)，消化吸收，初步建立起國(guó)產(chǎn)化體系階段。在此階段，由于改革開(kāi)放和國(guó)家的重視，以及研究開(kāi)發(fā)環(huán)境和國(guó)際環(huán)境的改善，我國(guó)數(shù)控技術(shù)的研究、開(kāi)發(fā)以及在產(chǎn)品的國(guó)產(chǎn)化方面都取得了長(zhǎng)足的進(jìn)步。第三階段是在國(guó)家的“八五”的后期和“九五”期間，即實(shí)施產(chǎn)業(yè)化的研究，進(jìn)入市場(chǎng)競(jìng)爭(zhēng)階段。在此階段，我國(guó)國(guó)產(chǎn)數(shù)控裝備的產(chǎn)業(yè)化取得了實(shí)質(zhì)性進(jìn)步。在“九五”末期，國(guó)產(chǎn)數(shù)控機(jī)床的國(guó)內(nèi)市場(chǎng)占有率達(dá) 50％，配國(guó)產(chǎn)數(shù)控系統(tǒng)（普及型）也達(dá)到了 10％?？v觀我國(guó)數(shù)控技術(shù)近 50 年的發(fā)展歷程，特別是經(jīng)過(guò) 4 個(gè) 5 年計(jì)劃的攻關(guān)，總體來(lái)看取得了以下成績(jī)。a.奠定了數(shù)控技術(shù)發(fā)展的基礎(chǔ)，基本掌握了現(xiàn)代數(shù)控技術(shù)。我國(guó)現(xiàn)在已基本掌握了從數(shù)控系統(tǒng)、伺服驅(qū)動(dòng)、數(shù)控主機(jī)、專機(jī)及其配套件的基礎(chǔ)技術(shù)，其中大部分技術(shù)已具備進(jìn)行商品化開(kāi)發(fā)的基礎(chǔ)，部分技術(shù)已商品化、產(chǎn)業(yè)化。b.初步形成了數(shù)控產(chǎn)業(yè)基地。在攻關(guān)成果和部分技術(shù)商品化的基礎(chǔ)上，建天津科技大學(xué)外文資料翻譯5立了諸如華中數(shù)控、航天數(shù)控等具有批量生產(chǎn)能力的數(shù)控系統(tǒng)生產(chǎn)廠。蘭州電機(jī)廠、華中數(shù)控等一批伺服系統(tǒng)和伺服電機(jī)生產(chǎn)廠以及北京第一機(jī)床廠、濟(jì)南第一機(jī)床廠等若干數(shù)控主機(jī)生產(chǎn)廠。這些生產(chǎn)廠基本形成了我國(guó)的數(shù)控產(chǎn)業(yè)基地。c.建立了一支數(shù)控研究、開(kāi)發(fā)、管理人才的基本隊(duì)伍。雖然在數(shù)控技術(shù)的研究開(kāi)發(fā)以及產(chǎn)業(yè)化方面取得了長(zhǎng)足的進(jìn)步，但我們也要清醒地認(rèn)識(shí)到，我國(guó)高端數(shù)控技術(shù)的研究開(kāi)發(fā)，尤其是在產(chǎn)業(yè)化方面的技術(shù)水平現(xiàn)狀與我國(guó)的現(xiàn)實(shí)需求還有較大的差距。雖然從縱向看我國(guó)的發(fā)展速度很快，但橫向比（與國(guó)外對(duì)比）不僅技術(shù)水平有差距，在某些方面發(fā)展速度也有差距，即一些高精尖的數(shù)控裝備的技術(shù)水平差距有擴(kuò)大趨勢(shì)。從國(guó)際上來(lái)看，對(duì)我國(guó)數(shù)控技術(shù)水平和產(chǎn)業(yè)化水平估計(jì)大致如下。a.技術(shù)水平上，與國(guó)外先進(jìn)水平大約落后 10～15 年，在高精尖技術(shù)方面則更大。b.產(chǎn)業(yè)化水平上，市場(chǎng)占有率低，品種覆蓋率小，還沒(méi)有形成規(guī)模生產(chǎn)；功能部件專業(yè)化生產(chǎn)水平及成套能力較低；外觀質(zhì)量相對(duì)差；可靠性不高，商品化程度不足；國(guó)產(chǎn)數(shù)控系統(tǒng)尚未建立自己的品牌效應(yīng)，用戶信心不足。c.可持續(xù)發(fā)展的能力上，對(duì)競(jìng)爭(zhēng)前數(shù)控技術(shù)的研究開(kāi)發(fā)、工程化能力較弱；數(shù)控技術(shù)應(yīng)用領(lǐng)域拓展力度不強(qiáng)；相關(guān)標(biāo)準(zhǔn)規(guī)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(gè)方面。a.認(rèn)識(shí)方面。對(duì)國(guó)產(chǎn)數(shù)控產(chǎn)業(yè)進(jìn)程艱巨性、復(fù)雜性和長(zhǎng)期性的特點(diǎn)認(rèn)識(shí)不足；對(duì)市場(chǎng)的不規(guī)范、國(guó)外的封鎖加扼殺、體制等困難估計(jì)不足；對(duì)我國(guó)數(shù)控技術(shù)應(yīng)用水平及能力分析不夠。b.體系方面。從技術(shù)的角度關(guān)注數(shù)控產(chǎn)業(yè)化問(wèn)題的時(shí)候多，從系統(tǒng)的、產(chǎn)業(yè)鏈的角度綜合考慮數(shù)控產(chǎn)業(yè)化問(wèn)題的時(shí)候少；沒(méi)有建立完整的高質(zhì)量的配套體系、完善的培訓(xùn)、服務(wù)網(wǎng)絡(luò)等支撐體系。c.機(jī)制方面。不良機(jī)制造成人才流失，又制約了技術(shù)及技術(shù)路線創(chuàng)新、產(chǎn)品創(chuàng)新，且制約了規(guī)劃的有效實(shí)施，往往規(guī)劃理想，實(shí)施困難。d.技術(shù)方面。企業(yè)在技術(shù)方面自主創(chuàng)新能力不強(qiáng)，核心技術(shù)的工程化能力不強(qiáng)。機(jī)床標(biāo)準(zhǔn)落后，水平較低，數(shù)控系統(tǒng)新標(biāo)準(zhǔn)研究不夠。3 對(duì)我國(guó)數(shù)控技術(shù)和產(chǎn)業(yè)化發(fā)展的戰(zhàn)略思考3.1 戰(zhàn)略考慮我國(guó)是制造大國(guó)，在世界產(chǎn)業(yè)轉(zhuǎn)移中要盡量接受前端而不是后端的轉(zhuǎn)移，即要掌握先進(jìn)制造核心技術(shù)，否則在新一輪國(guó)際產(chǎn)業(yè)結(jié)構(gòu)調(diào)整中，我國(guó)制造業(yè)將進(jìn)一步“空芯” 。我們以資源、環(huán)境、市場(chǎng)為代價(jià)，交換得到的可能僅僅是世界新經(jīng)濟(jì)格局中的國(guó)際“加工中心”和“組裝中心” ，而非掌握核心技術(shù)的制造天津科技大學(xué)外文資料翻譯6中心的地位，這樣將會(huì)嚴(yán)重影響我國(guó)現(xiàn)代制造業(yè)的發(fā)展進(jìn)程。我們應(yīng)站在國(guó)家安全戰(zhàn)略的高度來(lái)重視數(shù)控技術(shù)和產(chǎn)業(yè)問(wèn)題，首先從社會(huì)安全看，因?yàn)橹圃鞓I(yè)是我國(guó)就業(yè)人口最多的行業(yè)，制造業(yè)發(fā)展不僅可提高人民的生活水平，而且還可緩解我國(guó)就業(yè)的壓力，保障社會(huì)的穩(wěn)定；其次從國(guó)防安全看，西方發(fā)達(dá)國(guó)家把高精尖數(shù)控產(chǎn)品都列為國(guó)家的戰(zhàn)略物質(zhì)，對(duì)我國(guó)實(shí)現(xiàn)禁運(yùn)和限制， “東芝事件”和“考克斯報(bào)告”就是最好的例證。3.2 發(fā)展策略從我國(guó)基本國(guó)情的角度出發(fā)，以國(guó)家的戰(zhàn)略需求和國(guó)民經(jīng)濟(jì)的市場(chǎng)需求為導(dǎo)向，以提高我國(guó)制造裝備業(yè)綜合競(jìng)爭(zhēng)能力和產(chǎn)業(yè)化水平為目標(biāo)，用系統(tǒng)的方法，選擇能夠主導(dǎo) 21 世紀(jì)初期我國(guó)制造裝備業(yè)發(fā)展升級(jí)的關(guān)鍵技術(shù)以及支持產(chǎn)業(yè)化發(fā)展的支撐技術(shù)、配套技術(shù)作為研究開(kāi)發(fā)的內(nèi)容，實(shí)現(xiàn)制造裝備業(yè)的跨躍式發(fā)展。強(qiáng)調(diào)市場(chǎng)需求為導(dǎo)向，即以數(shù)控終端產(chǎn)品為主，以整機(jī)（如量大面廣的數(shù)控車床、銑床、高速高精高性能數(shù)控機(jī)床、典型數(shù)字化機(jī)械、重點(diǎn)行業(yè)關(guān)鍵設(shè)備等）帶動(dòng)數(shù)控產(chǎn)業(yè)的發(fā)展。重點(diǎn)解決數(shù)控系統(tǒng)和相關(guān)功能部件（數(shù)字化伺服系統(tǒng)與電機(jī)、高速電主軸系統(tǒng)和新型裝備的附件等）的可靠性和生產(chǎn)規(guī)模問(wèn)題。沒(méi)有規(guī)模就不會(huì)有高可靠性的產(chǎn)品；沒(méi)有規(guī)模就不會(huì)有價(jià)格低廉而富有競(jìng)爭(zhēng)力的產(chǎn)品；當(dāng)然，沒(méi)有規(guī)模中國(guó)的數(shù)控裝備最終難以有出頭之日。在高精尖裝備研發(fā)方面，要強(qiáng)調(diào)產(chǎn)、學(xué)、研以及最終用戶的緊密結(jié)合，以“做得出、用得上、賣得掉”為目標(biāo)，按國(guó)家意志實(shí)施攻關(guān)，以解決國(guó)家之急需。在競(jìng)爭(zhēng)前數(shù)控技術(shù)方面，強(qiáng)調(diào)創(chuàng)新，強(qiáng)調(diào)研究開(kāi)發(fā)具有自主知識(shí)產(chǎn)權(quán)的技術(shù)和產(chǎn)品，為我國(guó)數(shù)控產(chǎn)業(yè)、裝備制造業(yè)乃至整個(gè)制造業(yè)的可持續(xù)發(fā)展奠定基礎(chǔ)。參考文獻(xiàn)：［1］中國(guó)機(jī)床工具工業(yè)協(xié)會(huì) 行業(yè)發(fā)展部.CIMT2001 巡禮［J］.世界制造技術(shù)與裝備市場(chǎng)，2001(3)：18-20.［2］梁訓(xùn)王宣 ,周延佑.機(jī)床技術(shù)發(fā)展的新動(dòng)向［J］.世界制造技術(shù)與裝備市場(chǎng)，2001(3)：21-28.［3］中國(guó)機(jī)床工具工業(yè)協(xié)會(huì) 數(shù)控系統(tǒng)分會(huì).CIMT2001 巡禮［J］.世界制造技術(shù)與裝備市天津科技大學(xué)外文資料翻譯7場(chǎng)，2001(5)：13-17.［4］楊學(xué)桐，李冬茹，何文立，等?距世紀(jì)數(shù)控機(jī)床技術(shù)發(fā)展戰(zhàn)略研究［M］.北京：國(guó)家機(jī)械工業(yè)局，2000.天津科技大學(xué)外文資料翻譯1Numerical control technology and equiping 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 industry and most advanced industry to equip (such as information technology and his industry, biotechnology and his industry, aviation , spaceflight,etc. national defense industry industry) last technology and getting more basic most equipment. Marx has ever said " the differences of different economic times, do not lie in what is produced , and lie in how to produce, produce with some means of labor ". Manufacturing technology and equiping the most basic means of production that are that the mankind produced the activity, and numerical control technology is nowadays advanced manufacturing technology and 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 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 one's own numerical control technology and industry, and implement blockading and restrictive policy to our country in view of " high-grade , precision and advanced key technology of numerical control " and equiping. In a word, develop the advanced manufacturing technology taking numerical control technology as the core and already become every world developed country and accelerate 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 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 lot 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 technology The application 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 天津科技大學(xué)外文資料翻譯2development of some important trades (IT , automobile , light industry , medical treatment ,etc. ) to the national economy and the people's 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 development. Numerical control technology in the world at present and equiping 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 equipped The efficiency , quality are subjavanufacturing technology. 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 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 process 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 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 way, make the intensity , rigidity and dependability of the component improved. All these, to processing and equiping 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/min 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 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, spend 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 12* separately! 000r/mm and 1g. In machining accuracy, the past 10 years, ordinary progression accuse of machining accuracy of lathe bring 5|ìm up to from 10|ìm already, accurate grades of machining center from 3- 5|ìm, rise to 1- 1.5|ìm, and ultraprecision machining accuracy is it enter nanometer grade to begin already (0.01|ìm). In dependability, MTBF value of the foreign numerical control device has already reached above 6 000h, MTBF value of the servo system reaches above 30000h, 天津科技大學(xué)外文資料翻譯3demonstrate 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 machinery 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 highly 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 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 numerical 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 link 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 including 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 the 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. 1.3 Become the main trend of systematic development of contemporary numerical control intelligently , openly , networkedlily 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 intelligent 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 , adaptive operation , electrical machinery of parameter , discern load select models , since exactly makes etc. automatically automatically; The ones that simplified programming , simplified operating aspect are intelligent, for instance intelligent automatic programming , 天津科技大學(xué)外文資料翻譯4intelligent man-machine interface ,etc.; 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 countries 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, 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 producer and end user, through changing, increasing or cutting out the structure target(numerical control function), form the seriation, 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 variety , 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 function software developing 包含 ument ,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 , fictitious enterprise , basic Entrance that the whole world make too. Some domestic and international famous numerical control lathes and systematic manufacturing companies of numerical control have all introduced relevant new concepts and protos of a machine in the past two years, if in EMO2001 exhibition, " CyberProduction Center " that the company exhibits of mountain rugged campstool gram in Japan (Mazak ) (intellectual central production control unit, abbreviated as CPC); The lathe company of Japanese big Wei (Okuma ) exhibits " IT plaza " (the information technology square , is abbreviated as IT square ); Open Manufacturing Environment that the company exhibits of German Siemens (Siemens ) (open the manufacturing environment, abbreviated as OME),etc., have reflected numerical control machine tooling to the development trend of networked direction. 1.4 Pay attention to the new technical standard , normal setting-up 1.4.1 Design the norm of developing about the numerical control system As noted previously, there are better commonability , flexibility , adaptability , expanding in the open numerical control system, such countries as U.S.A. , European Community and Japan ,etc. implement the strategic development plan one after another , carry on the research and formulation of the systematic norm (OMAC , 天津科技大學(xué)外文資料翻譯5OSACA , OSEC ) of numerical control of the open system structure, 3 biggest economies in the world have carried on the formulation that nearly the same science planned and standardized in a short time, have indicated a new arrival of period of change of numerical control technology. Our country started the research and formulation of standardizing the frame of ONC numerical control system of China too in 2000. 1.4.2 About the numerical control standard The numerical control standard is a kind of trend of information-based development of manufacturing industry. Information exchange among 50 years after numerical control technology was born was all because of ISO6983 standard, namely adopt G, M code describes how processes, its essential characteristic faces the processing course, obviously, he can't meet high-speed development of modern numerical control technology's needs more and more already. For this reason, studying and making a kind of new CNC system standard ISO14649 (STEP-NC) in the world, its purpose is to offer a kind of neutral mechanism not depending on the concrete system , can describe the unified data model in cycle of whole life of the products , thus realize the whole manufacture process, standardization of and even each industrial field product information. The appearance of STEP-NC may be a revolution of the technological field of the numerical control, on the development and even the whole manufacturing industry of numerical control technology , will exert a far-reaching influence. First of all, STEP-NC puts forward a kind of brand-new manufacture idea , in the traditional manufacture idea, NC processes the procedures to all concentrate on individual computer. Under the new standard, NC procedure can be dispersed on Internet, this is exactly a direction of open , networked development of numerical control technology. Secondly, STEP-NC numerical control system can also reduce and process the drawing (about 75% ) , process the procedure to work out the time (about 35% ) and process the time (about 50% ) greatly . At present, American-European countries pay much attention to the research of STEP-NC, Europe initiates IMS plan (1999.1.1- 2001.12.3 ) of STEP-NC. 20 CAD/CAM/CAPP/CNC users , manufacturers and academic organizations from Europe and Japan participated in this plan. STEP Tools Company of U.S.A. is a developer of the data interchange software of manufacturing industry in the global range, he has already developed the super model (Super Model ) which accuses of information exchange of machine tooling by counting, its goal is to describe all processing courses with the unified norm. Such new data interchange form has already been verified in allocating the SIEMENS , FIDIA and European OSACA-NC numerical control at present. 2 pairs of basic estimations of technology and industry development of numerical control of our country The technology of numerical control of our country started in 1958, the development 天津科技大學(xué)外文資料翻譯6course in the past 50 years can roughly be divided into 3 stages: The first stage is from 1958 to 1979, namely closed developing stage. In this stages, because technology of foreign countries blockade and basic restriction of terms of our country, the development of numerical control technology is comparatively slow. During " Sixth Five-Year Plan Period " , " the Seventh Five-Year Plan Period " of the country in second stage and earlier stage in " the Eighth Five-Year Plan Period ", namely introduce technology, digest and assimilate, the stage of establishing the system of production domesticization arisesing tentatively. At this stage , because of reform and opening-up and national attention , and study the improvement of the development environment and international environment, research , development and all making considerable progress in production domesticization of the products of the technology of numerical control of our country. The third stage is and during the " Ninth Five-Year Plan Period " on the later stage in " the Eighth Five-Year Plan Period " of the country, namely implement the research of industrialization, enter market competition stage. At this stage , made substantive progress in industrialization of the domestic numerical control equipment of our country. In latter stage for " the Ninth Five-Year Plan ", the domestic occupation rate of market of the domestic numerical control lathe is up to 50%, it is up to 10% too to mix the domestic numerical control system (popular ). Make a general survey of the development course in the past 50 years of technology of numerical control of our country, especially through tackling key problems of 4 Five-Year Plans, all in all has made following achievements. a.Have establish the foundation of the technical development of numerical control, has mastered modern numerical control technology basically. Our country has already, the numerical control host computer , basic technology of special plane and fittings grasped and driven from the numerical control system and servoly basically now, among them most technology have already possessed and commercialized the foundation developed , some technology has already, industrialization commercialized. b.Have formed the industrial base of numerical control tentatively. In tackling key problems the foundation that the achievement and some technology commercialize , set up the systematic factories of numerical control with production capacity in batches such as numerical control in Central China , numerical control of the spaceflight etc.. Electrical machinery plant of Lanzhou, such factory and the first machine tool plant of Beijing , the first machine tool plant of Jinan ,etc. several numerical control host computer factories of a batch of servo systems and servo electrical machineries as the numerical control in Central China,etc.. These factories have formed the numerical control industrial base of our country basically. c.Have set up a numerical control research, development , managerial talent's basic team . Though has made considerable progress in research and development and industrialization of numerical control technology, but we will realize soberly, the research and development of the technology of advanced numerical control of our country, especially there is greater disparity in current situation and current demand of 天津科技大學(xué)外文資料翻譯7our country of engineering level in industrialization. Though very fast from watching the development of our country vertically, have disparity horizontally more than (compare foreign countries with ) not merely engineering level, there is disparity too in development speed in some aspects, namely the engineering level disparity between some high-grade , precision and advanced numerical control equipment has the tendency to expand . Watch from world , estimate roughly as follows about the engineering level of numerical control of our country and industrialization level.
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