Gear is a element of the industry, its importance is self-evident, as a symbol of industry, it is the creator of the design of the republic of the national emblem, expressed the ancient Chinese nation to build a modern industrial country. After several generations of struggle, China has leapt to become the world's manufacturing power, gear, a whispered everywhere, the key of basic components, is undergoing constant innovation and development, the current our country is in the technical innovation and industrial transformation and upgrading of the important period, the status quo of China's gear industry? What challenges and opportunities does it face?
With many questions and expectation, the machine tool business magazine recently and the world machinery network reporter special interview the China's mechanical generic components industry association gear branch (CGMA) vice President and secretary general wang long, had insight into the relevant situation of gear industry, secretary general wang as the leading industry and senior experts, made a penetrating analysis and detailed solutions.
Reporter: Mr. Wang, as an industry leader and senior expert, would like to brief you on the development status of the gear industry and the relevant industrial policies of the country.
Secretary general: more than 1000 manufacturing enterprises and more than 300 backbone enterprises. In 2016, the sales volume of gear products reached 220.5 billion yuan, accounting for 61% of the total sales of machinery general components, and the industry scale has been the largest in the world for several years. China's gear products are transforming from low-end to high-end, and some high-end products have reached international advanced level. However, China's automobile automatic transmission, industrial robot RV reducer, speed of more than 350km/h and other high-end gear products still rely heavily on imports, and the external trade deficit is huge. In 2016, China's imports of gear products reached us $14.203 billion, with exports of $54.81 billion and a trade deficit of us $8722 million.
The country's "national medium and long-term science and technology development plan outline (2006-2020), a clear key components and general component is priority to the development of manufacturing technology subject, major equipment to focus on research and development of key components and general parts needed design, manufacturing and the key technology of mass production. State of the equipment manufacturing industry adjustment and revitalization of planning "adhere to the development of the whole machine and improve the level of basic form a complete set, the combination of major technical equipment to achieve democracy, driving the development of foundation supporting products, put the focus on developing high precision gear as the industry adjustment and revitalization of one of the main tasks. Promulgated by the ministry of machinery components, basic manufacturing process and basic material industry "twelfth five-year" development plan ", a clear focus on developing 11 types of mechanical components, including large, high gear parameters and gear, etc. Industrial strength engineering is the cornerstone of "made in China 2025" and decides the success or failure of manufacturing power strategy. It is the foundation for the ten industries innovation and development in the outline of the plan. The implementation guide for the implementation of the industrial strong foundation (2016-2020) has clarified the content of the "one-stop" application plan of the high precision reducer.
Reporter: what are the main problems in the gear industry? According to the 13th five-year plan of the gear industry, what are the key priorities of the gear section?
Secretary general wang: in 2015, I'm responsible for writing the "Chinese" much starker choices-and graver consequences-in "gear industry development planning outline, the situation facing the gear industry is analyzed and the main problems existing, puts forward the development direction of the gear industry and development goals, has been clear about the key tasks and measures.
The main problems in the gear industry are the lack of basic research and basic data, which leads to the lack of data support for product design and manufacturing. Secondly, the lack of whole industry oriented gear generic technology and cutting-edge technology research and development, important transformation of scientific and technological achievements and the engineering application research on innovation platform, the lack of guidance and gear transmission device design, manufacture to improve and enhance reliability test evaluation service system; The third is the weak independent innovation ability of the gear industry, which leads to the heavy reliance on imports of high-end gear products, and the core technology is under the control of others. Fourth, the high-end product research and development, the manufacturing capacity is insufficient, the middle and low-end product capacity is serious surplus, the homogenization competition intensifies; Fifth, the product quality of the gear and its stability is poor, the early failure rate of the product is high, the service life is short, the reliability is low, can not meet the main demand of the host; Sixth, there is a general lack of high-level research and development and high-level skills, and the overall quality of staff needs to be improved. 7. Many small and medium-sized enterprises in the gear industry are in difficulty in financing difficulties, tax burden and other difficulties, and their risk tolerance is weak.
Gear chapter will focus on organization to carry out the following work: one is to conquer gear vibration noise reduction technology, lightweight design gear manufacturing technology, the gear surface modification technology, the gear near net shaping green manufacturing technology such as a number of core technologies, 2 it is to break through the industrial robot precision gear reducer, a speed of 350 km/h or high-speed locomotive gear, shield machine with TBM heavy-load gear reducer, a batch of key products such as automobile automatic transmission, 3 it is to advance the two integration and upgrade of four is gradually establish a relatively perfect gear r&d service platform, five is the implementation of quality and brand strategy, six is gear standardization strategy, seven is the implementation of gear steel quality promotion projects, eight is to help solve the problem of micro, small and medium enterprises financing difficulties.
Reporter: our country is a big country of gear production and marketing, but the gear product has a big gap with international advanced level in terms of service life and reliability. It is said that the application of gear anti-fatigue manufacturing technology can change this situation, please briefly introduce the main content and application effect of gear anti-fatigue manufacturing technology.
Mr. Wang: compared with the international advanced level, the gear products in China still have a large gap in power density, service life and reliability. We can solve this problem by implementing gear anti-fatigue manufacturing. Anti-fatigue manufacturing technology of the main content and using effect: one is the material metallurgy quality control technology, is used to improve the purity of material, uniformity and stability, improve the fatigue limit stress, from the source reduce the sensitivity of the influence of stress concentration and reduce material material defects; The second is the anti-fatigue design technique to solve the stress concentration problem of the parts from the design. Three is the anti-fatigue machine processing technology, which is used to change the microstructure, micromechanical property and surface integrity of the metamorphic layer. The four is the precision heat treatment technology, which is used to refine the grain and structure of the material, obtain the inner quality of the high quality and the high surface hardness, and reduce the heat treatment distortion. The five is surface hardening, shotblast strengthening, rolling pressure strengthening, laser impact strengthening and composite reinforcement technology for surface enhancement modification. Six is anti-fatigue assembly, fatigue life evaluation and test technology, etc. In conclusion, the application of anti-fatigue manufacturing technology can greatly improve the reliability, life and power density of gears, and achieve light quantification. The team of academician zhao zhenye of aviation materials research institute has developed and applied anti-fatigue manufacturing technology, which can improve the service life of gears and bearings by more than 10 times.
Reporter: what are the main gear detection devices? What is the normal gear nondestructive testing method?
Secretary general wang: gear testing equipment is mainly divided into CNC gear measuring center, the gear meshing on-line measuring instrument, the gear measurement separator, ultra-precision three coordinate measuring machine, laser gear measuring instrument five categories. At present domestic gear testing instrument is given priority to with CNC gear testing center, large module gear detection is given priority to with precision three coordinate measuring machine, gear mesh meter application is less, less online measuring gear separator application. At present, precision CNC measurement center mainly imports products, and domestic CNC measurement center is less. The gear meshing measuring instrument is divided into two types: single and double rotometer. The domestic application of more gear double-face meshing measuring instrument is the 3100, 3101 series products of hain group, the Harbin jingda JS series products, and the sny-3 products of chengdu quantity-cutting tool factory. Online measuring gear sorting machine is mainly used in the detection of batch production gear, such testing equipment, the Japanese Osaka fine machine abroad AG series gear separation measurement system, the United States Hommel gear sorting ITW4900 gear measuring machine and the United States online quick separator. Huo group cooperated with Beijing university of technology to develop 3510 gear online measuring machine. Precision coordinate measuring machine are mainly on three sides, kang three coordinate measuring machine, Zeiss is suitable for the large gear measuring MMZ T three coordinate measuring machine, Windsor the flagship product of LH series bridge type three coordinate measuring machine, xi 'an Edward three coordinate measuring machine, etc.
Nondestructive flaw detection can be divided into three categories: ultrasonic flaw detection, magnetic particle detection and shading detection. The ultrasonic flaw detection of gear is mainly aimed at detecting the internal defects of large gear forging. The gear magnetic particle inspection is the surface defect of the crack, slag, etc. It is also a nondestructive testing method to check the defect marks of gear surface.
Reporter: in recent years, China's key gear technology and high-end gear products have made those breakthroughs? What is the development goal of the future gear industry?
Secretary general: in recent years, some key gear manufacturing technologies and high-end gear products have made breakthroughs in our country, many of which have reached the international advanced level. For example, a major breakthrough in the research of the key manufacturing technology of the casting rack in the three gorges ship lifter solves the problem of the global problem of the induction hardening of large steel rack. The key technology of the large planetary gearbox of the nuclear power plant is solved, and the batch production of the gearbox is realized. Multi-megawatt wind speed gearbox, large Marine gear box and Marine equipment large module gear rack key manufacturing technology reach international advanced level. At present, China's nuclear power plant circulating pump gearbox has replaced the import, which can meet the needs of China's nuclear equipment. The megawatt wind power growth box not only satisfies China's wind power industry matching, but also realizes the batch export. From 2014 to 2017, there are three gear obtains the national progress prize in science and technology projects, respectively is "high-end heavy-load gear key technology and industrialization" project won the 2014 annual national scientific and technological progress second prize, "lead precursor 8 block automatic transmission (at) research and development and industrialization" project won the 2016 annual national scientific and technological progress first prize, "high-speed trains with high reliability and gear transmission system" project won the 2017 national scientific and technological progress second prize. At the same time, must also see many high-end gear products in China is still a large number of imports, such as: industrial robot precision gear reducer, shield machine Lord reducer, large aircraft, heavy helicopter main rotor speed reducer gear products. In the next five to 10 years, China's gear industry will achieve the following objectives. One is markedly enhance its capability of innovation, the gear industry technology innovation system with continuous innovation ability, break through a number of core technology, form some international famous brand and patent, standard and certification system in line with international standards, make several internationally competitive multinational companies, innovation capacity and international competitiveness in the international advanced level; Second, gear products supporting ability and the ability to export increase, high-end gear products manufacturing capacity, the overall performance and quality of products reach the international advanced level, some reached the international leading level, basic gear products meet the demand of domestic key equipment and large engineering support, import and export trade by the huge deficit into a surplus or flat; Third, 2-3 gear enterprises enter the world gear 10, a batch of "special, fine, special, new" enterprises steady development; Fourth, to improve the concentration of industries and form a number of gear industry accumulation areas with international competitiveness; Five is energy-saving materials saving result is outstanding, gear near net shape, dry cutting, hard machining, superfinishing comprehensive promotion application of advanced technologies such as gear material utilization increased by 35%, productivity increased by 50%, reduce energy consumption, gear transmission power loss decreased by more than 30%.
Reporter: premier li keqiang has repeatedly offered to have innovative thinking and brand awareness. Please brief us on the two aspects of gear industry.
Secretary general wang: innovative thinking refers to the method of solving the problem in new thought processes, through this kind of thinking can break through the boundaries of conventional thinking, to extraordinary even unconventional method, Angle of view to think about the problem, put forward different solutions, to create novel and original thinking. In recent years, in the face of the rapid technological development and social change, the gear branch has vigorously promoted innovative thinking and improved the innovative thinking ability of entrepreneurs through training and entrepreneurship BBS. For example, in the Internet +, big data and cloud computing, under the background of the development of science and technology, I assembly and entrepreneurs in the industry on the BBS explain Internet + brings opportunity and challenge for many times, emphasizes the entrepreneurs must have the Internet, thinking, to have an eye for development, new things, dare to change, to seize new opportunities.
The brand means high quality, high reputation, high efficiency and low cost. The brand is not only the intangible asset of the enterprise, but also the representative of corporate image. It is a great wealth. Brand awareness is an enterprise's basic concept of brand and brand building. It is the consciousness of enterprises to consciously maintain and create brand name. Gear association, cultivate the enterprise brand and brand awareness, in the industry to promote quality and leading benchmarking enterprise demonstration activities, promote the performance excellence, six sigma and lean manufacturing, etc. The application of advanced production management mode, strive to build the culture atmosphere of power quality, brand societe generale, should not only cultivate across borders, with broad top brand visibility and reputation,
We will also cultivate domestic famous brands and go to "one factory, one brand, one innovation". Gear industry to emerge a batch of famous brand, for example, "meteorological teeth", "law", "and" double loop drive "has become a global wind power gear box, heavy duty truck transmission as well as the famous brand of automobile and engineering machinery gear.
Reporter: in response to President xi's "One Belt And One Road" strategy, domestic industries have stepped out of the country to seize this unprecedented development opportunity. What are the main actions of the gear industry?
Secretary general wang: "One Belt And One Road" strategic focus of the CPC central committee and the state council is to build a more comprehensive, more in-depth, more diversified pattern of opening to the outside world, the situation of major initiatives, for our country to speed up the formation of advocating innovation, pay attention to coordination, advocate green, open, promote the sharing mechanism and the environment is of great significance. Faced with this unprecedented opportunity, the gear industry has mainly taken the following actions. One is through the organization and project meeting, in the form of analysis and study the market opportunity brought by "One Belt And One Road", the main research of engineering machinery, nuclear power, transportation and building materials industry market opportunities; The second is to study international and domestic related standards, conduct standard training, and lay the foundation for "going out". Three is the construction of the national "gear strength and reliability test technology of public service platform", complete the key common gear manufacturing technology of database and testing technology service system construction, support gear technology and product innovation; Four is driving gear industry application of the modern advanced manufacturing technology, intelligent manufacturing technology, establish a stable product quality and online monitoring system, automatic and intelligent manufacturing system to improve product quality and stability of quality, satisfy "all the way along the" demand for high-end gear products and services; The fifth is to encourage enterprises to expand beyond the borders of the country, such as farster in Thailand and the south high tooth layout of Germany du east.
Reporter: how to effectively solve the vicious competition in the industry? What useful work does the club do in the industry's self-discipline and low - end capacity?
Secretary general wang: for high-end gear industry capacity, mid-range serious overcapacity led to the present situation of the competition is fierce, gear branch mainly take the following measures for industry self-discipline and reduce low capacity. First, strengthen industry self-discipline, formulate industry rules and relevant standards, implement industry supervision, and resist low-quality products; The second is to play the role of market guidance and push forward the supply-side reform of gear. Third, cultivate "special, refined, special and new" small giant enterprises, build enterprise unique advantage, avoid homogenization competition; Fourth, we will actively promote merger and reorganization, encourage small businesses to enter big enterprises and then lengthen the industrial chain, and form a pattern of complementary and coordinated development of large enterprise groups and small and medium-sized enterprises. Fifth, promote technological transformation and eliminate backward production capacity.