Research report of emerging machine tool enterprises (full version)

Abstract [Editor's note] This article is a research report written by China Machine Tool & Tool Industry Association based on the research of emerging machine tool enterprises. It contains five parts: research overview, basic research situation, leading product technology and market analysis, operation mode and development innovation, and research experience. With suggestions. One. Tune...

[Editor's note] This article is a research report written by China Machine Tool & Tool Industry Association based on the research of emerging machine tool enterprises. It contains five parts: research overview, basic research situation, leading product technology and market analysis, operation mode and development innovation, research experience and Suggest.

One. Survey overview

Since 2011, China's economy has entered a new normal of transformation and upgrading. In order to understand the new changes in the machine tool industry under the new normal, the Machine Tool Association organized a research team, led by Wang Liming, secretary general of the Machine Tool Association, and conducted field visits to some emerging machine tool enterprises in the “Pearl River Delta” and “Yangtze River Delta” regions in June 2018. And research. The focus of the survey is to understand the development and evolution of the company, business model, leading products, service areas, and industrial upgrading ideas, to explore the role of emerging machine tool enterprises in the overall development of China's machine tool industry, and to understand and promote the development of new business forms in China's machine tool industry. The implementation of "Made in China 2025" provides a useful reference.

two. Research on the basic situation of the company

This time, we surveyed 9 companies in the “Pearl River Delta” and 5 companies in the “Yangtze River Delta”, with a total of 14 companies. Among the 14 companies surveyed, 11 are metal cutting machine tool manufacturers and 3 are laser processing machine tool manufacturers. Most of these enterprises are newly established private enterprises after 2000. After more than ten years of rapid development, they have become an emerging force in the development of China's machine tool industry. The basic situation of the research enterprise is as follows.

1. "Pearl River Delta" region metal cutting machine tool manufacturing enterprises 7

(1) Zhuhai Gree Intelligent Equipment Co., Ltd.

Zhuhai Gree Intelligent Equipment Co., Ltd. is a wholly-owned subsidiary of Gree Electric Group and was established in September 2015. The company's products cover more than 10 fields including servo manipulators, industrial robots, intelligent storage equipment, intelligent testing, heat exchanger-specific machine tools, unmanned automated production lines, and CNC machine tools. The company has established three R&D projects in Zhuhai, Guangdong Province. The production base has a total area of ​​about 300,000 square meters and is used for the incubation and industrialization of industrial robots, CNC machine tools, automation equipment, and automated production lines. According to reports, Zhuhai Gree Intelligent Equipment Co., Ltd. has more than 1,000 employees, and its output value reached 2.1 billion in 2017. Among them, about 500 sets of machine tools have been produced, and the output machine tools are mainly used for processing internal parts of the Group. The company has now built a "precision CNC machine tool center" constant temperature manufacturing workshop, purchased the Longmen Machining Center produced by Daxie and Toshiba, a large-scale quilt of Haikete Company, and a number of advanced mother machines such as Stuart Precision Grinding Machine, which have been developed and produced. Lijia, lying, five-axis machining center, drilling and attack center, graphite processing machine, laser cutting machine, injection molding machine, etc., the future development is based on 3C processing, air-conditioning compressor processing, complete production lines and high-end machine tools. The characteristics of Gree Intelligent Equipment Co., Ltd. is that the intelligent equipment products are complete in variety and rich in equipment resources, which can meet the needs of the intelligent equipment field. The company's complementary role in CNC machine tools, industrial robot integration applications, large-scale automated production line solutions, etc. is very obvious, can provide customers with complete solutions and improve after-sales service.

(2) Shenzhen Genesis Machinery Co., Ltd.

Founded in 2005, Shenzhen Genesis Machinery Co., Ltd. is headquartered in Bao'an District, Shenzhen. It has three production bases with a plant area of ​​over 70,000 square meters and 1,800 employees. The monthly output can reach more than 1,800 machine tools. Sales of 3.4 billion yuan. It owns two brands, Taikan and Yuken. CNC machine tools include drilling and tapping machines, parts processing centers, mold processing centers, engraving and milling machines, high-gloss machines, glass engraving machines, and sweepers. Lathe, gantry machining center, etc. The company is geared towards 3C, automotive, mold and high-end manufacturing, exerts strong supply chain capabilities, strengthens R&D and testing capabilities, focuses on cost-effective machine tool batch integration manufacturing, and jointly develops CNC systems to develop new applications such as Horizon and Longmen Machining Center. Products, and layout of manufacturing bases in South China and East China.

(3) Guangdong Kejie Machinery Automation Co., Ltd.

Founded in 1998, Guangdong Kejie Machinery Automation Co., Ltd. is registered in Jiangmen, Guangdong. It currently has more than 960 employees, covering an area of ​​110,000 square meters and a factory building of 30,000 square meters. The company specializes in three-axis, four-axis and five-axis linkage high-speed CNC engraving and milling machine series for equipment manufacturing, shoe molding machine, JTHB high-gloss machine (glass processing), glass CNC machining center, high-speed drilling and milling center, six-degree-of-freedom robot, LS fiber laser cutting machine, graphite high speed machine, TM teaching machine, etc. Among them, JTGK series high-speed CNC engraving and milling machine is a representative new technology product of the company. Currently has two core brands: "Jiatie" and "Kejie". Developed JT CNC system by yourself. The company is committed to the development and production of 3C high-end engraving and milling machine. The company's products have been exported to Germany, the United Kingdom, Japan and other industrial powers.

(4) Guangdong Runxing Technology Co., Ltd.

In 2008, Guangdong Runxing Technology Co., Ltd. was established in Xiegang Town, Dongguan City, Guangdong Province. The company has 680 employees and covers an area of ​​about 70,000 square meters. In 2017, the output of CNC machine tools was 8,470 units, and the sales revenue was 1.22 billion yuan. In 2013, the company established the Guangdong Engineering Technology Research Center (the establishment of CNC machine tool research and development center). In recent years, the company has built new factories, purchased Dahua Company's Wojia and Longmen Processing Centers, etc., and made efforts to improve the self-control ability of key parts and laid out the Chongqing manufacturing base. The company has a supporting parts supply chain system and has strong processing and assembly capabilities. The company's products are mainly general-purpose machining centers, including: drilling and tapping machining center, vertical machining center, horizontal machining center, gantry machining center, engraving and milling machining center, industrial robot six series of more than 60 varieties. In 2017, the company launched a series of glass, ceramic and graphite processing machine tools. The company's products are mainly used in electronic products (including IT products, communication products, consumer electronics), auto parts, various types of mold processing, and in automation equipment, new energy. , medical equipment, instrumentation, general machinery and other industries have applications.

(5) Dongguan Qiaofeng Machinery Co., Ltd.

In 2009, Qiao Feng Machinery Co., Ltd. established a factory in Dongguan, Guangdong Province, and began to import parts and components from Taiwan, Japan, and the European Union. It has become a professional manufacturer of CNC machine tools. In 2012, the company purchased two factories in Nanjing Lishui (Longmen and Tijia) and Dongguan Changping Chenwubei Industrial Zone. The company now covers an area of ​​14,400 square meters and has 390 employees. In 2017, the output of machine tools was 2,155, and the sales revenue was about 500 million yuan. The main products include high-speed drilling and tapping machining center, vertical machining center (line rail, hard rail), heavy cutting gear spindle vertical machining center, gantry machining center, CNC lathe and turning center, horizontal machining center, high-light machine, Vertical lathes, etc. The company hired Taiwan engineers to guide the technology and production, and purchased various advanced testing equipment from abroad, such as laser interferometer, coordinate measuring machine and motor dynamic balance meter. The Japanese-style unitized batch management production mode and the European machine tool industry's food delivery material management system are adopted. The modular assembly and commissioning operations are carried out according to the nine units, and the production and joint responsibility system is used to comprehensively control the processing and assembly quality. The company's machine tool products are sold at home and abroad, among which the Longmen Machining Center and Liga have entered the aircraft manufacturing users in China.

(6) Dongguan Jugang Machinery Industry Co., Ltd.

Founded in 2006, Dongguan Jugang Machinery Industry Co., Ltd. has more than 500 employees and a total construction area of ​​63,000 square meters. In 2017, the output of machine tools was 1,800 units, and the sales revenue was 420 million yuan. Jugang's products include: drilling and tapping center, vertical machining center, horizontal machining center, linear motor gantry machining center, bridge gantry machining center and other five series of more than 20 models, products used in metal, graphite, ceramics, etc. 3C processing of traditional and new materials, as well as automotive, military, medical equipment and other industries. The company's information management uses SAP's ERP and PLM systems, as well as OA office systems, warehouse barcode management systems, and CRM sales management systems. The company has its own C80\C90 series CNC system, which has 4 business divisions and electric equipment workshops. The company is equipped with Daxie company's horizontal and gantry machining centers, as well as horizontal boring and guide grinding machines. It has the key processing capability of machine tools. Strict testing of the self-made parts process and purchased parts to ensure the machine assembly process requirements.

(7) Shenzhen Dingtai Intelligent Equipment Co., Ltd.

Shenzhen Dingtai Intelligent Equipment Co., Ltd. was established in 2003. The headquarters and technology research and development center is located in Shenzhen, Guangdong Province. The company has established production bases in Shenzhen, Guangdong and Kunshan, Jiangsu. The company has a complete supply chain of matching parts, and purchases the optical machine to assemble and assemble, forming integrated manufacturing as the main means. The CNC system jointly developed by the company and Huazhong CNC Co., Ltd. has been batch-matched, and the products include high-speed CNC with various specifications. Drilling and milling centers, high-light machines and machining centers, and include robotic automation smart devices. The company's products have been widely used in the manufacturing industries of consumer electronics, communications, automotive and precision molds.

2. 4 metal cutting machine tool manufacturing enterprises in the “Yangtze River Delta” area

(1) Neway CNC Equipment (Suzhou) Co., Ltd.

The company is located in Suzhou High-tech Zone, with an investment of 150 million US dollars and covers an area of ​​200,000 square meters. In 2017, the number of employees exceeded 800 and the sales revenue exceeded 1 billion yuan. The company has a constant temperature comprehensive production workshop, test center, machining workshop, heat treatment workshop, standard product assembly workshop, logistics center and so on. The company's Neway Machine Tool Research Institute is positioned to develop high-end CNC machine tools and currently has more than 100 R&D engineers. The company's product varieties include: vertical horizontal CNC lathe, vertical horizontal machining center, gantry machining center, CNC floor boring and milling machine, processing automatic line and so on. The company introduced the high-precision boring and milling center of Swiss SIP (Sip), the high-precision CNC universal grinding machine of Klimberg, Switzerland, the guide grinding machine of Italy Visionu, the horizontal machining center of Heckert, Germany, and the five companies of Saia, Spain. Surface gantry machining center, etc., and equipped with three coordinate measuring machine, laser interferometer, dynamic balance instrument, spindle temperature rise test bench and other testing equipment. The use of these devices provides a reliable guarantee of the accuracy of machine tool components. The company adopts advanced ERP management system. The assembly process is divided into main shaft gear box assembly, bed and column assembly, beam and sliding saddle and spindle box assembly, mechanical assembly, mechanical assembly, electrical assembly, and electrical. Assembly, machine debugging, geometric accuracy inspection, electrical function inspection and debugging, servo adjustment, whole machine dry running test, anti-vibration re-cut test, re-examination geometric accuracy, position accuracy detection, work accuracy detection, machine storage, shipping A total of 18 manufacturing and inspection processes. The company's products are mainly general-purpose CNC machine tools, and the company's products have the strength to compete with Korean and Taiwanese machine tools.

(2) Nantong Guosheng Intelligent Technology Group Co., Ltd.

Nantong Guosheng Intelligent Technology Group Co., Ltd. is located in Gangzha Economic Development Zone, Nantong City, Jiangsu Province. It was established in 2000 and has 883 employees, covering an area of ​​220,000 square meters. In 2017, the output of machine tools was 2,150 units, with a total output value of about 850 million yuan. It owns many subsidiaries such as Guosheng Zhike, Guosheng Precision Machinery, Guosheng Foundry, Suzhou Zhonggu (Electrical Processing Machine Tool), David Seiko (Taiwan Joint Venture-Horizontal Boring and Milling Machine), and Nvidia (Sino-German Cooperation-CNC Lathe). The company's industry has been inherited for four generations. Since its establishment in 1996, it has been engaged in the processing of sheet metal processing companies, and has provided optical machines. It has gradually developed into a focus on R&D and manufacturing of CNC vertical machining centers, high-speed gantry machining centers, horizontal machining centers, and Medium and high-end CNC machine tools and production lines, such as boring and milling machines, CNC lathes, turning and milling composite centers, are engaged in casting, sheet metal processing, machining, final assembly, etc. The machine tool manufacturing industry chain is complete. Among them, sheet metal processing products have been long-term supporting for international famous enterprises such as Germany Dmag, Germany Bomag, Germany Trumpf, Sweden Sandvik, Japan Toshiba Machinery, Canada Husky, Foxconn Group. The company is committed to providing solutions to end customers with its manufacturing strength and after-sales service to meet the cost-effective selection requirements of customers.

(3) Jiangsu Habo Precision Machinery Technology Co., Ltd.

Jiangsu Habo Precision Machinery Technology Co., Ltd. was established in 2016. The company is located in Changzhou, Jiangsu. More than 90% of the company's core team has “985” university master's degree or above or overseas study experience. All of them have experience in research and development of ultra-precision processing equipment. The company's main products include ultra-precision turning, grinding, grinding and polishing equipment, as well as ultra-precision functional components (super-precision spindles, ultra-precision turntables and guide rails). The company is mainly engaged in the manufacturing of high-end precision and ultra-precision CNC equipment. It integrates R&D, manufacturing, production and sales. At present, the main products are ultra-precision hard lathe, ultra-precision single-point diamond lathe and ultra-precision CNC die-turn lathe, 2017 Started sales of ultra-precision machine tools, high-precision spindles and turntables.

(4) Jiangsu Fuqiang Technology Co., Ltd.

The company is located in Suzhou and employs 1,800 people. In 2017, its sales revenue was 1.2 billion yuan. The company is an integrated manufacturer of intelligent manufacturing and automation solutions. The main hardware products include: inspection and wire-forming equipment, such as 3C field circuit board air tightness inspection machine, automatic dispenser, battery assembly line. The company has the ability to assemble and integrate CNC machine tools, such as assembling high-speed machining centers, drilling machining centers, high-gloss machines and other machine tools. Under the leadership of Huazhong CNC Co., Ltd., the company provided the “National Intelligent Manufacturing Demonstration Factory” equipment for the parent company, Suzhou Shengli Precision Manufacturing Technology Co., Ltd., which mainly includes 189 CNC machine tools, stereo library, AGV trolley and joint robot. Etc., forming 20 automated processing lines, mainly processing 3C parts and watch parts.

3. Laser equipment manufacturing companies 3

(1) Foshan Hongshi Laser Technology Co., Ltd.

The company is located in Shunde, Foshan City. It was established in 2006 and has 650 employees. The company has a total construction area of ​​over 40,000 square meters. In 2017, the output of laser machines was 1,500, and the sales revenue was 1.01 billion yuan. The company has four standardized intelligent equipment manufacturing. Base, the main products are fiber laser plane cutting machine, fiber laser cutting machine, fiber laser tube and tube integrated machine, supporting fiber laser power 0.5-15kW. The company has technical features such as flexible manufacturing and digital hierarchical management in the fields of laser robots, multi-axis linkage professional cutting, precision welding intelligent automatic production lines. Hongshan Laser Intelligent Equipment has been operating stably in more than 100 countries and regions around the world, and has benchmarked customers in precision instruments, auto parts, kitchen and bathroom hardware, electrical and electronic, smart home and other industries.

(2) Shenzhen Dien Laser Equipment Co., Ltd.

Shenzhen Dien Laser Technology Co., Ltd. was established in Shenzhen in 2008. The company has a production base covering an area of ​​more than 30,000 square meters. In 2017, it produced 1,800 laser cutting machines with a sales income of 1.5 billion yuan and 800 employees. In 2016, the company was successfully joint venture with Swiss Baichao Laser Group, namely: Shenzhen Dien Laser Technology Co., Ltd. is a Sino-foreign joint venture listed company jointly invested by Swiss Baichao Laser Group and China Dien Laser. The brand is updated to: Baicha Dien Laser. The main products of Baichaodi Energy Laser are: high power fiber laser cutting machine (2-12kW), medium power fiber laser cutting machine (<2kW), after years of professional research and development, production and sales of metal laser cutting machine, laser cutting machine in China The field has market influence.

(3) Suzhou Xunlei Laser Technology Co., Ltd.

Suzhou Xunlei Laser Technology Co., Ltd. was established in Suzhou Industrial Park in Suzhou in 2009. The company has three production R&D bases with a total construction area of ​​80,000 square meters. The company employs more than 600 people and has an annual output of more than 1200 laser processing equipment, including laser cutting machines, laser welding machines, laser micromachining and other fields. In 2017, sales revenue exceeded 1.2 billion yuan. The company has three mainstream product lines of laser cutting machine, laser welding machine and laser marking machine. The maximum power of laser is 12kW. The main products are laser cutting machine, laser welding machine, laser marking machine, laser engraving machine, fully automatic laser matching application. Equipment - robots, non-standard equipment, and nearly 30 kinds of laser application equipment such as optical fiber, green light, violet light, stripping, and laser marking series. The company is engaged in R&D, design, production and sales of automated production lines.

three. Leading product technology and market analysis

1. Leading products and technical features

The leading products of the 14 emerging machine tool companies in this survey vary with their respective backgrounds, development history and market positioning. They show diversity changes and can be roughly divided into 3C, general gold cut, ultra-precision parts and There are four major categories of machine tools and laser processing.

(1) 3C product machine tools

3C products refer to computers, communications, and consumer electronics. The parts of such products have the characteristics of small size, light weight, high processing precision, especially high surface quality, large processing volume and high processing efficiency. Around the processing of such parts, the main products are drilling and tapping machines and engraving and milling machines (and a variety of dedicated engraving and milling machines).

Drilling and tapping machine. This is a kind of machining center that users are familiar with, and it is also the most extensive product of all enterprises, especially the model of the machine tool manufacturing industry in South China. The top tool magazine and C-type compact structure are its main structural features, and light load and high speed and high efficiency are its main working characteristics. The maximum width of the table is 500mm, and the maximum rapid traverse speed is 60m/min. The spindle is driven by direct-connected motor or electric spindle. The maximum speed is 36000r/min, the main motor power range is 3.7-5.5kW, and the tool magazine capacity is generally 16, 21. The tooling time (TT) is 1 s, and the positioning accuracy is generally ±0.005/300 mm.

Engraving and milling machine. This is a kind of machine tool for engraving and milling with high-speed and small-diameter tools. The structure of the small gantry and the higher speed, engraving and milling precision and surface roughness of the drilling center are its main technical features. The maximum width of the table is 750mm, the maximum speed of the electric spindle is 36000r/min, and the maximum rapid traverse speed is 60m/min. This type of machine has developed a variety of special machine tools in the mobile phone industry, generally using natural granite beds and columns, such as grinding, slotting, opening, cutting and chamfering for mobile phone glass or ceramic back cover. Glass machine and ceramic machine; high-light machine dedicated to mirror processing of metal phone case and buttons, etc.; turning and milling machine with additional turning function on the engraving and milling machine (adding turntable on the worktable and fixed turning tool on the milling head) The surface of the mobile phone casing can be obtained differently from the surface of the engraving and milling process to meet the individual requirements of the customer; in addition, there is a graphite machine dedicated to the engraving and milling of graphite materials, and a mobile phone through-hole drilling machine.

(2) General gold cut

It mainly includes three categories: CNC car, machining center and gantry machining center.

CNC car. Can be divided into horizontal, vertical and large CNC horizontal car three categories, mainly concentrated in East China's Neway. Guosheng was just starting to produce turning products after the introduction of some of its designers after the closure of the DMG MORI Shanghai plant. Only Gree in South China produces a small number of horizontal turning centers. The horizontal turning center has a diameter range of 160-630mm, a 45° slant bed, the main drive is a belt drive, and the machine is equipped with a non-powered turret or a power turret. The guide rails are divided into linear guides and slide guides according to the model. The model of the power turret has a C-axis function, which enables three-axis linkage. The large CNC sleeper has a diameter range of 850-1900mm, a flat bed, a V-flat rail, a 4-station index turret, and a spindle cylinder hydraulic cylinder for automatic shifting. The vertical turning center products are also concentrated in Neway, single-column single-tool type with a cutting diameter range of 550-2500mm.

Machining Center. Can be divided into horizontal and vertical.

The horizontal machining centers are produced in Kejie, Qiaofeng, Jugang, Dingtai in South China and Guosheng and Neway in East China. At present, Neway's production is the largest. The layout of the machine tool is divided into positive T type (medium and large size) and inverted T type (medium and small size). The maximum size of the table is 1100mm×1100mm. The spindle taper hole is divided into HSK and BT. The linear axis rapid traverse speed is more than 20m. /min, with automatic channel change function, the table is 1°, mostly three-axis linkage, and also has four-axis linkage type with B axis.

Each of the vertical machining centers has its own products with a wide range of specifications. The machine layout has C type (fixed column type), moving column type, bridge type (table fixed) and small gantry type; the linkage axis has 3 axes, 3+1 axis, 3+2 axis and tilting table 5 axis linkage According to the purpose, there are general-purpose and high-speed high-precision mold types; according to the type of guide rail, there are linear ball guides, linear roller guides, sliding (hard rail) guide rails and two-track rails plus one slide rail (general Z-axis is a sliding guide rail) According to the main drive type, there are belt type, direct type, gear type; the maximum width of the table is 800mm, and the maximum width of the door type plus table is 1000mm.

Gantry Machining Center. South China's Qiao Feng, Run Xing, Ding Tai, Gree and East China's Guosheng and Neway have production. The variety specifications are very rich. There are fixed beam worktables, fixed beam moving columns and viaducts in the overall layout of the machine tool; there are five sides and five axes in function (including five types of viaducts, all of which are A/C axis pendulum). Head) and general three-axis gantry; T-shaped and four-sided embracing square and rectangular shape on the shape of the ram; heavy and high-speed type on the working load; linear guide rails are mostly used on the rail type, and a few are sliding guides; In the spindle drive mode, there are direct drive, belt drive, gear drive and electric spindle; in the control mode, it is generally semi-closed loop control, and the five-axis linkage machine adopts full closed loop control. The medium and small size machine tool has an automatic tool change function, and the medium and large size machine tool has an automatic head change function. The machine's largest specification table is 3000mm wide, with a maximum load capacity of 45t and a fast speed of less than 20m/min.

(3) Ultra-precision parts and machine tools

This refers specifically to the three ultra-precision parts of Jiangsu Habo Precision Machinery Technology Co., Ltd. and three ultra-precision machine tools for its specific application.

Fluid (gas/liquid) ultra-precision hydrostatic turret. The table top is available in 150 and 300mm diameters. Take the 300mm gas static pressure turntable as an example, the maximum axial/radial load is 100/60kg, the maximum speed is 50r/min, the rated torque is 10.73N·m, the positioning accuracy/repetitive positioning accuracy is ±1′′/1′′, axial And radial motion error 0.1μ. It can be used in light load ultra-precision machine tools, ultra-precision measuring instruments, satellite attitude ground simulators, multi-axis turntables and other fields.

Fluid (gas/liquid) ultra-precision hydrostatic spindle. Take the gas static pressure main shaft as an example, the maximum axial/radial load is 180/80kg, the main shaft is driven by synchronous motor, rated speed 3000r/min, rated torque 15 N·m, rated power 5kW, positioning accuracy/repetitive positioning accuracy ±1 "/1", axial and radial motion error 0.05μ, axial/radial stiffness 438/130N/μm. Mainly used in ultra-precision turning spindles.

Fluid (gas/liquid) series of ultra-precision hydrostatic guides. Taking the hydrostatic guide rail as an example, there are currently three specifications of 400, 600, 2100mm in the stroke, positioning accuracy ± 0.5μ (full stroke), ± 0.8μ (full stroke), ± 1.5μ (full stroke), linear motor drive.

Ultra-precision CNC single-point diamond lathe. Horizontal T-shaped layout, using natural granite as the base and guide rail material, the whole machine is supported on the active vibration isolation self-balancing system bracket, the main shaft (C-axis), the turntable (the knife table B-axis) and the guide rail adopt the aforementioned three super Precision gas static pressure functional components. The machining accuracy is based on a 75mm diameter aluminum alloy. The surface accuracy (PV-maximum difference/peak) ≤0.2μ, the surface roughness (Ra) ≤2.5nm, and the DELTA TAU POWERPMAC 64-bit CNC system running in Windows environment. The machine can be used for the processing of optical lenses, optical cores, and mirror-finished mechanical parts. It can also be expanded to a four- or five-axis machine with flexible configuration for spherical, aspherical, free-form, microarray, Fresnel lens Precision Machining.

Ultra-precision hard car. Horizontal slant bed layout, natural granite bed, ultra-precision hydrostatic spindle (including static pressure tailstock), ultra-precision hydrostatic guide, Hyprostatik hydrostatic screw feed drive, Germany SAUTER 12-station turret. The maximum processing diameter is 380mm, the maximum workpiece length is 350mm, the maximum bearing weight is 150kg, the spindle axial/radial runout is ≤0.2μ, the C-axis positioning accuracy/repetitive positioning accuracy is ≤2′′/1′′, SIEMENS 840D numerical control system, HEIDENHAIN high-precision grating Full closed loop control.

Ultra-precision horizontal CNC die-turn lathe. The horizontal layout is made of natural granite as the base and guide rail material. The whole machine is supported on the active vibration isolation self-balancing system bracket. The German hydrofloating company produces the hydrostatic main shaft and the tailstock main shaft, and the ultra-precision hydrostatic rotary table ( B-axis), ultra-precision hydrostatic guide rail, maximum machining diameter 600mm, maximum workpiece length 3000mm, maximum load capacity 2000kg, spindle and B-axis axial/radial runout ≤0.2μ, spindle positioning accuracy/repetition positioning accuracy ≤2′′/ 1′′, machining shape error <5μ, surface roughness (Ra) <10nm, DELTA TAU Advantage 900 CNC system running in Windows environment, full closed loop control. The equipment can be used for ultra-precision machining of surface microstructure of key mold roll parts of RTR (imprint) process in LCD display, concentrating photovoltaic system, traffic signage, naked-eye 3D equipment, etc.

(4) Laser equipment

Laser processing equipment of Baicha Dieneng, Hongshan and Suzhou Xunlei can be divided into five types: laser plane cutting, laser tube cutting, 3D laser robot cutting machine, laser micromachining equipment and laser welding machine. The use of optical fiber transmission is the best choice for current products. The main key components such as power supply, laser, laser head, rolling guide, ball screw, rack and pinion, CNC system, servo system and servo motor are mainly from the United States, Germany, Switzerland, British, Japanese and other overseas brand products, the configuration grade is generally higher.

Laser plane cutting machine. This is the most extensive product of the three companies, welded bed and integral pressure cast aviation aluminum alloy beam, the maximum laser power is 15kW, the maximum cutting range is 8000mm×2500mm, the maximum acceleration is 2.8g, the maximum running speed is 196m/min, repeat The positioning accuracy is ±0.02-0.03mm, and the high automation product has the function of automatic channel change.

Laser pipe cutting machine. Both Hongshan and Xunlei have production, the maximum laser power is 8000W, the maximum cutting diameter is 220mm, and the square tube is 200mm×200mm. The fully automated product has automatic loading and unloading function. Hongshan also has a five-axis linkage pipe cutting machine. Angle cutting head for cutting the groove.

3D robotic cutting machine. Hongshan products, the maximum load of 30kg, maximum arm extension 2000mm, 6 joints, repeatable accuracy ± 0.05mm.

Laser welding equipment. There are many types of 3D laser welding machines that use a scanning galvanometer laser welding head, a 6-joint robot and a flexible table to perform continuous welding on the space weld. The fiber-optic weld tracking filler wire welding machine is equipped with a weld seam tracking system that optimizes and adjusts the welding parameters in real time and performs cold wire filling welding on wide gap welds. The galvanometer welding machine, with a maximum laser power of 3KW, is mainly used in high-efficiency laser spot welding of mobile phone shields, metal phone cases, metal capacitor casings, computer shielded metal screens, razor blades, electronic connectors and other electronic products. Or seal welding. In addition, there are fiber-conducting welding machines (including continuous welding machines), soldering machines, plastic welding machines, and so on.

Laser micromachining equipment. Including glass, sapphire cutting drilling machine, PCB (printed circuit board) / FPC (flexible circuit board) precision board machine, ceramic precision cutting and marking machine and automatic wafer cutting machine.

2. Leading products adapt to market conditions

Emerging machine tool companies can be germinated for many reasons, and it is an important part of adapting products to market demand and being able to respond quickly and flexibly.

(1) Seizing the opportunities of 3C and home appliance market development is a key factor in the emerging of South China machine tool enterprises

Taking the mobile phone market as an example, from the replacement of ordinary mobile phones to smart phones, and the explosive development caused by this, the product chain of processing metal casings and glass panels provides an unprecedented development opportunity for enterprises. The drilling center of the processing casing, the glass engraving machine for processing the glass panel, and the drilling machine for the sound hole are the hot products in the market. After that, we paid close attention to the trend of individualized demand in the market, and timely introduced high-gloss machines and turning and milling machines that can process higher surface quality and different textures. When the demand for curved screens and ceramic mobile phone back covers appeared, the graphite machine, 3D hot bending machine, curved surface sweeper and ceramic engraving machine for processing curved screen hot pressing molds were introduced in the market. In fact, the demand for manufacturing equipment in the mobile phone market has not stopped. The transformation of the next-generation 5G mobile phone case from the box to the frame and the material changes (such as ceramic housing, glass housing) have already caused the main models. The sales volume of the drill attack center has fallen sharply. The good news is that companies have noticed such changes and are thinking about the future direction. During the interview, we learned that some enterprises have invested and built factories along the Yangtze River, including East China. Perhaps this is the result of their thinking. "We are doing light, the north is heavy." In the self-recognition, it seems that some of their future trends can also be seen.

(2) Adopting new laser technology and seizing the development opportunities of laser equipment market are the key factors for the success of emerging laser equipment manufacturers

The new laser technology mentioned here includes two factors. First, the fiber laser technology does not require the complicated optical path transmission system of the conventional laser equipment, which greatly reduces the difficulty of design, manufacture and maintenance, and the cost is low; Fiber laser manufacturing technology and market development are rapid. The development opportunities of the laser processing equipment market also include two factors, one is the rapid application of traditional applications, such as precision machinery, auto parts, kitchen and bathroom hardware, electrical and electronic, smart home, and the new application areas and new Application demand, such as changes in materials, thickness, cutting efficiency, etc., is rapidly increasing in demand for high-power fiber laser equipment. The laser processing equipment enterprise has seized the development opportunity of perfect combination of this technology and market demand, and has achieved the revitalization and development of the enterprise.

(3) Focus on product development in sub-sectors is an important factor in the success of emerging gold-cut machine tool manufacturing enterprises

The Longmen Machining Center is a typical example. When everyone is subject to the depression and sluggishness of large machine tools, especially the Longmen machine tool market, Neway, Guosheng and Genesis have shown another completely different scenario, with less monthly output. Three or forty, and six or seven. The reasons are manifold, but if the product is adapted to the market, the product diversity based on market segmentation is one of the reasons for success. Newwell, Guosheng and Genesis started the machine tool manufacturing business in 2000, 2010 and 2008. It should be said that the time is not long, and the time for entering the development of the gantry machine tool is later than this, but now Newway’s The gantry machining center has developed into 7 series of 85 varieties of specifications, Guosheng 4 series of 36 varieties of specifications, Genesis 2 series of 38 varieties of specifications. This dense product spectrum is an important magic weapon for their response to diverse market needs.

3. Analysis of main components and CNC system

A comprehensive analysis of the product support of 14 companies can be summarized and summarized.

First, with overseas support, the share of China's products is weak. Rolling components (including ball/roller screw, linear ball/roller guide, screw support bearing, spindle bearing, ceramic bearing, etc.), tool magazine and automatic tool changer (disc, bucket, chain, etc.) , spindle gearbox, electric spindle, CNC system, servo drive system, etc. basically use German (Siemens), Japan (Fanaco, Mitsubishi), Taiwan products (new generation). The four- and five-axis high-end CNC systems and servo drive systems are the same as Siemens and FANUC.

Second, even for mid-range or mid-range products, the situation is still the case. As can be seen from the introduction of these leading products, many products are not high-tech high-end products, and the application fields of these products are mostly concentrated in the 3C and household appliances markets, not to mention the current "supporting shortage" period. When looking for new sources of supply for the supply of supporting parts, the domestic machine tool parts can still not follow the trend, and the deep drawbacks can be seen. It is time to solve them.

Third, the situation of laser products is more prominent, and the cost of the matching parts is higher than that of the gold cutting machine. In addition to a few mechanical parts such as fuselage, beam, and appearance protection, the other core key components include the same rolling components as the gold cutting machine, fiber laser, ultra-high precision planetary reducer and rack, servo motor, and swing angle laser head. , guide rails and lead screws, laser heads, lenses (for laser heads), joint robots in laser three-dimensional cutting or welding machines, servo controllers / control motors and some electrical components, mostly in the United States, Germany, Switzerland, Japan , British brand products.

Fourth, the domestic CNC system has a certain performance. In the case that the external dependence of the main supporting links of China's machine tool industry is at a relatively high level, the investigation found that the domestic CNC system still has certain functions in South China and East China enterprises, such as Huazhong CNC in Dingtai, Genesis, Runxing,乔锋产品上的应用以及在苏州胜利3C产品生产线乃至智能化示范工厂方面的应用。其中可借鉴的一点是,国产数控系统的推广与应用要与用户紧密配合,从发挥企业产品自身技术优势角度以及实现用户工艺要求为核心,开展多种形式的合作,定制数控系统的技术路线,并在生产应用中不断持续改进,就能取得进步。

4. 生产及制造工艺特点——流水作业

由于这些企业产品量大,在装配作业中普遍采用流水作业(包括电柜的组装),机床固定,人员流动,一批批投,几天后一批批出。这样的作业方式对于外协外购品的组织、工序的合理设计、“配膳”的跟进、工序作业与检验标准的制定与落实等一系列管理提出了很高的要求。在这点上,我们感觉这些企业具备了规模批量化生产作业的组织能力、管理能力和控制能力。

四. 运营模式与发展创新

1.新兴机床企业的运营模式

我国装备制造业产业规模已连续多年居全球第一,约占世界总量的三分之一,其中电力装备的制造总量大约占世界的60%,造船工业占比达40%,汽车年产量和高铁的拥有量位居世界第一,3C产品和家用电器产量世界第一。我国装备制造业的高速发展有赖于工业母机——机床产业的支撑。特别是2000年以来,在我国“珠三角”和“长三角”一带, 3C产品以及家用电器和汽车零部件制造业快速发展,对加工机床需求急速上升,据专家测算,“珠三角”和“长三角”一带,仅钻削中心、C型立加和精雕机类机床年需求量超过10万台,加工玻璃、陶瓷和金属的“高光机”年需求量超过4万台。由此造就了一大批新兴民营机床企业迅速崛起,成为机床行业新的增长极和行业新生力量。

在华南企业中有“轻资产”与“重资产”两种运营模式之分,资产的轻与重指的是企业的生产设备和设施。一般说,从3C产品做起的企业,属于“轻资产”型,即没有或很少加工设备,且厂房条件较为简朴,以外协外配套和组装为主要生产模式。从传统机床做起的企业,属“重资产”型,较“轻资产”型企业多了一些关键把关机械加工设备(当然,关键的检测设备都是有的),机床的基础件乃至主轴加工能自行解决。这两种模式孰优孰劣难分仲伯,14家企业无论资产轻与重,目前都获得了成功。资产的轻重不一定就是企业的固定模式,实际上“轻资产”企业也很眼热“重资产”企业。但有一点是大家共识的,即资产的轻重一定要量力而行,只有挣到了钱,才能谈投入,任何时候不能置企业于资不抵债、资金断流的危险中。经调研和初步分析,新兴民营机床企业的投资和运营模式可分为以下类型。

(1)大型企业集团投资机床企业的运行模式

本次调研的“珠海格力智能装备有限公司”和“纽威数控装备(苏州)有限公司”是属于大型企业集团投资的子公司,由于大型企业集团财力雄厚,创建机床公司初期投资力度大,基础厂房建设配套,初期购置一批世界先进的加工母机和检测设备基本到位。公司引进机床行业技术人才,目标定位在中高端数控机床的研发和生产,初期生产的机床可为集团母公司企业加工配套,稳扎稳打,逐步推广在全国装备制造业销售应用。这类机床企业按照母公司运营模式运行,整体管理规范,但由于进入机床产业时间较短,需要有一个技术和产业逐步积累提高过程。从总体看,这类企业具有较强发展生命力,是我国机床行业崛起的新生力量。

(2)以配套供应链为纽带的机床集成制造模式

据专家介绍,2017年全球智能手机年销售量超过15亿台,其中手机主要机加工件(手机面板、中框和盖板等)90%以上在我国加工制造。在我国“珠三角”和“长三角”地区,3C行业和家用电器零部件加工量也非常巨大,因此这类加工机床的需求非常庞大,这些用户行业对机床需求订货的特点是:机床订货数量大(一次合同几百台、几千台)、交货期紧迫、要求机床加工稳定、投资回收期较短、用户服务及时等,为适应这些行业加工需要,一批以配套供应链为纽带的机床集成制造企业应运而生。这类企业以民营企业为主,具有强大的配套供应链和快速决策市场反应能力,以采购光机、数控系统、滚动导轨和丝杠、电器件、防护和附件等,迅速组织整机组装、调试和交货。这种运营模式是我国机床制造业发展中非常独特的模式,对我国3C等制造业迅速发展具有重要意义。随着机床行业的技术进步和企业的资金积累,这类企业随3C领域产品的发展和对设备需求的变化,普遍意识到产品转型升级的迫切性和重要性,在新机型开发、配套件和整机的检测、技术人员的培养等方面开始重视投入,在核心部件的制造上也开始着手布局。相信随着时间推移,这类发展好的企业也将成为机床行业发展较快的新生力量。

(3)掌握数控机床核心技术的新型制造模式

企业发展演变通过技术进步和资金积累等手段,发展实力增强,进而逐步掌握机床整体设计技术、运动控制技术、机床驱动和伺服优化技术、试验检测技术、可靠性等核心技术,并拥有机床关键件如主轴、床身、立柱等关键件加工手段和整机装配检验能力,企业具备技术和产品创新能力,实现两头在内、中间在外的制造模式,即研发、关键件制造、整机组装和用户服务由主机制造企业掌握,大量的配套件实现国内外采购,企业逐步向“专、特、精”方向演变,成为掌握数控机床核心技术的新型制造模式。

本次调研的不少民营机床企业已经开始向上述模式演变,其中江苏哈博精密机械科技有限公司是以高校高科技人才为主体的科技成果转化型企业,该企业掌握超精密机床的核心技术,以设计、整机装配测试和服务为主,在逐步加强关键件制造能力的基础上,相信将成为我国超精密机床研发、生产新的重要力量。

(4)激光加工设备制造行业发展模式

激光加工是将激光束照射到工件的表面,以激光的高能量来切除、熔化材料以及改变物体表面性能。由于激光加工是无接触式加工,工具不会与工件的表面直接摩擦产生阻力,所以激光加工的速度极快、加工对象受热影响的范围较小而且不会产生噪音,可以对多种金属、非金属加工,特别是可以加工高硬度、高脆性及高熔点的材料,激光加工具有适应性广、生产效率高、质量可靠等特点。

近年来,随着光纤激光技术和激光器技术突破,以及激光器功率提高和成本大幅度下降,激光加工设备的性价比迅速提高,激光加工应用越来越广泛,其中激光切割机和激光焊接机发展尤为迅猛,由此推动激光加工设备制造业绩井喷式增长。目前我国已经拥有一批年销售收入超十亿元的激光设备制造企业。据介绍2017年全球激光器销售额120亿美元(其中光纤激光器占51%以上),光纤激光器装机9.5万台。2017年我国激光切割机市场销售量超1万台,预测近几年将以20%以上速度增长。

从调研来看,我国激光设备制造骨干企业一般掌握整机机型设计和自动化配套技术,激光加工设备核心件——中、大功率激光器一般从国外进口,高端激光头、数控装置、伺服驱动、电器件、滚动功能部件、减速器和齿条等重要部件也以进口为主,机座等焊接结构件国内加工,主机厂进行总装、检验和用户服务。这种制造模式的关键是机型设计、应用软件开发和自动化配套技术,整机制造质量、价格和服务也是行业竞争的重要因素。由此可见,我国激光加工设备行业发展模式是:关键技术突破带动和市场需求牵引下的集成制造发展模式。

2.新兴民营机床企业的运营特点

(1)投资效益明显

从调研企业资料分析,华南地区新兴民营机床企业一般具有轻型投资结构,能充分发挥厂房和制造设备的效能;企业没有历史包袱,有利于成本控制;具有灵活的人才吸引和激励机制;人员精干,管理严谨,运营高效,投资效益明显,如企业销售利润率、人均销售收入、固定资产投资收益率、单位建筑面积产出等经济指标都处于行业先进水平。如本次调研的深圳市创世纪机械有限公司,厂房面积7万平方米,2017年销售额超过34亿元,人均销售额190万元;广东润星科技有限公司,占地面积约7万平方米,销售收入12.2亿元,人均销售额180万元;激光设备制造行业是近年来“爆发”行业,本次调研的佛山市宏石激光技术有限公司、深圳迪能激光设备有限公司和苏州迅镭激光科技有限公司,2017年该3家企业平均人均年销售收入达到184万元,该指标相当于金属加工机床行业重点联系企业平均值的3倍。

(2)重大投资决策能力强

据调研,新兴民营机床企业的成长过程中,经过市场经济的洗礼和磨练,一批对产业发展具有敏锐洞察力的民营企业家脱颖而出,他们在所处的企业投资体制中处于主导地位,这批民营企业家工作勤奋,事业心强,对企业发展战略、重大建设投资、技术和人才引进等重大决策等能够迅速判断、决策和实施,决策过程不需经过层层审批,提高了投资的时效性,此举有利于企业抓住机遇,加快发展。重大决策也十分重视实效,如多家企业的信息化建设(ERP、MES等)实际应用效果明显。当然,其总体战略判断的准确性,会成为重大决策成败的关键因素。

(3)市场需求反应快速

紧紧抓住市场需求快速反应是民营机床企业运营的重要特点之一。如深圳市创世纪机械有限公司曾经有一款机床新机型,从接到用户信息、组织人员开始加班连轴转研制样机,经过40多天研制出样机,样机经用户检验认可后,即接受用户批量订货近千台,并当年组织供货。该公司提出:多品种、大批量、高性价比、交货及时作为企业的重要竞争力。

(4)注重制造链与配套链

调研的新兴民营机床企业一般都具有比较稳定的机床配套链和加工协作链,推崇以诚信为本,在运作过程中协调处理主机与配套、加工协作之间的关系。如南通国盛智能科技集团股份有限公司、深圳迪能激光科技有限公司等始终坚持从不欠款的原则,一是不欠供应商的款,二是不接受客户欠款,使产业链运作十分顺畅,净化了产业生态环境。

(5)用户服务理念与实践创新

坚持用户至上原则,强化用户服务环节是新兴民营机床企业经营特色之一。据介绍,南通国盛智能科技集团股份有限公司拥有遍及全国的几十个售后服务网点,每年定期访问重点用户,多数情况下可以24小时内对用户使用问题做出快速反应,机床售出2年内保修,可免费更换损坏件,对出售的一般机床就进行两次维修,售出机床如果两次维修后仍出问题,说明这台机床有缺陷,就直接给客户换新的机床,做到让用户无忧。

3. 企业升级与发展创新

前不久,习近平总书记在2018年两院院士大会上讲话指出:“工业母机、高端芯片、基础软硬件、开发平台、基本算法、基础元器件、基础材料等瓶颈仍然突出,关键核心技术受制于人的局面没有得到根本性改变”,“要以智能制造为主攻方向推动产业技术变革和优化升级,推动制造业产业模式和企业形态根本性转变”,讲话为机床行业企业转型升级指明了方向。

从调研看,2014-2017年是为3C产业服务的新兴机床企业增长的爆发期,自2018年来,3C产业机床需求有所下降,特别是钻攻机,多数被调研企业判断需求同比下降80%以上。目前机床行业面临新的发展机遇:一是5G国际通讯标准的发布,涉及智能手机升级(材料和结构变化)和通讯基站的升级;二是新能源汽车的发展;三是通用机械加工业的升级;四是航空航天军工等行业的快速发展,以上产业需要大批新型数控机床和高档数控机床进行更新换代。机床行业面临新的挑战,新兴民营机床企业也面临产业升级新机遇。

在调研座谈中,大家认为:民营机床企业升级要把握方向,理性分析,科学定位。要以科技创新为先导,强基础、补短板,掌握关键核心技术,提高竞争力。主导产品的近期发展目标要以取代进口中端机床的超百亿元机床的市场需求为主攻方向。鉴于我国关键功能部件发展严重滞后的严峻局面,有条件的民营企业可研究投资发展功能部件产业。

专家指出:民营机床企业的发展中,要吸取传统国有机床企业发展的经验和教训,“前事不忘,后事之师”,避免陷入“中等发展水平陷阱”,这些“陷阱”有:

盲目追求经营高指标

脱离市场需求和本身实际情况,要求企业经营指标连年高速增长,几年内连续翻番。此举或致使发展战略误判,造成企业重大损失。

“大而全,小而全”

在市场经济体系下,从世界机床产业总体来看,大部分企业的发展趋势是“专、特、精”,在掌握核心技术的基础上,应追求专业化协作分工和通用件外购配套等。

低价销售,打“价格战”

过度低价销售,打“价格战”属于短视行为,不可持续。此举影响了企业声誉,也扰乱了行业发展生态。发展的正道是企业的核心技术、管理、质量、服务及性价比等的竞争,由此推动企业的技术进步。

· 依靠进口件组装销售模式

采取购进光机,关键配套件全部依靠进口件组装销售,在企业本身并不掌握核心技术的情况下,这种经营模式在技术、经济和市场竞争上不会持久。一但国内外局势变化,这类企业或将陷于十分尴尬局面。

五.调研体会与建议

1. 调研主要体会

机床协会安排的“珠三角”和“长三角”14家新兴机床企业调研工作,时间紧,任务重。十分感谢调研企业的热情接待,百忙中安排企业领导会见、座谈和交流,陪同调研组参观了企业的加工、装配、测试和新产品开发等环节,提供了企业产品技术资料和经营指标等信息,使得协会现场调研工作高效运转,调研任务圆满完成。简要总结,有以下体会:

通过调研,开展了协会与新兴机床企业之间对话交流,就协会举办的展览会、协会会员活动和行业统计、行业服务等工作进行沟通,使企业进一步了解协会行业工作的内涵,增强了协会行业工作的沟通力和凝聚力。


通过调研,进一步了解我国新兴民营机床企业的发展历程。新兴民营机床企业具有适合时势的发展模式和运行机制,开发了一批适用的数控机床新产品,为我国成为制造大国做出应有贡献。经过近十多年的发展,我国民营机床企业迅速成长,成为支撑我国制造业发展的重要力量之一。再过十几年,民营机床企业将继续发展壮大,行业作用将愈加明显。因此,做好为新兴民营机床企业的服务工作,也是机床协会为全行业服务的重要内容之一。

2. 工作建议

鉴于机床行业以“十八罗汉”为代表的传统企业正处于转型升级的关键期,新兴民营机床企业也处于升级创新期,特别是目前中高档数控机床大量进口、国产功能部件发展严重滞后的严峻形势,建议政府进一步加强对机床行业的支持,加强对机床行业的宏观指导和政策扶持,如出台有关产业政策支持传统机床企业转型升级、鼓励新兴机床企业创新发展、对功能部件和数控系统生产企业实施税收优惠、保护机床骨干企业免受国外企业兼并、实施鼓励国产数控机床发展的进出口政策、强化推动国产机床设备的应用政策等。

机床协会要进一步做好为全行业的服务工作。在行业发展信息发布、分会工作及会员吸收、行业运营统计、国际展览和交流活动、重大机床用户交流等一系列活动中,鼓励新兴机床企业参与活动。特别是对重点骨干民营机床企业,要进一步重点关注。同时要及时了解新兴民营机床企业的发展要求,及时向政府有关部门反映企业诉求,争取政府支持。

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