In today's world, manufacturing competition is becoming more and more fierce, and the manufacturing cycle of products is becoming shorter and shorter. Competition based on time, individuality, quality and price has become an important strategy for enterprises to occupy the market. As a special type of machinery manufacturing, power generation equipment manufacturing is no exception. If you do not actively adopt the first technology to improve the competitiveness of enterprises, it will be in a difficult position in the fierce competition. This competitive capability of enterprises can be enhanced by comprehensively using advanced manufacturing technology (MAT) to comprehensively improve the level of flexible automation of enterprises. AMT refers to equipment, computer hardware and software and management methods that can significantly improve the design, processing, testing, material storage and transportation, marketing and production management capabilities of enterprises under current technical conditions.
It mainly includes: computer network manufacturing, flexible manufacturing system (FMS), computer integrated manufacturing system (CIMS), intelligent manufacturing system (IMS), sophisticated manufacturing system (LPS), agile manufacturing system (AMS), virtual manufacturing system (VMS) Manufacturing technology and manufacturing systems; flexible manufacturing units (FMC), robots, machining centers (MC), CNC machine tools (NC), laser processing, automatic inspection equipment, automated warehouses and other factory automation hardware facilities; material requirements planning ( Software tools such as MRP), Manufacturing Resource Planning, Just-In-Time Production Planning (JIT), Computer Aided Design and Analysis (CAD/CAE), Computer Aided Manufacturing (CAM), Expert Systems, and Management Information Systems (MIS).
Many foreign companies have made great efforts to introduce and implement AMT. AMT can bring many benefits to the company, including: reducing the number of employees, improving product quality, strong production flexibility, improving production efficiency and shortening the time to market. Computer-aided design and analysis technology can greatly shorten the product development cycle. Computer-aided manufacturing can improve product production accuracy and repeatability, reduce scrap rate, improve product quality, and shorten manufacturing cycle. In computer-controlled production systems, valuable production data is available for online measurement, analysis and feedback. In addition, AMT improves product quality by reducing manual errors, mitigating production control tasks, simplifying troubleshooting, and using automated inspection equipment. Product time-to-market is one of the most critical factors in today's enterprise competition. Applications such as virtual manufacturing (VM) and computer integrated manufacturing (CIM) have shortened the time it takes for companies to respond to changing market demands. GEPowersystem, a world-leading multinational company in the power generation equipment manufacturing industry, has vigorously implemented AMT, representing the development direction and level of AMT in power generation equipment manufacturing. The company leverages its technological advantages to develop a wide range of product-based manufacturing processes around the world using advanced manufacturing technologies and models such as network manufacturing, virtual manufacturing and agile manufacturing.
2 China's power generation equipment manufacturing manufacturing technology status China's power generation equipment manufacturing industry was mainly built by the former Soviet Union in the 1950s. It is now in an important historical period and faces tremendous pressure from both home and abroad. On the one hand, in China, due to the low level of power supply and demand balance, the market demand for power generation equipment has declined. On the other hand, with the gradual deepening of reform and opening up and the internationalization of the domestic market, China's power generation equipment manufacturing industry is not only To face the fierce competition of domestic counterparts, we must face the challenges of large international companies. This is a severe test for China's power generation equipment manufacturing industry, where manufacturing levels and competitiveness are still at a lower level. Regardless of the product's market competitiveness, product design and development capabilities, product quality level and cost level, market rapid response capability, etc., China's power generation equipment manufacturing industry still has some shortcomings, mainly in: () varieties of products It is relatively simple, the design method is poor, the development cycle of new products is long, the product design and development level is not high, and the independent development capability is weak. In the 1980s, major domestic power generation equipment manufacturers began to use CAD/CAE to design and analyze the main components of power generation equipment. Some special design software has been developed and a number of achievements have been made. Through the research and technology introduction, the foreign CCAD/CAM/CAE/PDM commercial software has been introduced. In some aspects, it has reached the world advanced level, but the systemization and integration are poor, and the role of advanced manufacturing technology is not fully utilized.
The production equipment of major power generation equipment manufacturers in China is relatively old, the overall level of automation is low, and the manufacturing methods are not advanced enough. Since the late 1980s, domestic advanced manufacturing equipment. For example, Dongfang Electric Machinery Co., Ltd. and Harbin Electric Machinery Co., Ltd. have introduced a number of equipment including five-axis linkage large-scale numerical control equipment. At the same time, using modern numerical control technology to carry out numerical control transformation on a batch of machine tools, the degree of automation of the equipment has been greatly improved.
The manufacturing process is relatively backward, the production cost is high, and the product quality is not stable enough. In the mid-1990s, the development and application of CAPP/CAM, especially the complex parts of power generation equipment and the research and development of CAM/CNC of key components, have done a lot of work, and in some respects have reached the world advanced level. CAPP is being promoted now, but the power generation equipment manufacturing technology is poorly systematized and integrated, and is generally in its infancy.
Management methods such as production planning and scheduling are relatively backward. In recent years, in order to accelerate market responsiveness, next-generation production management techniques such as Material Requirements Planning (MRP), Manufacturing Resource Planning, and Enterprise Resource Planning (ERP) have begun to receive attention.
From the current situation of China's power generation equipment manufacturing industry, we have done considerable basic work in different aspects of advanced manufacturing technology applications. We have widely used CAD technology to analyze and calculate key components using CAE for a certain number of various CNC machines. Equipment and machining centers, CAM/CNC and CAPP technologies are gradually being applied. There is a big gap between the level of application of advanced manufacturing technology and the adoption of advanced manufacturing models. However, it has certain conditions in terms of software and hardware facilities. It has laid a technical and material foundation for further adopting advanced manufacturing technologies and manufacturing models to accelerate the transformation of traditional power generation equipment manufacturing.
3 Application analysis of advanced manufacturing technology in power generation equipment manufacturing The main power generation equipment harmonic manufacturers have successively introduced one batch of Guoxi uc product parts, which are characterized by large and high precision. There are many types of bookmark2 power generation equipment, which can be mainly divided into: Thermal power generation equipment (various types of boilers, steam turbines, steam turbine generators, control equipment, auxiliary equipment); hydropower equipment (various types of turbines, hydroelectric generators, control equipment, auxiliary equipment); nuclear power generation equipment ; wind power equipment, etc.
The production method is a typical single-piece small batch production. The market demands that design and manufacturing cycles become shorter and shorter, not only to reduce costs but also to be reliable. The use of Computer Collective Manufacturing (CIM) can reduce the time it takes for companies to respond to changing market demands. The use of flexible manufacturing systems can reduce the number of employees, improve product quality, increase production flexibility, increase production efficiency, and reduce manufacturing costs. Flexible automation can promote new product development, simplify product retrofits, and make small-volume production such as power generation equipment economical. Using virtual manufacturing technology to provide a powerful modeling and simulation environment for the whole process of enterprise production, the design, manufacture and assembly of power generation equipment products can be realized on the computer and can cover all aspects related to the production environment. Workshop processing to business operations) provides virtual environment support. Virtualization has greatly accelerated the product development process and can further improve the ability of enterprises to respond quickly to the market. The use of Internet/in-tranet manufacturing technology enables all power generation equipment manufacturers and enterprises to make full use of shared material resources, technical resources and knowledge resources to conduct design and production in a collaborative manner, and to realize the networking of the manufacturing process.
The application of advanced manufacturing technology in the power generation equipment manufacturing industry can run through the whole process of product design, development, production, operation and management of the enterprise. The following mainly analyzes and introduces from several aspects.
3.1 Application in product design and development The domestic major power generation equipment manufacturers began to use CAD/CAE to design and analyze the main components of power generation equipment in the 1980s. CAD has been widely used in power generation equipment manufacturing at different levels. For example, as the research and development of the hydraulic model of the turbine core, advanced technologies such as blade computer-aided design (dedicated CAD), three-dimensional flow field finite element calculation analysis and performance estimation (CAE/CAT), and numerical control machining (CAM) have been applied. For example, in the design and analysis of the shafting of steam turbine generator sets and hydro-generator units, CAD/CAE and other technologies are used to design, assemble and simulate dynamic response calculations. In some products, the preliminary application of computer integrated manufacturing (CIM) technology has achieved significant efficiency engineering (CE), etc., especially the newly proposed advanced manufacturing technology of virtual products is applied to China's power generation equipment manufacturing industry, which will be beneficial to It is of great significance to get rid of the product development and development cycle and the weak development of self-development. It is of great significance to realize the product development policy of “production generation, trial generation, generation generation, research generationâ€. Advanced technologies that can be further developed and applied in the power generation equipment manufacturing industry include: implementing computer three-dimensional aid design for all products, and implementing various functions such as solid modeling, feature modeling, parametric design, constraint management, and correlation design. Including: three-dimensional modeling of product parts, to achieve three-dimensional design of the product.
PDM-based data, graphics library sharing and product configuration management to increase the borrowing rate of mature parts.
PDM-based digital product definition and management, to achieve unified product modeling, generate product rate structure tree, support for shared information such as finite element analysis, virtual assembly, motion mechanics analysis, dynamic analysis, product visualization, etc., also for virtual manufacturing ( VM) lay the foundation.
VPD refers to the digital product development process including product design, analysis, experiment and testing on the computer, so that all aspects of the product can be evaluated before the actual prototype is manufactured, reducing the physical Model dependence accelerates the development process. Including: (Product Data Management, ProductDataManagement) Manage power generation equipment product data.
Further finite element analysis and optimization of various key components of power generation equipment, and optimize the structure of the parts according to stress and strain conditions, so that the structure is more reasonable, and the purpose of reducing production cost and improving product quality is achieved.
Assemblable analysis and virtual assembly of various products, that is, according to the part model provided by PDM, realize the virtual assembly of the product parts and the whole machine, reasonably determine the coordination difference of each part, and carry out assembly evaluation for kinematics, Kinetic analysis provides a model.
The level of Haohua production technology has the meaning of M. 1. It can be solved with a combination of engineering and reverse engineering. /ww.bookmark7 adjustment mechanism and other key institutions kinematics, power plant equipment rotor dynamic analysis, that is, the use of virtual assembly model, kinematics analysis; use dynamic analysis, analysis of vibration morphology, provide an effective means for improved design.
Product process management based on PDM, that is, establishing a product development process model, using message pre-release, version management, authority approval, etc., to achieve dynamic tracking and real-time monitoring of the design development process, to achieve collaborative work, and accelerate product development.
Using the virtual assembly model to achieve product visualization, industrial design, color design, etc., can lay the foundation for network manufacturing through the internet.
There are many curved parts in power generation equipment, such as turbine blades, steam turbine blades, etc., which are related to fluid dynamic characteristics. In the development process, it is generally necessary to verify the design and modify the surface model through experiments, and use reverse engineering to speed up the development process.
Domestic power generation equipment manufacturers mainly use serial engineering in the development, design and manufacture of products. In some respects, design and manufacturing are out of line, and the product is available for a long period of time. Parallel engineering is carried out in parallel from product development to production, and work together in cooperation. In the development stage, the manufacturability of the parts and the economics of the products are taken into consideration, which can greatly shorten the product cycle and reduce the cost.
3.2 Application in product manufacturing process and process technology Domestic major power generation equipment manufacturers began to use CNC machining technology to process main components in the 1990s, and research and develop CAM technology in complex and typical parts processing. For example, the five-axis CNC machining technology for large-scale turbine blades, the FMS for steam turbine blade manufacturing, the CNC machining technology for steam turbine cylinders, and the FMS for turbine generator blade machining have been developed. CNC machining technology has been widely used in power generation equipment manufacturing at different levels.
In view of the characteristics of power generation equipment manufacturing, further promote the application of advanced manufacturing technologies such as FMS, CIMS, VM, etc. The advanced manufacturing technologies for improving the manufacturing applications of power generation equipment manufacturing in China include: technology using CNC machine tools, CNC machining centers with CAM Technology that automates part or all of the machining process. Make full use of the 3D model of CAD products, define and simulate machine tools in CAM and simulation software, simulate machining process systems such as machining tools and fixtures, formulate process routes and process contents of parts, perform tool path trajectory planning, tool position trajectory calculation, and tool Interference calculation, CNC machining program for processing machine tool post processing. Using the machining process simulation software to perform virtual machining on the motion and state of the computer simulation processing object during the machining process, check the collision interference phenomenon caused by factors such as NC code and clamping, optimize the machining scheme and processing technology, and have an animation function.
The parts and components of each power generation equipment are transmitted through PEM, the process resource library of each enterprise is established through CAPP, the processing information of the processed parts is input to the computer, and the process files such as the process route and the process content of the parts are automatically output by the computer. Including blank selection and blank drawing generation, positioning fixture selection, processing method selection, processing sequence selection, process equipment selection, process parameter selection, etc., can optimize the processing technology, reasonable equipment load, and greatly reduce the process preparation cycle.
Promote FMS technology based on machining centers, including machining centers, warehouses, material handling systems and control systems. FMS can achieve high processing flexibility, which is conducive to the single-piece processing, small batch production and strong market response agility of power generation equipment.
Special processing and emerging manufacturing technologies, such as the use of special processing such as rapid prototyping technology in the manufacture of turbine models, can greatly shorten the trial cycle.
Three-dimensional measurement and large-scale measurement technology There are many large-scale curved parts in the power generation equipment that require three-dimensional coordinate measurement, and many large parts require dimensional measurement. The use of computer-assisted non-contact photoelectric measurement 3.3 in production management and operation management, in general, China's power generation equipment manufacturing production management level is still very low. According to the experience of foreign countries in the same industry, the use of advanced manufacturing technologies including the throwing 3, 1, and Wa Wa volumes is of great significance for China's power generation equipment manufacturing industry to improve production management level and achieve good economic benefits. The advanced technologies that can be applied include: an important tool for realizing scientific decision-making in business management, using Internet-based and group intelligent decision support systems, CSCW-based group decision support systems (GDSS) and multi-organization decision support systems (ODSS). Support can help enterprises to correctly formulate their production and operation strategic plans and marketing strategies to win market competition.
The new generation of production management technology has developed rapidly. ERP has surpassed MRP in terms of function and technology. From the perspective of enterprise-wide system, it is customer-centric and enterprise resource planning for the whole enterprise activity, which can effectively integrate and manage enterprises. Inside and outside information on the supply and marketing of character property, it strongly supports enterprises to implement advanced manufacturing models.
From the perspective of global optimization, the key technologies of business process reengineering (BPR, Business Process Pengineering) (such as basic research, modeling and simulation technology workflow system technology, etc.) can be used for the personnel, business processes, technologies, and organizations of the enterprise. Restructuring of structure and culture to improve the economic efficiency of enterprises.
With the globalization of power generation equipment manufacturing, cooperation between enterprises in various countries is strengthened, and production-centered virtual manufacturing (VM) technology can be used to quickly and easily evaluate production plans, verify process flow and resource status, and optimize manufacturing environment configuration and production. Supply plan.
GEPowerSystems, a world-leading power generation equipment manufacturing company, has a lot of integration, high manufacturing flexibility, rapid manufacturing and optimal use of human resources. Inter-enterprise joint integration makes full use of the strengths of each enterprise, targets the requirements of the market, and cooperates to complete the task. After the completion of the task, the company will be dismantled and then organized according to the needs.
4 Problems and Countermeasures for Promoting and Implementing Advanced Manufacturing Technologies In the past, we briefly analyzed the current situation of China's power generation equipment manufacturing industry in advanced manufacturing technology and the possibility of promoting the application of various advanced manufacturing technologies and models in power generation equipment manufacturing. Learning from the experience and lessons of foreign companies implementing AMT, simply analyze the possible problems in promotion and implementation: the process of implementing and promoting AMT may be too long; not all available information resources are used for decision-making; financial evaluation of investment is not sufficient In the planning stage, it is not common to invite personnel from various departments to participate in the discussion; the company attaches importance to technical training, but does not pay enough attention to training in production management; the initial countermeasures to solve the problem and the factors that need attention: implementation of AMT in software and hardware Huge capital investment is required in support systems and employee training. Because it involves huge investment, and its implementation will affect all aspects of people, technology and management, it is a complex system engineering. Therefore, the preliminary argument for implementing an AMT must be very detailed. If the equipment and software have been purchased, the plant has been built and put into use before it finds the problem. It is quite difficult to re-adjust it. AMT must be consistent with the company's overall strategy, including business strategy, marketing strategy, technology strategy and manufacturing strategy.
The large-scale project serves as the implementation factor of the enterprise management of the implementation of the inter-company cooperation of the AM deer industry*Pub. The company has a clearly defined AMT implementation goal; the enterprise has a long-term definition of AMT; The need for automation; top management's desire to achieve long-term benefits in short-term ventures; implementation group structure and member influence factors continue to train employees after AMT implementation.
Top-down planning and bottom-up implementation in the enterprise; experience gained by the company prior to the implementation of the test; in short, before the implementation of AMT, from the leadership to the general staff must have a deep understanding of the technical characteristics of AMT, Implementation conditions and benefits that can be brought to the enterprise, so that education first, rational planning, strict argumentation, selection of personnel, efficiency-driven, and attention to AMT localization, scientific management.
5 Conclusion China's power generation equipment manufacturing industry is facing increasingly fierce competition. Innovation has become the focus of corporate competition strategy. New production models are paying more and more attention to knowledge, and advanced manufacturing technologies must be used to transform traditional industries. However, in China, the application of advanced manufacturing technology and the development of advanced production mode in the power generation equipment manufacturing industry must be based on China's national conditions, on the basis of tracking and digesting foreign advanced production models, combining national conditions, and drawing on the strengths of others to develop China's advanced production mode of power generation equipment manufacturing. Promote modern advanced manufacturing technology.
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