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The main way to improve the design reliability of domestic CNC machine tools
CNC machine tools are typically composed of three key components: the CNC system, the servo system, and the machine tool body. Among these, the reliability of the CNC system plays a critical role in determining the overall reliability of the entire machine. Modern CNC systems often adopt a modular hardware structure, allowing different functional modules to be selected and combined based on the specific requirements of the machine tool. By following principles such as optimization, standardization, and generalization, the design and manufacturing of these modules significantly enhance the flexibility and maintainability of the numerical control system.
Currently, China has been continuously improving the functionality of its CNC systems. Beyond basic machining capabilities, modern CNC systems should also include features like human-machine interaction, self-diagnosis for machine failures, protection mechanisms, and tool management. These added functions not only simplify the operation and maintenance of the machine but also greatly improve the reliability and efficiency of CNC machine tools.
During the "Ninth Five-Year Plan," leading Chinese manufacturers collaborated on the national key scientific research project titled "Study on Numerical Control Technology and Assembly Engineering." This initiative aimed to enhance the design reliability of CNC machines. Through the absorption and integration of advanced foreign technologies from companies like FANUC and SIEMENS, the Mean Time Between Failures (MTBF) of domestic CNC machines increased to over 400 hours, bringing them closer to the standards of international competitors.
The servo system serves as the electric drive link between the CNC system and the machine tool body. As the reliability of the CNC system improves, so do the performance metrics of the machine, including maximum speed, tracking accuracy, part quality, productivity, and ease of use. These factors are largely influenced by the dynamic and static performance of the servo system. Therefore, enhancing the design of the servo system is crucial for improving the overall reliability of the CNC machine.
Significant advancements have been made in servo technology, with AC drives gradually replacing DC drives and digital control taking the place of analog control. This has led to the development of AC digital drive systems. The application of Digital Signal Processors (DSPs) has further improved the speed and responsiveness of the servo system, reduced sampling time, simplified debugging, and enhanced system flexibility, ultimately boosting the reliability and performance of the machine.
The reliability of the machine tool body, which includes the mechanical transmission structures and functional components, also plays a vital role in the overall performance of the CNC machine. In China, despite efforts in the design and manufacturing of mainframes, many functional components—such as ball screws, linear guides, lathes, machining centers, and robots—are still inferior in quality and reliability compared to foreign counterparts. To address this, China must focus on the research and development of high-quality functional components, aiming to match or surpass foreign brands in terms of performance, durability, and reliability.
In addition, the development of new cutting materials, innovative tool designs, and improvements in tool life and precision maintenance are essential for the long-term success of the CNC industry. During the "Tenth Five-Year Plan," the machinery manufacturing sector in China experienced rapid growth, with an increasing demand for CNC machines. This period offered excellent opportunities for the development of the domestic machine tool industry. However, after joining the WTO, foreign machine tools gained more access to the Chinese market, intensifying competition. Therefore, improving the design reliability of CNC machines is of great importance for ensuring operational reliability, enhancing competitiveness, and driving the continued growth of the machinery industry.