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機(jī)械工業(yè)近期行業(yè)技術(shù)發(fā)展重點(diǎn)
第一章 行業(yè)技術(shù)發(fā)展現(xiàn)狀
機(jī)械工業(yè)是為國(guó)民經(jīng)濟(jì)提供技術(shù)裝備和為人民生活提供耐用消費(fèi)品的裝備產(chǎn)業(yè)。國(guó)民經(jīng)濟(jì)各部門生產(chǎn)技術(shù)的進(jìn)步和經(jīng)濟(jì)效益的高低，在很大程度上取決于它所采用機(jī)械裝備的性能和質(zhì)量，機(jī)械工業(yè)的技術(shù)水平是衡量一個(gè)國(guó)家科技水平和經(jīng)濟(jì)實(shí)力的重要標(biāo)志之一。
經(jīng)過近50年的發(fā)展，機(jī)械工業(yè)已經(jīng)成為我國(guó)工業(yè)中具有相當(dāng)規(guī)模和一定技術(shù)基礎(chǔ)的最大產(chǎn)業(yè)之一。1997年實(shí)現(xiàn)銷售收入13651億元，占全國(guó)工業(yè)的21%；利潤(rùn)257億元，稅621億元，分別占全國(guó)工業(yè)的15%；出口創(chuàng)匯363億美元，占全國(guó)外貿(mào)出口額的20%。其發(fā)展速度高于同期工業(yè)的平均增長(zhǎng)速度。
近年來，機(jī)械工業(yè)企業(yè)自主開發(fā)創(chuàng)新能力有所增強(qiáng)，1997年科技人員總數(shù)達(dá)48萬人，技術(shù)開發(fā)經(jīng)費(fèi)支出達(dá)85億元，占全行業(yè)銷售收入的0.62%，有57家大型企業(yè)建立了國(guó)家級(jí)技術(shù)中心，有9%的企業(yè)建立了專門技術(shù)開發(fā)機(jī)構(gòu)，行業(yè)整體技術(shù)水平有了明顯進(jìn)步，主要表現(xiàn)在：為國(guó)民經(jīng)濟(jì)提供成套技術(shù)裝備和汽車的能力有較大提高；產(chǎn)品結(jié)構(gòu)正向合理化方向發(fā)展。
盡管機(jī)械工業(yè)的綜合技術(shù)水平近幾年有了大幅度提高，但與工業(yè)發(fā)達(dá)國(guó)家相比，仍存在著階段性的差距。主要問題在于：
1．科技進(jìn)步對(duì)機(jī)械工業(yè)增長(zhǎng)的貢獻(xiàn)率目前僅為34%，先進(jìn)國(guó)家高達(dá)70%以上。
2．產(chǎn)品設(shè)計(jì)技術(shù)、制造工藝及裝備、制造過程自動(dòng)化技術(shù)、管理技術(shù)落后，是制約機(jī)械產(chǎn)品水平的主要因素。
3．機(jī)械產(chǎn)品技術(shù)水平不高，達(dá)到80年代末、90年代初國(guó)際先進(jìn)水平的僅占18%，達(dá)到80年代中期國(guó)際水平的占27%，其余產(chǎn)品均在80年代以前的水平線上。
從總體上看，機(jī)械工業(yè)技術(shù)開發(fā)能力和技術(shù)基礎(chǔ)薄弱，發(fā)展后勁不足；技術(shù)來源主要依靠引進(jìn)國(guó)外技術(shù)，對(duì)國(guó)外技術(shù)的依存度較高，對(duì)引進(jìn)技術(shù)的消化吸收仍停留在掌握已有技術(shù)和提高國(guó)產(chǎn)化率上，沒有上升到形成產(chǎn)品自主開發(fā)能力和技術(shù)創(chuàng)新能力的高度。
第二章 技術(shù)發(fā)展的總體目標(biāo)
以數(shù)控機(jī)床、電力電子應(yīng)用及自動(dòng)化技術(shù)、大型農(nóng)業(yè)機(jī)械和施工機(jī)械、轎車關(guān)鍵技術(shù)、環(huán)保裝備五個(gè)方面作為重點(diǎn)，以發(fā)展和應(yīng)用先進(jìn)制造技術(shù)為手段，以高新技術(shù)和產(chǎn)品的產(chǎn)業(yè)化為突破口，以提高企業(yè)技術(shù)創(chuàng)新能力和競(jìng)爭(zhēng)力為目標(biāo)，提高企業(yè)技術(shù)創(chuàng)新水平。到2001年，提供1000種具有自主知識(shí)產(chǎn)權(quán)和較大市場(chǎng)需求潛力的產(chǎn)品。主要產(chǎn)品品種的40%達(dá)到90年代初國(guó)際水平，5%達(dá)到國(guó)際先進(jìn)水平，90%的重點(diǎn)骨干企業(yè)產(chǎn)品標(biāo)準(zhǔn)接近或達(dá)到國(guó)際先進(jìn)企業(yè)標(biāo)準(zhǔn)。
第三章 技術(shù)發(fā)展的方向和重點(diǎn)
3.1以數(shù)控機(jī)床為代表的基礎(chǔ)機(jī)械
數(shù)控機(jī)床是先進(jìn)制造業(yè)的基礎(chǔ)機(jī)械，是最典型的多品種、小批量、高技術(shù)含量的機(jī)電一體化產(chǎn)品。目前世界數(shù)控機(jī)床年產(chǎn)量超過15萬臺(tái)，品種超過1500種。1997年我國(guó)數(shù)控機(jī)床產(chǎn)量已達(dá)9051臺(tái)（占機(jī)床總產(chǎn)值20%以上），但由于國(guó)產(chǎn)數(shù)控機(jī)床不能滿足市場(chǎng)需求，在國(guó)內(nèi)市場(chǎng)上的占有率逐年下降，每年仍需大量進(jìn)口數(shù)控機(jī)床，進(jìn)口額度大幅度增加。1996年進(jìn)口達(dá)13924臺(tái)（價(jià)值12.46億美元）。
目前我國(guó)數(shù)控機(jī)床技術(shù)發(fā)展中存在的主要問題是：
?。?）產(chǎn)品成熟度差，可靠性不高
國(guó)外數(shù)控系統(tǒng)平均無故障時(shí)間（MTBF）在10000小時(shí)以上，國(guó)內(nèi)自主開發(fā)的數(shù)控系統(tǒng)僅3000～5000小時(shí)；整機(jī)平均無故障工作時(shí)間國(guó)外達(dá)800小時(shí)以上，國(guó)內(nèi)最好只有300小時(shí)。
?。?）產(chǎn)品品種少，不能滿足市場(chǎng)需求
國(guó)外數(shù)控機(jī)床品種已達(dá)到1500種，國(guó)內(nèi)只有500多種,且性能水平低，高速、高效、高精度產(chǎn)品幾乎沒有。
（3）創(chuàng)新能力低，市場(chǎng)競(jìng)爭(zhēng)力不強(qiáng)
生產(chǎn)數(shù)控機(jī)床的企業(yè)雖達(dá)百余家，但大多數(shù)都未能形成規(guī)模生產(chǎn)，企業(yè)效益差，創(chuàng)新能力低，制造成本高，產(chǎn)品市場(chǎng)競(jìng)爭(zhēng)能力不強(qiáng)。
?。?）數(shù)控機(jī)床行業(yè)的專業(yè)化零配件及部件的協(xié)作生產(chǎn)配套體系不健全，大多數(shù)企業(yè)都是“大而全、小而全”的結(jié)構(gòu)模式。
近期我國(guó)在數(shù)控機(jī)床的發(fā)展方面，要采取跟蹤高級(jí)型、發(fā)展普及型、擴(kuò)大經(jīng)濟(jì)型，以普及型為主的策略，重點(diǎn)發(fā)展：
?。?）經(jīng)濟(jì)適用、量大面廣的產(chǎn)品
經(jīng)濟(jì)適用的普及型數(shù)控車床、加工中心、數(shù)控銑床。
?。?）高速、高效和專用、成套數(shù)控機(jī)床
高速、高效數(shù)控車床及加工中心；高效數(shù)控鍛壓成套裝備，其中包括，可自動(dòng)換頭沖壓機(jī)床、復(fù)合式柔性沖壓中心、四邊折彎?rùn)C(jī)等；大型精密模具數(shù)控成套裝備，其中包括數(shù)控仿型銑床及龍門式數(shù)控銑床、智能化電加工機(jī)床等。
?。?）數(shù)控機(jī)床專業(yè)化配套系統(tǒng)
新一代數(shù)控及伺服系統(tǒng)系列產(chǎn)品；數(shù)控機(jī)床高速主軸、電主軸電機(jī)系列產(chǎn)品；數(shù)控機(jī)床機(jī)械手、刀庫及動(dòng)力刀架系列產(chǎn)品；數(shù)控機(jī)床高速配套零部件及輔件系列產(chǎn)品；其中包括，高速滾珠絲桿、高速陶瓷軸承、高速防護(hù)裝置等系列產(chǎn)品。
發(fā)展目標(biāo)：
?。?）扶植重點(diǎn)企業(yè)開發(fā)經(jīng)濟(jì)適用、量大面廣的數(shù)控機(jī)床并形成批量生產(chǎn)，使這些企業(yè)產(chǎn)品的市場(chǎng)占有率有明顯提高，成為名牌產(chǎn)品；
（2）發(fā)展數(shù)十種高速、高效、專用、成套數(shù)控機(jī)床系列新品種，以滿足汽車、農(nóng)機(jī)、航空、模具等行業(yè)的需求；
?。?）數(shù)控機(jī)床關(guān)鍵配套產(chǎn)品：數(shù)控系統(tǒng)，滿足國(guó)內(nèi)數(shù)控機(jī)床50%的配套需求；高速主軸及電主軸年產(chǎn)達(dá)千套；機(jī)械手、刀庫、動(dòng)力刀架及數(shù)控機(jī)床高速配套零部件、輔件系列產(chǎn)品滿足國(guó)內(nèi)50%的配套需求。
3.2電力電子應(yīng)用及自動(dòng)化技術(shù)
電力電子技術(shù)是集微電子、計(jì)算機(jī)和自動(dòng)化技術(shù)于一體的綜合技術(shù)，是節(jié)能節(jié)材的最佳技術(shù)之一。目前，國(guó)外電力電子技術(shù)已經(jīng)發(fā)展到以IGBT為代表的第三代，并向智能電力電子時(shí)代發(fā)展，我國(guó)現(xiàn)在仍處于以晶閘管為代表的第二代。國(guó)內(nèi)電力電子市場(chǎng)品種滿足率僅35%，新產(chǎn)品市場(chǎng)基本上被國(guó)外產(chǎn)品占領(lǐng)。
現(xiàn)場(chǎng)總線智能儀表和總線式自動(dòng)測(cè)試系統(tǒng)是集自動(dòng)化技術(shù)、計(jì)算機(jī)技術(shù)和通信技術(shù)于一體的新一代自動(dòng)化儀表系統(tǒng)，已成為世界范圍自動(dòng)化技術(shù)發(fā)展的熱點(diǎn)，是當(dāng)代工業(yè)自動(dòng)化的主要標(biāo)志。我國(guó)仍處于由模擬式儀表系統(tǒng)向數(shù)字式儀表系統(tǒng)過渡的模數(shù)混合式儀表系統(tǒng)階段，水平落后10～15年，因此在低技術(shù)產(chǎn)品市場(chǎng)上還占有80%左右份額，但在高技術(shù)產(chǎn)品市場(chǎng)的占有率不到60%，新產(chǎn)品市場(chǎng)幾乎全為國(guó)外產(chǎn)品占領(lǐng)。
因此，抓住當(dāng)前時(shí)機(jī)在2～3年內(nèi)以IGBT，現(xiàn)場(chǎng)總線智能儀表和自動(dòng)測(cè)試系統(tǒng)為突破，攻克重點(diǎn)技術(shù)和產(chǎn)品，并實(shí)現(xiàn)產(chǎn)業(yè)化。這一領(lǐng)域重點(diǎn)發(fā)展：
?。?）IGBT器件及其裝置，大功率晶閘管及其裝置
研制新一代雙極晶體管IGBT、高品質(zhì)大電流IGBT等大功率晶閘管制造技術(shù)，并開發(fā)變頻調(diào)速裝置、逆變開關(guān)電源、大容量整濾源等的工程應(yīng)用。
（2）現(xiàn)場(chǎng)總線智能儀表
研制開發(fā)變送、執(zhí)行、配套等類現(xiàn)場(chǎng)總線儀表。產(chǎn)品產(chǎn)業(yè)化技術(shù)開發(fā)、并開展示范工程的應(yīng)用研究。
?。?）自動(dòng)測(cè)儀系統(tǒng)和設(shè)備
開發(fā)總線式自動(dòng)測(cè)試系統(tǒng)的基礎(chǔ)產(chǎn)品，形成適度規(guī)模，同時(shí)建立用于機(jī)電產(chǎn)品和社會(huì)公益事業(yè)的典型自動(dòng)測(cè)試系統(tǒng)，做好示范和推廣應(yīng)用。
3.3大型農(nóng)業(yè)機(jī)械和施工機(jī)械
3.31農(nóng)業(yè)機(jī)械
工業(yè)發(fā)達(dá)國(guó)家農(nóng)機(jī)產(chǎn)品在不斷采用新技術(shù)的基礎(chǔ)上，正業(yè)環(huán)境方向發(fā)展。目前我國(guó)已能生產(chǎn)14大類、3000多個(gè)品種的農(nóng)機(jī)產(chǎn)品，但是產(chǎn)品的綜合技術(shù)水平僅相當(dāng)于國(guó)外70年代水平。主要問題在于：
1）產(chǎn)品水平不高，品種不全 綜合技術(shù)經(jīng)濟(jì)指標(biāo)落后，可靠性差，壽命短。以拖拉機(jī)為例，MTBF值國(guó)外可以達(dá)到330小時(shí)以上，而我國(guó)僅100余小時(shí)。品種上：大型缺，小型雜，不成系列。
2）產(chǎn)品生產(chǎn)達(dá)到經(jīng)濟(jì)規(guī)模的少，重復(fù)生產(chǎn)、小規(guī)模生產(chǎn)，難以保證質(zhì)量。
農(nóng)機(jī)領(lǐng)域重點(diǎn)發(fā)展：
1）促進(jìn)農(nóng)業(yè)生產(chǎn)產(chǎn)業(yè)化的大中型拖拉機(jī)及配套農(nóng)具 拖拉機(jī)平均無故障時(shí)間從110小時(shí)提高到300小時(shí)以上；
2）聯(lián)合收割機(jī) 聯(lián)合收割機(jī)可靠性系數(shù)從0.5～0.7提高到0.9以上；
3）主要農(nóng)產(chǎn)品加工機(jī)械（含烘干倉儲(chǔ)機(jī)械） 農(nóng)村產(chǎn)業(yè)化和中西部地區(qū)脫貧致富需要的農(nóng)產(chǎn)品深加工機(jī)械；
4）節(jié)水灌溉設(shè)備 噴、滴灌設(shè)備將灌溉水的有效利用率由大水漫灌的40%提高到80%以上。
農(nóng)機(jī)產(chǎn)品的使用可靠性及壽命指標(biāo)普遍提高一倍以上，主要產(chǎn)品的技術(shù)標(biāo)準(zhǔn)與國(guó)際標(biāo)準(zhǔn)接軌。
3.32施工機(jī)械
施工機(jī)械是國(guó)民經(jīng)濟(jì)大型工程項(xiàng)目建設(shè)必須的關(guān)鍵設(shè)備。我國(guó)已初步具備16個(gè)大類，3100多個(gè)品種規(guī)格產(chǎn)品的生產(chǎn)能力，部分產(chǎn)品已開始進(jìn)入國(guó)際市場(chǎng)。但與國(guó)民經(jīng)濟(jì)發(fā)展要求和國(guó)際先進(jìn)水平相比較，差距還是很大。一是產(chǎn)品的綜合技術(shù)水平不高，尤其是產(chǎn)品的質(zhì)量、壽命、可靠性、安全舒適性等指標(biāo)以及機(jī)電一體化等高新技術(shù)的應(yīng)用與國(guó)外先進(jìn)水平還有很大的差距；二是產(chǎn)品結(jié)構(gòu)性短缺，成套服務(wù)能力差，遠(yuǎn)不能滿足需要，如路面施工機(jī)械基本上還要靠進(jìn)口；三是大部分企業(yè)生產(chǎn)規(guī)模小，制約著行業(yè)經(jīng)濟(jì)效益的進(jìn)一步提高。
施工機(jī)械重點(diǎn)發(fā)展：
1）推土機(jī)、液壓挖掘機(jī)、輪式裝載機(jī)；
2）汽車起重機(jī)、大型叉車；
3）攤鋪機(jī)、壓路機(jī)；
4）無開挖式管道鋪設(shè)機(jī)；
5）江河湖庫清淤設(shè)備。
發(fā)展目標(biāo)：
大型工程機(jī)械可靠性指標(biāo)達(dá)到400小時(shí)，壽命指標(biāo)達(dá)到10000小時(shí)。
3.4轎車關(guān)鍵技術(shù)
我國(guó)汽車工業(yè)長(zhǎng)期以卡車為主要產(chǎn)品，改革開放以后，轎車產(chǎn)品得到了快速發(fā)展。1998年轎車產(chǎn)量達(dá)到52萬輛。
我國(guó)汽車工業(yè)存在的主要問題：
（1）重復(fù)建設(shè)嚴(yán)重，造成無序競(jìng)爭(zhēng)，難以集中形成實(shí)力，發(fā)揮規(guī)模效益。
?。?）自主開發(fā)能力薄弱，大多數(shù)企業(yè)“九五”期間仍偏重于對(duì)生產(chǎn)環(huán)節(jié)進(jìn)行改造，包括多數(shù)中外合資的零部件企業(yè)對(duì)產(chǎn)品開發(fā)能力建設(shè)幾乎沒有投入。目前，國(guó)內(nèi)對(duì)轎車產(chǎn)品尚不具備自主開發(fā)能力，機(jī)電一體化的高新技術(shù)零部件產(chǎn)品還必須引進(jìn)技術(shù)。
近期轎車重點(diǎn)發(fā)展：
?。?）經(jīng)濟(jì)型轎車
以轎車車身為突破口，利用技貿(mào)結(jié)合、與國(guó)外公司合作等方式，先抓車身聯(lián)合研制，并建立經(jīng)濟(jì)型轎車的公用設(shè)計(jì)數(shù)據(jù)庫，與CAS、CAD、CAE、CAM等技術(shù)結(jié)合，形成我國(guó)汽車工業(yè)在經(jīng)濟(jì)型轎車方面的自主開發(fā)能力。
?。?）轎車動(dòng)力總成
消化吸收引進(jìn)技術(shù)，與國(guó)外有實(shí)力的企業(yè)進(jìn)行合資、合作、聯(lián)合開發(fā)，在國(guó)產(chǎn)汽油機(jī)上普及電控燃油噴射技術(shù)（EMS），并研究開發(fā)缸內(nèi)直噴（GDI）技術(shù)，開發(fā)應(yīng)用電控機(jī)械變速器（AMT）技術(shù)。
（3）轎車關(guān)鍵零部件
以機(jī)電一體化汽車電子部件為突破口，從引進(jìn)技術(shù)、合資入手，在保證高起點(diǎn)、大批量、專業(yè)化生產(chǎn)的同時(shí)，要集中力量抓緊下一代新產(chǎn)品的研制開發(fā)和應(yīng)用，重點(diǎn)是電控防抱死制動(dòng)系統(tǒng)（ABS）、安全氣囊（Air Bag）、高效穩(wěn)定的汽車尾氣三元催化轉(zhuǎn)換器，并達(dá)到與整車同步或超前發(fā)展。
?。?）高附加值專用汽車和客車
重點(diǎn)開發(fā)各類高性能專用底盤。對(duì)專用汽車以低底盤車輛和沙漠越野車輛為主；客車以低地板城市客車為主，要求具有良好的動(dòng)力性、操縱性、舒適性和低污染。
3.5環(huán)保裝備
環(huán)保產(chǎn)業(yè)是防治環(huán)境污染、改善生態(tài)環(huán)境、促進(jìn)資源優(yōu)化配置、支持資源綜合利用的支柱產(chǎn)業(yè)。全世界環(huán)保機(jī)械的年銷售額約2000億美元，集中于美國(guó)、歐州、日本等經(jīng)濟(jì)發(fā)達(dá)國(guó)家。我國(guó)環(huán)保機(jī)械行業(yè)基礎(chǔ)弱、起步晚，年產(chǎn)值僅100多億人民幣。隨著各方面對(duì)環(huán)境保護(hù)的日益重視，可持續(xù)發(fā)展戰(zhàn)略的實(shí)施，市場(chǎng)需求不斷增長(zhǎng)，環(huán)保機(jī)械將成為機(jī)械工業(yè)新的經(jīng)濟(jì)增長(zhǎng)點(diǎn)。
環(huán)保機(jī)械行業(yè)主要差距在于：
?。?）產(chǎn)品結(jié)構(gòu)不合理，品種少
初級(jí)產(chǎn)品所占比重較大，具有當(dāng)代水平的機(jī)電一體化產(chǎn)品少，急需的大型成套設(shè)備不能滿足現(xiàn)實(shí)市場(chǎng)需求。在目前3000多種環(huán)保機(jī)械產(chǎn)品中，約有五分之一的產(chǎn)品由于性能、可靠性、 適用性、結(jié)構(gòu)設(shè)計(jì)等原因，應(yīng)該限制生產(chǎn)或限期淘汰。大型煙氣脫硫、脫氮成套設(shè)備、大型城市污水處理廠成套設(shè)備、大型城市垃圾處理廠成套設(shè)備目前主要依賴進(jìn)口，高濃度有機(jī)廢水、難降解工業(yè)廢水處理
技術(shù)及設(shè)備發(fā)展緩慢。
?。?）產(chǎn)品質(zhì)量、技術(shù)水平比國(guó)際先進(jìn)水平落后20年
相當(dāng)多的產(chǎn)品沒有行業(yè)或國(guó)家標(biāo)準(zhǔn)，產(chǎn)品規(guī)格型號(hào)、基本性能參數(shù)不統(tǒng)一，質(zhì)量檢測(cè)無依據(jù)。
?。?）生產(chǎn)企業(yè)規(guī)模小、開發(fā)能力薄弱
規(guī)模小、裝備條件差、檢測(cè)手段不全的中小企業(yè)占全行業(yè)企業(yè)總數(shù)的78%。年產(chǎn)值在3000萬元以上的企業(yè)僅占全行業(yè)的3.2%，并且主要集中在電除塵器、袋式除塵器等少數(shù)幾種產(chǎn)品生產(chǎn)領(lǐng)域。
近期環(huán)保機(jī)械重點(diǎn)發(fā)展：
?。?）煙氣脫硫設(shè)備
循環(huán)流化床鍋爐及爐內(nèi)脫硫脫硝技術(shù)（CFPBC、PFBC技術(shù)）、大型整體煤氣化燃?xì)庹羝?lián)合循環(huán)技術(shù)及裝備（IGCC技術(shù)）。
（2）城市污水處理成套設(shè)備
活性污泥法、氧化溝法、移動(dòng)曝氣法為主體的城市污水處理成套設(shè)備，以日處理10～25萬噸污水處理廠為目標(biāo)，提供污水處理成套設(shè)備、污泥利用和處置成套設(shè)備、控制和監(jiān)測(cè)系統(tǒng)。
?。?）城市固體垃圾處理和綜合利用裝備
城市生活垃圾分類、焚燒、堆肥技術(shù)及裝備，以日處理100噸、300噸處理廠為目標(biāo)，提供垃圾處理成套裝備。
?。?）環(huán)境監(jiān)測(cè)儀器
便攜式多功能多參數(shù)水質(zhì)監(jiān)測(cè)儀、12種總量控制的污染物監(jiān)測(cè)儀、大氣環(huán)境污染監(jiān)測(cè)儀器和系統(tǒng)以及水處理過程自動(dòng)控制系統(tǒng)等。提高產(chǎn)品檔次、水平、可靠性和精度。
主要目標(biāo)：
?。?）大型成套設(shè)備的國(guó)產(chǎn)化率達(dá)到70%以上；一般工程項(xiàng)目的設(shè)備國(guó)產(chǎn)化率達(dá)到90%以上；高濃度有機(jī)廢水和難降解工業(yè)廢水處理技術(shù)及成套設(shè)備國(guó)產(chǎn)化率達(dá)到80%以上。
（2）一般環(huán)保機(jī)械60%以上的產(chǎn)品達(dá)到90年代初水平，5%～10%的產(chǎn)品達(dá)到當(dāng)代國(guó)際水平。
?。?）發(fā)展新產(chǎn)品品種，開發(fā)新產(chǎn)品200種以上。
晉中工業(yè)信息網(wǎng)向高效、節(jié)能、保護(hù)農(nóng)
Chapter 1 Industry and Technology Development Status
Machinery industry is the provision of technical equipment for the national economy and people's lives for the provision of consumer durable goods, equipment industry. National economic departments production and technological progress and economic benefits of high and low, to a large extent it depends on the use of the machinery and equipment and the performance and quality, machine-building industry is the skill level of a country's technological level and economic strength of one of the important symbols.
After nearly 50 years of development, China's machinery industry has become a considerable size in the industry and certain technical basis of one of the largest industries. 1997 sales income 1.3651 trillion yuan, accounting for 21 percent of the national industry; profits 25.7 billion yuan, 62.1 billion yuan tax, which accounted for 15 percent of the national industry; export 36.3 billion U.S. dollars, accounting for 20 per cent of foreign trade exports. Its growth rate higher than the same period the average industrial growth rate.
In recent years, the machinery industrial enterprises in the development of independent innovation capability has increased, scientific and technical personnel in 1997 amounted to 480,000 the total number of people, technology development expenditures amounted to 8.5 billion yuan, the industry-wide sales revenue of 0.62 percent, with 57 large enterprises to establish a national - Class technology center, nine percent of the enterprises set up special technology development institutions, the overall technological level of industries with significant progress, the main problems: the national economy to provide complete sets of equipment and vehicles have greater ability to improve the product structure being rationalized Direction.
Although the machinery industry's integrated technical level in recent years has significantly increased, compared with the industrialized countries, there is a stage in the gap. The main question is:
1. Scientific and technological progress of the machinery industry's contribution to the growth rate at present is only 34 percent in advanced countries are as high as 70 percent.
2. Product design technology, manufacturing technology and equipment, manufacturing process automation technology, management, backward technology, mechanical products is restricting the level of the main factors.
3. Mechanical products of high technological level, to the late 1980s and early 1990s, the international advanced level of only 18 percent to the mid-1980s the international level of 27 per cent and the remaining products in the 1980s before the level of online.
Overall, machinery industrial technological development capability and technical foundation is weak, the development potential shortage of technology sources rely mainly on the introduction of foreign technology, the higher the degree of dependence on foreign technology, the introduction of technology digestion and absorption are still in control technology and has been Guochanhuashuai increase, the products did not rise to the formation of independent development capability and a high degree of technological innovation capability
Chapter II of the overall objectives of technological development
To CNC machine tools, power electronics applications and automation technology, large-scale agricultural machinery and construction machinery, car key technology, environmental protection equipment in five aspects as a key to the development and application of advanced manufacturing technology as a means to high-tech industries and products into The breakthrough point, to enhance their technological innovation capacity and competitiveness as the goal, enhance their level of technological innovation. By 2001, to provide 1,000 kinds of independent intellectual property rights and greater potential for market demand of products. The main products reached 40 percent of species of the early 1990s, the international standard, five percent up to international advanced level, 90 percent of key enterprise product standards close to or reached advanced international business standards.
Chapter III of technological development in the direction and focus
3.1 to CNC machine tools as the representative of the basic machinery
NC machine tools is the foundation of advanced manufacturing machinery, is the most typical variety, low-volume, high-tech electromechanical integration of the products. The world annual production of CNC machine tools more than 150,000 Taiwan, more than 1,500 kinds of species. 1997 China's output of CNC machine tools has reached 9051 Taiwan (accounting for over 20 percent of total output value of machine tools), but because China-made CNC machine tools can not meet the market demand in the domestic market share decline year by year, a year still importing large quantities of CNC machine tools, A substantial increase in the amount of imports. 1996 imports amounted to 13,924 Taiwan (worth 1.246 billion U.S. dollars).
At present, China's CNC machine tool technology in the development of the main problems are:
(1) maturity poor, reliability is not high
CNC average foreign trouble-free time (MTBF) in more than 10,000 hours, the domestic independent development of numerical control system only 3,000 to 5,000 hours;整機(jī)trouble-free an average working hours of 800 hours over foreign and domestic best only 300 hours.
(2) less product variety, can not meet the market demand
Foreign NC machine tools has reached 1,500 kinds of species, only 500 domestic and low levels of performance, high-speed, highly efficient, almost no high-precision products.
(3) low innovation capacity, are on the market
CNC machine tool production of the enterprises must raise about 8 per though, but most have failed to scale production, poor corporate efficiency, low innovation capacity, high manufacturing costs, product market competitiveness is not strong.
(4) the professionalization of CNC machine tools industry spare parts and components produced in collaboration supporting system is not perfect, most businesses are "Dear Quean, the small but complete" model of the structure.
CNC machine tools in China's recent development, to take the High-tracking the development of universal, and expand economic, universal-oriented strategy, focusing on development:
(1) application of economic, Damian-volume products
The universal application of economic CNC lathes, machining centers, CNC milling machine.
(2) high-speed, efficient and dedicated, complete sets of CNC machine tools
High-speed, efficient CNC lathes and machining centers; efficient NC forging equipment, including that automatically for the first punching machine, the composite flexible stamping center, four sides bending machines; large precision molds NC equipment, including several - Profile milling machines and gantry milling machine, intelligent processing, machine tools, etc..
(3) of CNC machine tools specialized support system
NC Servo System and a new generation of products, high-speed spindle CNC machine tools, electric spindle motor products; manipulator NC machine tools, knives and the driving force Turret products; high-speed CNC machine tool parts and accessories supporting products which Including, high-speed ball screw, high-speed ceramic bearings, protective devices, such as high-speed products.
Development Goals:
(1) to foster the economic development of key enterprises apply, Damian wide of the NC machine tools and of mass production, so that the products of these enterprises have significantly increased market share, abrand-name products;
(2) the development of dozens of high-speed, highly efficient, dedicated, complete sets of CNC machine tools series of new varieties to meet the automotive, agricultural machinery, aviation, mold, and other industry needs;
(3) of CNC machine tools supporting key products: NC system, meet the domestic CNC machine tools 50 percent of the matching demand and high-speed main spindle with an annual output of 1,000 sets of mechanical hand, the knife, power tool carrier and supporting high-speed CNC machine tools Parts, accessories series of products to meet domestic demand for 50% of the supporting
3.2 power electronic applications and automation technology
Power electronics technology is set microelectronics, computers and automation technology in an integrated technology, energy-saving materials is the one of the best technology. At present, foreign power electronics technology has been developed to the IGBT as the representative to the third generation, power electronics and smart development of the times, our country is still in the SCR as the representative to the second generation. Domestic varieties to meet the power electronics market rate of only 35 per cent, new products market is basically occupied by foreign products.
Field Bus-Bus smart instrumentation and automatic test system is set automation technology, computer technology and communication technology in one of the new generation of automated instrumentation systems, automation technology has become the worldwide development of the hot and contemporary industrial automation is the main hallmark. China still in the system from analog to digital dashboard instrumentation systems transition module hybrid instrument system stage, behind the level of 10 to 15, low-technology products in the market still occupied about 80 percent share, but in high-tech products market The share of less than 60 percent, the new product markets for foreign products for almost the entire occupation.
Therefore, seize the current opportunity in two to three years to IGBT, Fieldbus smart instrumentation and automatic test system for the breakthrough, capturing key technologies and products and to achieve industrialization. The key development areas:
(1) IGBT devices and devices, high-power devices and SCR
Developing a new generation of bipolar transistors IGBT, high-quality high-current, such as high-power IGBT SCR manufacturing technology and the development of Frequency Control device, switch power inverter, high-capacity filter sources such as the entire application.
(2) Fieldbus intelligent instrument
Development of transmission, implementation, support and other types of Fieldbus instrumentation. Products industrialization of technological development and demonstration projects of applied research.
(3) Automatic measuring instrument systems and equipment
Bus-developed the basis automatic test system products, a moderate scale, while machinery and electrical products and for the establishment of social welfare undertakings of the typical automatic test system, to model and promote the use of.
3.3 large-scale agricultural machinery and construction machinery
3.31 Agricultural Machinery
Agricultural Machinery products in the industrialized countries continue to adopt a new technology based on the industry are environmental direction. China has been able to produce 14 categories, more than 3,000 varieties of agricultural machinery products, but products of integrated technical level equivalent to only the level of foreign 1970s. The main question is:
1) product level is not high, incomplete varieties comprehensive technical and economic indicators backward, poor reliability and short life. A tractor as an example, MTBF values abroad can reach more than 330 hours, but China only 100 hours. Variety: the lack of large and small miscellaneous, not series.
2)The production to achieve economy of scale of less duplication of production, small-scale production, it is difficult to guarantee quality.
Farm Machinery key development areas:
1) To promote the industrialization of agricultural production of large and medium-sized tractor and a tractor tools trouble-free time from an average of 110 hours to 300 hours or more.
2) Combine the reliability coefficient of combine harvesters from 0.5 to 0.7 to 0.9 above;
3) major agricultural products processing machinery (including dry storage machinery) and the industrialization of rural central and western regions become prosperous in need of deep processing of agricultural machinery;
4) water-saving irrigation equipment spray, drip irrigation equipment will be the effective utilization of water from the flood Manguan 40 percent to more than 80 percent.
The use of agricultural machinery products and the reliability of life indicators generally improve more than doubled, the main products of the technical standards with international standards.
3.32 Construction Machinery
Construction machinery and the national economy is large-scale construction projects must be of key equipment. China has initially have 16 categories, more than 3,100 different specifications of the product production capacity of some products have begun to enter the international market. But with the development of the national economy and international advanced level, compared to the gap is big. First, the integrated products of high technological level, in particular the quality of the product, life expectancy, reliability, safety and comfort, and other indicators, such as high-tech electromechanical integration and application of advanced foreign standards also is a wide gap between the second is structural products Shortage of packages of services is poor, far can not meet the needs, such as road construction machinery largely depends on imports; Third, most of the production of small scale enterprises, constraining the industry to further improve economic efficiency.
Focus on the development of construction machinery:
1) bulldozers, hydraulic excavators and wheel loaders;
2) truck crane, forklift large;
3) paver, roller;
4) No excavation for the laying of pipelines;
5) the rivers, lakes dredging equipment.
Development Goals:
Large-scale construction machinery reliability index reached 400 hours, life indicators have reached 10,000 hours.
3.4 sedan key technologies
China's automobile industry to long-term truck as the main product of reform and opening up, the car has been rapid development of products. 1998 car output reached 520,000.
China's automobile industry the main problems:
(1) duplicate construction, causing disorderly competition, difficult to concentrate on a power play of scale.
(2)Weak independent development capabilities, the majority of enterprises "9th Five-Year" period is still a strong bias towards the production processes to be transformed, including the majority of Sino-foreign joint venture enterprises parts of the product development capacity-building almost no input. At present, the domestic passenger car products do not have the self-development capacity, electromechanical integration of high-tech parts must also introduce advanced technology products.
Car recent focus on development:
(1) economic cars
To car body to make a breakthrough, combining the use Jimao, cooperation with foreign companies, including through the body to grasp the joint development, economic cars and the establishment of the common design database, with the CAS, CAD, CAE, CAM, and other technical integration, forming China's automobile industry Economic cars in the independent development capability.
(2) car powertrain
Digest and absorb foreign technology and foreign enterprises strength of the joint venture, cooperation, joint development and in domestic gasoline engine on the universal electronic control fuel injection technology (EMS), and research and development of direct injection (GDI) technology, development and application of electronic control machinery Transmission (AMT) technology.
(3) car key parts
To electromechanical integration automotive electronics components as a breakthrough point, from the introduction of technology, starting with a joint venture, to ensure a high starting point, high-volume, specialized production at the same time, efforts should be concentrated on the next generation step up research and development of new products and applications, with a focus on prevention, control Baosi braking system (ABS), airbags (Air Bag), high efficiency and stability of ternary automobile exhaust catalytic converters and achieve synchronization with the vehicle ahead or development.
(4)High value-added specialized vehicles and minibuses
Special focus on the development of various types of high-performance chassis. The Special Purpose Vehicle to lower the chassis of vehicles and desert off-road vehicles mainly low-floor bus to the main city bus, requires a good dynamic, handling, comfort and low pollution.
3.5 environmental protection equipment
Environmental protection industry is the prevention and treatment of environmental pollution and improved the ecological environment and promote optimal allocation of resources, comprehensive utilization of resources to support the pillar industries. The world of environmental protection machinery of the annual sales of about 200 billion U.S. dollars, concentrated in the United States, Europe, Japan and other developed economies. China's environmental protection machinery industry based on the weak, late start, the annual output value over 100 billion yuan only. With all the face of the increasing emphasis on environmental protection, the implementation of the strategy of sustainable development, market demand is growwing, environmental protection machinery machinery industry will become new points of economic growth.
Environmental protection machinery industry is the main difference:
(1) product structure is irrational, less variety
Larger proportion of primary products, with the contemporary level of integration of mechanical and electrical products less urgent need of large complete sets of equipment can not meet the real needs of the market. In the current more than 3,000 kinds of environmental protection machinery products, about one-fifth of the product because of performance, reliability, suitability, structural design, and other factors, should limit production deadlines or eliminated. Large-scale flue gas desulphurization, nitrogen and complete sets of equipment, large urban sewage treatment plant complete sets of equipment, large-scale urban garbage treatment plant complete sets of equipment currently relies mainly on imports, high concentrations of organic wastewater, industrial wastewater treatment refractory
Slow development of technology and equipment.
(2)Product quality and technical level than the advanced international level behind 20
A considerable number of products no industry or national standards, product specifications models, the basic performance parameters are not unified, quality testing without basis.
(3) Manufacturing enterprises are small, weak development capacity
Small in scale, poor equipment, means of detecting the failure of SMEs industry-wide 78 per cent of the total number of enterprises. In more than 30 million yuan in output value of enterprises accounted for only 3.2 percent of the entire industry, and are mainly concentrated in the ESP, bag filter, and so on a few product areas.
The recent focus on the development of environmental protection machinery:
(1) flue gas desulfurization equipment
Circulating fluidized bed boiler and furnace desulfurization denitrification technology (CFPBC, PFBC technology), large-scale integrated gasification combined-cycle gas steam technology and equipment (IGCC technology).
(2) sets of urban sewage treatment equipment
Activated sludge process, oxidation ditch, moving aeration law as the mainstay of urban sewage treatment complete sets of equipment to deal with the 10 to 250,000 tons of sewage treatment plants as the goal, to provide sewage treatment c