More than 90% of China's high-end machine tools are loaded with CNC systems from foreign companies. Siemens and FANUC have taken 40% of the cost of the whole machine. The head of the machine-building industry has only “empty shellsâ€.
Yu Dehai, who is over 60 years old, has a simple flat head. His face is thin and his face is serious. He always has a lot of thoughts. He has been engaged in the equipment industry for more than 30 years. He has always hidden a painful question: when China became the world's machine tool manufacturer. Why did it not become glory when it was the first big country?
Starting from the center of Dalian, 30 kilometers east of a bay to Jinzhou, this is the “paradise†of the equipment manufacturing industry. Dalian Guangyang Technology Co., Ltd. (hereinafter referred to as Dalian Guangyang), which develops CNC system for Chinese machine tools, is here. .
Chairman Yu Dehai wore gray-white sportswear, a bit old, and quickly walked in the noisy underground machine tool production workshop. If he doesn't go out, he usually stays here for more than 10 hours every day. The front-line employees have become accustomed to the company's top management.
“When the level and possession of CNC machine tools become an important indicator of the country's manufacturing level, industrial modernization level and national comprehensive competitiveness, a country, especially a manufacturing country like China, cannot have its own CNC system. Yu Dehai told reporters in a noisy workshop.
The CNC system, known as the "brain" of machine tools, has been firmly held in the hands of a few companies such as Siemens and Japan FANUC. 40% of the manufacturing costs of high-end machine tools in China are purchased from foreign systems. In order to equip China's high-end CNC machine tools with an autonomous "brain", Chinese companies have gone through imitation routes and have tried to introduce huge amounts of technology, but the results have been minimal.
Today, Yu Dehai is taking his dreams into reality.
Machine tool spell
“Pure imported machine tools are very expensive. Like our SMEs, although they purchase domestic equipment, the CNC system is still imported.†Wang Fuqiang is the head of a diesel engine parts manufacturing enterprise in the southern industrial park of Tongzhou District, Beijing. Other equipment manufacturers provide matching parts. Why not use a domestic CNC system? His answer is simple and straightforward, and the failure rate of foreign CNC systems is low.
"China's high-end CNC machine tools are developing at a high speed, but they cannot change the fact that they rely on foreign technology. This dilemma is the reality of China's high-end CNC machine tools. The development speed is indeed very fast, but the key technologies and core technologies are highly dependent on foreign countries. More than 95% of high-end CNC systems use imported systems," said Shi Yong, director of the Institute of Strategy and Planning of China Machinery Industry Information Research Institute.
The experience of buying machine tools more than 20 years ago has made Yu Dehai unforgettable. He needed to buy a high-end machine tool at the time, but the domestic company could not provide it and had to go to a well-known Japanese machine tool company to purchase it. What surprised Yu Dehai was that the harsh conditions imposed by the other party made him almost unable to feel the sincerity of sales.
After many negotiations, the machine tool purchase agreement was finally signed, but the line of words in the agreement text touched the heart of Dehai. "This product will automatically detect the movement of the equipment. After the machine is transferred, it will not be able to operate without the confirmation of the company or its agents. The company and its agents are not responsible for any loss caused by the inability of the equipment to operate."
This means that although Dehai paid for the purchase of this machine, it could not completely control the machine. The production plant must strictly limit the installation location, users and uses of the machine tool. What makes Dehai dissatisfied is that the factory also encrypts and locks in order to prevent movement and change of use. Once the equipment moves, it will automatically lock up. The equipment of millions of yuan will immediately become a pile of scrap iron, and the other party will not bear any responsibility.
Yu Dehai understands that the purpose of the seller is to restrict China's use of machine tools in key areas such as aerospace, aviation, military, precision manufacturing, scientific research, etc., so that China cannot master core technologies, and Chinese companies permanently import machine tools.
In the end, Yu Dehai also bought the machine tool that made him feel painful and humiliating. This experience also deeply awakened his worries about China's high-end CNC machine tool industry.
The restrictions are far more than the end users such as Dalian Guangyang.
Jinan No. 2 Machine Tool Plant is an industry-recognized machine tool manufacturer with world-leading level. In 2011, the forging machine tool it produced was purchased by Ford Motor's US headquarters, and the news made the entire Chinese machine tool industry excited.
The gantry boring and milling machine of another high-end CNC machine tool produced by Jinan No. 2 Machine Tool Plant has reached the advanced level, but it needs to be used with the CNC system produced by Siemens and other enterprises. Production equipment procurement and matching system, this is the embodiment of rationalization of the division of labor, the original and reasonable business of the procurement system has been passive due to the monopoly of the other party.
"There is no money to buy the system. The purchase system needs to issue a report, declare where the system is used, and finally what to use, after a series of cumbersome approvals can be obtained." Ren Liwei, deputy general manager of Jinan No.2 Machine Tool Plant said . The approval of the application is not the worst thing. For Jinan No. 2 Machine Tool Plant, the approval cycle of several months or even half a year will not allow the company to focus on the customers waiting for it. As a major customer of Jinan No. 2 Machine Tool Plant, it is not difficult to understand why it happened in Dehai.
Breaking the monopoly
In 1993, the state-owned enterprise that had been away from work for many years in Yu Dehai began to start a business. It relied on the accumulation of technology in the past to quickly gain market recognition. In the same year, it developed from a small workshop to a person who hired three people and founded it. Dalian Guangyang Technology Co., Ltd.
After being "card necked" on the control system, Yu Dehai had the idea of ​​developing China's own high-end CNC system.
Unlike other industries, CNC is a super-interdisciplinary subject involving many disciplines such as control, drive, motor execution, inspection, software, communication, electronics, machinery, and crafts. It has many cross-sections and deep depth.
At that time, there were not many enterprises that developed CNC systems in China, but most of them stayed at the low-end. The domestic high-end CNC system has been taking the old road of repeated development and the well-known three-step, introduction, digestion and absorption. Analyze research by importing high-end foreign machine tools. Dalian Guangyang just entered the line and did not have the option to embark on this road.
Soon, Yu Dehai found that this road could not go. The precision and reaction speed of the counterfeit CNC system and the original system were very different, which was far from meeting the requirements. Yu Dehai, who was hindered by imitation, realized after calm thinking that this was just a function of imitating the function of the imported system, and did not really grasp the essence of these functions.
In 2004, when Dehai realized this, Dalian Guangyang was facing the most painful decline since its establishment. Due to mistakes in decision-making direction, several scientific research projects bearing high hopes have lost successively, and huge amounts of investment have failed. Dalian Guangyang has collapsed.
"What you are seeing now is our successful side. There are many more failures than success. It is hard to be sure of all the considerations. In the past few years, I earned 10 million, 20 million, 30 million yuan. If you go on, you may lose hundreds of millions of yuan." Yu Dehai said.
Since the development of the CNC system, Yu Dehai has devoted almost all of his energy to technical research. Today, his desk is still full of various large and small parts.
Yu Dehai's dedication to technology has attracted a group of technical talents to Dalian Guangyang. Chen Hu, chief engineer of the company, is a well-known planner of China's optical bus-type CNC system. He graduated from Tsinghua University with a major in mechanical manufacturing automation and has been engaged in research and development in the field of numerical control systems. In the winter of 2007, he and Yu Dehai saw each other as soon as possible, and immediately declined the invitation of the University of California, from Beijing alone to Dalian Guangyang.
In order to verify the five-axis linkage function and performance of the CNC system, Yu Dehai needs two key functional components. The domestic components are not accurate enough to meet the demand and can only be purchased abroad. I did not expect this purchase but bought a problem. Yu Dehai originally planned to purchase parts from a US company. The company refused to purchase intentions because it did not sell to Chinese companies. However, the other party later changed the name and said that it can be sold, but it needs to provide product use and provide process drawings.
Yu Dehai was deeply stimulated. He gave up the purchase intentions that had been basically negotiated and returned to Dalian to conduct research in his own factory. A few years later, Dalian Guangyang successfully developed several key components such as direct-drive single-axis turntables. This turning made Dalian Guangyang extended from CNC system to the development and production of key parts of machine tools.
In the process of self-development, Yu Dehai led the team from the development of CNC systems to the manufacture of two-axis turntables. Later, in order to achieve high-performance matching with CNC systems, they developed key functional components such as servo drives and servo motors. At the same time, Dalian Guangyang has also stepped up research and development of its proprietary core technology. Its multi-axis linkage and high-speed, high-precision motion control functions have replaced the CNC system with many foreign goods.
"The goal of the CNC system is to meet the customer's manufacturing needs, and where the demand comes from, from the process." This is the thinking path of Yu Dehai different from others. In the following years, Yu Dehai pushed back the functional requirements of the CNC system from the user's point of view. After repeated analysis and optimization, in 2006, Dalian Guangyang five-axis CNC system was born.
The past is not as good as smoke. There are too many dreams, pains and humiliations in the heart of Dehai.
"Guangyang mode"
The development of high-end CNC systems has been successful, and this moment of celebration should be the beginning of new challenges.
High-end CNC systems need to be applied to high-end machine tools, while Dalian Guangyang itself does not produce machine tools. Although Dalian Guangyang has been influential in the field of industrial control, it is still a face in the field of high-end CNC systems.
In the year of successful system development, Yu Dehai found a Dalian machine tool factory in the same city. He is confident that the "big brother" of the industry can use his CNC system. The other party was quite positive and appreciative of Dalian Guangyang's achievements in the field of numerical control systems, but refused the possibility of immediate support, but said that if there is a customer needs, it will cooperate.
Yu Dehai understands the difficulties of machine tool companies. Machine tool enterprises have to sell to end users. If the users don't approve, there is no way for machine tool companies. For high-end machine tools, millions of yuan of investment of millions of yuan, few end users dare to take the risk to try to install new domestic systems.
How to effectively promote the system has become a problem in front of Dehai, and the further improvement and improvement of the system depends on the verification and data accumulation of the customer's actual application.
Yu Dehai has invested in the development of high-end CNC systems and has won the respect and support of experts and scholars in the industry. After learning that the system application was blocked, Lu Yanzhen, the former vice minister of the Ministry of Machinery Industry, tried to persuade a domestic company to use Dalian Guangyang's system at a gantry machining center purchased from Jinan No. 2 Machine Tool Plant. This machine that had already decided to support the Siemens CNC system finally installed the CNC system of Dalian Guangyang. In the following months of operation, the performance of the system gave Yu Desong a sigh of relief, and the products produced by the machine tools loaded with Dalian Guangyang CNC system were no different from the imported systems.
The successful practical application made Yu Dehai confident in the CNC system he developed, but he had to face the cruel reality - the supporting application still did not make much progress. Seeing that the system can not be applied, Yu Dehai is very anxious. In the end he made an amazing decision to produce machine tools. Since the numerical control system cannot be promoted, the complete machine with its own numerical control system can process the parts that meet the requirements and always satisfy the customers.
On the one hand, Yu Dehai actively promoted the control system to the machine tool main engine factory. On the other hand, he purchased the optical machine and configured the independent numerical control system to form a CNC machine tool. He demonstrated and introduced the CNC system products to the customer with the actual processing capability.
In the production workshop of the machine tool, Yu Dehai pointed out that the parts that were neatly stacked told the visitors that this was all independently developed by us. After the successful development of the system and key components, the production machine tool is only a further extension.
The foundation is weak, the supporting is backward, and the technology is blocked. In the current situation of this industry, even if the high-end CNC machine tools are developed for many years, China's machine tool manufacturing enterprises are still in a passive state, and it is difficult to impact the peak. However, Yu Dehai is no longer alarmed. He is waiting for the breakthrough opportunity created by Dalian Guangyang in the world of machine tools.
In 2007, Yu Dehai proposed the numerical control industrial system engineering theory. This theory advocates the construction of a complete CNC technology chain and industrial chain, which combines the whole machine with the system and combines the processing technology with the control technology. Through a series of expansion operations, Dalian Guangyang has built a whole industrial chain and a full-technology chain model from CNC system technology research and development, key component manufacturing to machine tool industrialization development, which is called “Guangyang Mode†by the industry.
The following year, Dalian Guangyang created Dalian Kede CNC Co., Ltd. (hereinafter referred to as Cod), specializing in the production of high-end CNC machine tools. Among them, the numerical control system and key functional components occupying most of the cost of CNC machine tools completely use the products independently developed by Guangyang. At this point, Dalian Guangyang has created a complete CNC industrial chain.
Zhang Guobao, then deputy director of the National Development and Reform Commission, told Yu Dehai that he had high hopes for Dalian Guangyang. “There are few large enterprises in the field of numerical control. Guangyang is one of them, and it is almost the most technically advanced in the numerical control industry.†He hopes that domestic brands will develop and enhance the independent competitiveness of the machine tool industry.
Challenge "teacher"
Yu Dehai's CNC machine tools have also achieved success.
When a unit engaged in aerospace research and development learned that Dalian Guangyang could produce five-axis CNC machine tools equipped with independent research and development of CNC systems, the relevant responsible persons and technicians quickly rushed to Dalian with the impeller billets that needed to be processed. The person in charge should personally look at the processing effect of Dalian Guangyang Machine Tool. In close cooperation with the technical staff of both parties, it took only two days to complete the previous one-month debugging work using imported machine tools. The parts produced were very satisfactory after the expert evaluation, and then the unit decided to purchase and use.
A message at the end of July 2013 once again boiled the entire machine tool industry. The high-precision five-axis vertical machine tool manufactured by Cod is officially exported to Germany.
At the China International Machine Tool Show in April last year, Dalian Guangyang's five-axis vertical machining center and five-axis horizontal machining center were exhibited, attracting the attention of a German machine tool dealer with a keen sense of smell. Dalian Guangyang's five-axis vertical machining center on-site processing products show high precision that is not inferior to the international high-end CNC machine tools, and the price is only half of these big brands - such price is usually only enough to buy a set of Siemens, hair Naco's CNC system. The head of the company signed a purchase contract with Yu Dehai on a five-axis vertical machining center on the spot, and Dalian Guangyang will deliver the product to Germany in the shortest possible time.
This global machine tool dealer with more than 100 years of history brought this Chinese-made machine tool to the German market at the EMO 2013 Machine Tool Show in Hannover, Germany.
From the embargoed, restricted imports to the sale of machine tools to the other's door, Dalian Guangyang, the “studentâ€, challenged the former “teacherâ€.
When the machine tools in Dehai gradually became famous, the number of customers who came here began to increase.
"No, absolutely not, don't sell." All visiting guests, even media reporters, were trying to ask Yu Dehai whether he could use the machine tool produced by Cod to match the import system. His answer was always firm and powerful.
"If Cod's high-end CNC machine tools use FANUC and Siemens CNC systems, then our high-end CNC system will always be buried by well-known foreign brands, and there will never be a day when national brands will go to the world stage of history." De Haining can lose short-term benefits, but also put the long-term development goals of the company in the first place. Although this may bring some difficulties to the enterprise, this road must only go on like this, so that China's CNC brand can be established.
“Dalian Guangyang’s current biggest challenge is that capacity cannot meet the needs of the market.†Yu Dehai is full of confidence in his machine tool.
According to data from the China Machine Tool Industry Association, in 2013, machine tool exports were US$9.53 billion, imports were US$16.09 billion, and the import and export deficit was US$6.56 billion. Director Xin Liwei of the Machinery and Equipment Department of the Dalian Economic and Information Technology Commission said bluntly: "The long-term stable and reliable operation is the main evaluation index of CNC machine tools and CNC systems. The domestic CNC system needs to go a long way."
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