The national major project "ECK2150A CNC piston elliptical lathe" of a certain numerical control has passed the national acceptance.
On January 26, 2016, the national major project "ECK2150A CNC Piston Elliptical Turning Machine", undertaken by Changsha Yipai CNC Co., Ltd., passed the acceptance inspection of the Ministry of Industry and Information Technology. Experts determined that: "ECK2150A fills the technological gap in China in the processing of large-diameter piston elliptical shapes, breaking the foreign blockade of core high-tech equipment", "the equipment's technical indicators have reached the internationally advanced level", and "the processed products are stable, making important contributions to the successful implementation of the national key technological research and development project."
This project involves large-power marine diesel engine pistons with a maximum diameter of 500mm, a maximum length of 750mm, and a complex and special shape. This type of machine tool is subject to foreign technological blockade, and China has long relied on imports. After undertaking the national major equipment project, Chairman Zhu Genghong personally led the team, bringing together a group of backbone engineers including Chen Guoquan, Yang Jian, Tan Mingzhi, Song Jian, and Han Ping to overcome difficulties and successfully develop the ECK2150A CNC piston elliptical turning machine. This machine tool has many outstanding innovations:
1. It adopts a horizontal inclined bed structure, with X1 and X2 axes arranged in parallel on the Z-axis. A dedicated linear servo tool holder is installed on the X1 axis for the elliptical processing of the outer circle of the piston; an eight-station hydraulic turret is installed on the X2 axis for piston ring groove and top surface processing. The elliptical surface, ring groove, and top surface precision processing of the piston are completed in one clamping, ensuring processing accuracy and improving processing efficiency;
2. It develops a linear servo motor and driver specifically for the processing of large-diameter elliptical pistons, improving the frequency response characteristics of the linear servo system and increasing the rigidity of the linear servo system. The linear servo motor achieves the following performance indicators: working stroke 2mm, maximum frequency response greater than 450Hz (-3dB), static stiffness not less than 100N/μm, repeat positioning accuracy not less than 0.001mm, positioning accuracy not less than 0.002mm, acceleration not less than 98m/s² 2;
3. It optimizes a mathematical model for piston surface data processing suitable for large-diameter elliptical processing. This mathematical model has a large processing range for pistons, processes a large amount of data, and can perform real-time processing of ultra-large CNC quantities of piston surfaces.
The ECK2150A CNC piston elliptical turning machine prototype was delivered to Shaanxi Diesel Engine Heavy Industry Co., Ltd. in 2013 and has produced more than 20,000 large engine pistons for major equipment. The processing accuracy is stable, and it has operated for two years without failure, completely replacing Shaanxi Diesel's original British machine tools, and has become the only machine tool in Shaanxi Diesel Engine Heavy Industry Co., Ltd. capable of producing elliptical pistons. In November 2015, Shaanxi Diesel Engine Heavy Industry Co., Ltd. purchased a second ECK2150A CNC piston elliptical turning machine. In September 2015, Changzhou CSR Parts Co., Ltd. purchased this product. Currently, the achievements of this project have formed the ECK25 series of large-diameter piston elliptical turning machines, with an annual production capacity of 100 sets of diesel engine elliptical piston processing machines, and an annual output value of 80 million yuan; these equipment can produce 40 million pistons annually, with an indirect output value of approximately 1.6 billion yuan. The successful completion of this project will play a key supporting role in improving China's CNC machine tool and basic equipment manufacturing technology level, promoting the industrial upgrading of the equipment manufacturing industry, forming China's high-end CNC machine tool and basic manufacturing equipment technology system and independent innovation capabilities, and continuously promoting the application of linear drive technology in China's logistics systems, industrial equipment, information and automation systems, transportation and civil use, military and other fields.
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