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向效率要效益:孚尔默助力常州聚美夯实国产高端刀具制造之路-数控机床市场网

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class=newshow_title>向效率要效益:孚尔默助力常州聚美夯实国产高端刀具制造之路</DIV> <DIV class=newshow_time>2023-10-25&nbsp;&nbsp;来源: 孚尔默&nbsp;&nbsp;作者:-</DIV> <DIV class=newshow_fontshow id=zoom><div><br /></div><div><font size="2">&nbsp;</font></div><div><font size="2">&nbsp; &nbsp; &nbsp;&ldquo;从 1999 年创业办厂,到 2005 年成立聚美,自始至终我只有一个想法,就是&lsquo;做好的刀具&rsquo;,因为我相信只有好的产品才会有市场。也是在 05 年,公司购进了第一台五轴数控设备,虽然还只是价格相对便宜的国产品牌,却正式开启了我们的高品质刀具制造探索之路。&rdquo;</font><span style="font-size: small">常州聚美精密工具有限公司(以下简称&ldquo;常州聚美&rdquo;)总经理恽益群先生向记者回忆自己创业时的经历。</span></div><div><font size="2">&nbsp; &nbsp;</font></div><div style="text-align: center"><img src="/uploadimages/2023/10/25/6fc50aba-3cbb-4658-b319-e612656ed8ff.jpg" border="0" alt=" " width="395" height="269" /></div><div style="text-align: center">&nbsp; </div><div style="text-align: center"><img src="/uploadimages/2023/10/25/85d2d27b-f00a-4e66-992c-1080230f65c5.jpg" border="0" alt=" " width="396" height="263" />&nbsp;</div><div><font size="2"><br /></font></div><div style="text-align: center"><font size="2" color="#0000ff">图 1:常州聚美精密工具有限公司成立于 2005 年,总投资金额达 6310 万元,公司人均年产值突破百万,其所生产的刀具产品广泛应用于模具、车辆、IT 数码行业、冶金、电子产品及机械设备等领域。</font></div><div><font size="2">&nbsp;&nbsp;</font></div><div><font size="2">&nbsp; &nbsp; &nbsp;从国产品牌,到随后的澳大利亚品牌,再到瑞士、德国、美国,常州聚美在一台台精密加工设备的更替变化中不断成长前行。恽益群先生调侃说道,开厂赚的钱几乎都用来买设备了,每次一听到有好的设备,就控制不住想要。正是这份对品质的坚守,常州聚美在行业内</font><span style="font-size: small">打出了自己的一片天,工厂人均年产值突破百万,旗下的铣刀系列更是凭借着极高的耐用性力压进口刀具产品,赢得众多客户信赖。</span></div><div><font size="2"><br /></font></div><div style="text-align: center"><img src="/uploadimages/2023/10/25/034541c7-f16f-453b-853a-754096419cef.jpg" border="0" alt=" " width="395" height="264" /></div><div><font size="2"><br /></font></div><div style="text-align: center"><font size="2" color="#0000ff">图 2:常州聚美精密工具有限公司总经理恽益群先生(图右)和孚尔默中国公司销售经理王蛟先生。</font></div><div><font size="2">&nbsp;&nbsp;</font><span style="font-size: small">&nbsp;&nbsp;</span></div><div><font size="2">&nbsp; &nbsp; &nbsp;和很多的中小型民营企业一样,常州聚美时常面临着价格、成本的挑战。&ldquo;价格战就意味着要降本,而降本就是要提高效率。&rdquo;恽益群先生也在此过程中掌握了一门诀窍:&ldquo;行走的计算器&rdquo;,无论是新设备进厂,还是工艺革新,他的心里都有一本明晰的&ldquo;效益账单&rdquo;。</font><span style="font-size: small">&ldquo;对我们来说,一面是无法改变的刀具材料、涂层成本,一面是越来越高的精度、交期要求,如何获利维持公司运营?借助更高精度、高自动化的前沿设备,向加工效率要效益是我们的策略。孚尔默的五轴刃磨机床,给了我极大的惊喜。&rdquo;</span></div><div><font size="2">&nbsp;&nbsp;</font></div><div><font size="2">&nbsp; &nbsp; <strong>&nbsp;&ldquo;效益持久战&rdquo;,稳定性是根本</strong></font></div><div><font size="2">&nbsp;&nbsp;</font></div><div><font size="2">&nbsp; &nbsp; &nbsp;2020 年,第一台孚尔默 VGrind 360E 五轴刃磨机床肩负提效降本的&ldquo;重任&rdquo;入驻常州聚美工厂。&ldquo;孚尔默第一台机床进厂,我印象极其深刻,设备调试完毕,当天就投入了生产,开机一晚上,运行、生产、自动化设备都十分稳定。&rdquo;恽益群先生回忆说,&ldquo;更戏剧性的是,</font><span style="font-size: small">那天其实有一台其他品牌的刃磨机同时进厂,集成在同一条生产线、加工相同的刀具,但那台机床的精度、稳定性就远远不及孚尔默,最后,该品牌的技术人员来调试了近一个月都没有达到我们的要求,只能做退货处理。如此对比,让我们对孚尔默机床的性能有了更直接的</span></div><div><font size="2">信任感。&rdquo;</font></div><div><font size="2">&nbsp;&nbsp;</font></div><div><font size="2">&nbsp; &nbsp; &nbsp;在提升效率的同时,保障加工稳定性,孚尔默依靠的是一系列的专用&ldquo;磨&rdquo;法。首先,就是 VGrind 系列开创性的&ldquo;垂直双主轴&rdquo;结构,这也是恽总在采访中提及最多,最为赞赏的一点。VGrind 360E 在 C 轴的最佳转动点上采用了上下垂直布局的两根磨削主轴,砂轮组</font><span style="font-size: small">位于枢轴点,与其他结构的双主轴刃磨机床相比,大大缩短了线性轴的运动距离,减少了加工时间;两个定位点的特性,也解决了以往固定和浮动轴承的定位问题,极大提升了机床刚性。两个磨削主轴还可装载不同的砂轮组,配合砂轮自动更换装置能够确保砂轮组的高效更</span></div><div><font size="2">换。</font></div><div><font size="2">&nbsp;&nbsp;</font></div><div><font size="2">&nbsp; &nbsp; &nbsp;此外,机床整体设计和各处细节,也都在为加工一致性&ldquo;保驾护航&rdquo;。VGrind 360E 的机床床身均采用聚合物混凝土,具有卓越的坚固性和出色的减震效果;孚尔默坚持机床所有部件均自主设计生产的模式,让所有设备都能保持最佳的出厂性能;机床电机和主轴的高效</font><span style="font-size: small">冷却方案,进一步改善热稳定性,以长期保持设备的效率与精度&hellip;&hellip;这些特性正是专注于高品质、通用型刀具加工的常州聚美所亟需的。</span></div><div><font size="2">&nbsp;&nbsp;</font></div><div><font size="2">&nbsp; &nbsp; &nbsp;&ldquo;我们所生产的刀具大多是用于加工汽车模具,其对于耐用性、精度的要求十分严苛,且批量较大,因此,我们对设备的要求不仅需要它能够精准高效加工,更要绝对保障一致性,一个批次上千把刀都要做到同一精度、同一光洁度。孚尔默机床在这一方面就做的非常好。&rdquo;</font><span style="font-size: small">恽益群先生介绍说,&ldquo;一把刀,只要程序调好,几乎不需要怎么调试,就能完全达到精度要求。连续加工时,尤其是夜班生产,孚尔默机床更是能做到第一把刀和最后一把刀几乎毫无差别。除了人为的操作失误,这几年来机床从来没生产过废品。&rdquo;</span></div><div><font size="2">&nbsp;&nbsp;</font></div><div><font size="2">&nbsp; &nbsp; &nbsp;<strong>1 台,2 台&hellip;&hellip;8 台,物超所值的体验</strong></font></div><div><font size="2">&nbsp;&nbsp;</font></div><div><font size="2">&nbsp; &nbsp; &nbsp;2021 年、2022 年、2023 年,常州聚美又陆续不断地采购了共计 8 台孚尔默 VGrind 360E机床,占据了工厂现有设备的 1/3,成为了公司当之无愧的生产主力军。在被问到为什么会如此信任孚尔默时,恽总给出了四个字的回答&mdash;&mdash;&ldquo;物超所值&rdquo;。</font></div><div><font size="2">&nbsp;&nbsp;</font></div><div style="text-align: center"><img src="/uploadimages/2023/10/25/a6b39404-51a1-4ffd-9930-80245d4b466d.jpg" border="0" alt=" " width="399" height="268" /></div><div style="text-align: center">&nbsp; </div><div style="text-align: center"><img src="/uploadimages/2023/10/25/c0f4fe18-b0b7-45a9-839a-a8ed6b40d13d.jpg" border="0" alt=" " width="402" height="263" /></div><div style="text-align: center">&nbsp; </div><div style="text-align: center"><img src="/uploadimages/2023/10/25/c3beb5b0-51a0-429a-89b9-76e74852bf2c.jpg" border="0" alt=" " width="311" height="461" />&nbsp;</div><div><font size="2"><br /></font></div><div style="text-align: center"><font size="2" color="#0000ff">图 3:从 2020 年至 2023 年,常州聚美陆续不断地采购了共计 8 台孚尔默 VGrind 360E 五轴刃磨机床。</font></div><div><font size="2">&nbsp;&nbsp;</font></div><div><font size="2">&nbsp; &nbsp; &nbsp;&ldquo;从效率上来说,同样的刀具,我们在原来的旧设备上做 4 把刀的时间,孚尔默机床能做 5 把,由于机床操作简单、精度高,调机时间又缩短了接近一半,再加上双主轴、换砂轮速度快,整体的加工效率一下就提升了。另外,机床集成的强大的 NUMROTOplus&reg;软件,让</font><span style="font-size: small">它的通用性也很强,几乎能加工我们所有种类的产品。可以说,现在 8 台设备的产能抵得上原来的 10 台,也就是说降低了我们的设备采购成本,让我觉得物有所值、物超所值!&rdquo;恽益群先生介绍说道。</span></div><div><font size="2">&nbsp;&nbsp;</font></div><div><font size="2">&nbsp; &nbsp; &nbsp;孚尔默中国公司销售经理王蛟补充介绍说:&ldquo;除了机床本身结构带来的各项优势外,VGrind 360E 集成的自动化方案也是我们助力常州聚美高效生产的关键。&rdquo;据悉,VGrind 360E内置有自动上下料机械爪以及料盘。工人只需将所需的毛坯料放置在料库内,设置好程序,</font><span style="font-size: small">机械爪便会自动上料,加工生产,而后抓取成品放置于料盘,配合机床配置的线性光栅尺、砂轮测头等多个实时监控、补偿加工精度的程序或部件,从而实现无人值守的全自动化加工。&ldquo;我们工厂目前有 25 台加工中心,全天候开机生产,每班只有 3 个工人操作看守,如</span><span style="font-size: small">果没有高度自动化的智能设备,是不可能完成加工任务的。孚尔默的自动化方案正是我们所需要的。&rdquo;恽益群先生介绍说。</span></div><div><font size="2"><br /></font></div><div style="text-align: center"><img src="/uploadimages/2023/10/25/343b9269-3a62-42dc-a5c7-b9ed8defc26b.jpg" border="0" alt=" " width="382" height="266" /></div><div style="text-align: center"><font size="2" color="#0000ff"><br /></font></div><div style="text-align: center"><font size="2" color="#0000ff">图 4:VGrind 360E 内置有自动上下料机械爪以及料盘,配合机床配置的线性光栅尺、砂轮测头等多个实时监控、补偿加工精度的程序或部件,可实现无人值守的全自动化加工。</font></div><div><font size="2">&nbsp; &nbsp;&nbsp;</font></div><div><font size="2">&nbsp; &nbsp; &nbsp;未来,常州聚美将继续在高精度、高品质国产刀具加工之路上奋进前行,孚尔默也将始终相伴左右。&ldquo;把产品做好,满足好客户需求,是我们不断奋斗想守住的初心,也是聚美作为民营企业为国产刀具发展做出的最实际的努力。&rdquo;恽益群先生在采访最后说道。</font></div><div><font size="2">&nbsp;</font></div></DIV> <DIV 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