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Non-excavation equipment mainly depends on imports
According to Wang Jianye, chairman of the China Heavy Machinery Industry Association, the development of non-excavation equipment in China started in the 1960s. It should not be too late, but at that time China's industrial development model was different from that of foreign countries. In terms of non-excavation equipment, foreign companies have been producing in several enterprises. They encountered setbacks and failures in the process of product development. Each company summed up its experience, learned lessons and then did it again, so the superior survived, and the bad ones were eliminated. Now. But in China's situation, everyone is concerned that once a company fails, it means that all companies fail, and everyone stops. Today, most of China’s large roadheaders still come from imports. Imported equipment is expensive, and although prices have fallen in recent years, the average cost per device is still in the tens of millions of dollars.
In the interview, Wang Jianye showed reporters a product sample of the roadheader. The photo above was printed beautifully. He said: "These equipment are said to be domestic production. In fact, they are all manufactured in cooperation with foreign companies. We only do some rough machining work such as shelling, do not master the core technology, and in fact are acting as wage earners."
Wang Jianye introduced that currently the only company that has independently developed domestically is the Shanghai Tunnel Company. The shield machine used to build the Shanghai Metro is all from the Shanghai Tunnel Company, and it is the company's own equipment. The equipment was put into use last year and the performance was completely passed. "After more than ten kilometers, the paint on the cutter head did not fall out," he said.
According to industry insiders, the situation in Shanghai is only a special case and it is not representative. Because Shanghai's geological conditions are too "good." The full-face tunneling machine and the shield machine are different from each other. They must be aimed at different geological conditions. It is not good for Shanghai's shield machine to get Beijing.
Wang Jianye also admitted that at present, China's full-face tunnelling machine technology development and production have not yet passed. "So it can only be said that for the shield machine of geological conditions in Shanghai, domestic equipment is passed."
B market value
Drive and enhance related industries
According to the plan, before 2020, the national, railway, highway, subway, water conservancy, oil and gas and other non-excavation construction mileage of more than 6,000 kilometers, these projects are inseparable from the roadheader and shield machine. Even if each device is calculated for a maximum life of 15 kilometers, 400 units are needed, with a total value of 4 billion U.S. dollars, or about 32 billion U.S. dollars.
At present, the annual output value of China's heavy machinery factories is more than 3 billion yuan. From this point of view, the market value of roadheaders and shields does not seem to be large. According to Wang Mengshu, there are currently five underground construction methods: drilling and blasting, shallow-buried excavation, deep-buried pipeline, excavation, and shield. Among these methods, the proportion of works that really require the use of roadheaders and shield machines is actually very small.
However, Wang Jianye values ​​the promotion of industrial competitiveness and the leading role of related industries: First, it can promote the development and progress of the information industry. Underground construction is usually carried out on both sides. Finally, “docking†is required. This requires advanced positioning technology for accurate positioning. Although GPS positioning systems are now available, the use of high-precision measuring instruments, precision machinery, optics, computers, and other high-tech tools is indispensable.
Second, drive the development of control technology. The current control technology is developing in the direction of intelligence, decentralization, and networking, and it has penetrated into all areas of industrial production. Underground engineering requires advanced electrification control and information network control.
Third, to promote the technical upgrading of hydraulic systems. In addition to the traditional mechanical transmission, the underground excavation equipment also employs a large number of hydraulic transmissions. For China's equipment industry with relatively weak basic components, it is now possible to take this opportunity to upgrade the level of industrial technology.
In general, the roadheader technology embodies the comprehensive and intensive technologies of high technology such as computers, new materials, automation, informatization, systems science, management science, and non-linear science, and reflects the comprehensive national strength and scientific and technological level of a country.
In addition, Wang Jianye also believes that the development of large-section rock tunneling machines, etc., can also promote the improvement of the level of enterprise management, design and application of technology.
C International Frontier
To develop both big and small
The improvement of the technical level of roadheaders and shield machines is closely related to the actual needs of industrial development and underground engineering. In the process of industrialization, western countries have gradually mastered the design and manufacturing technologies. The advancement of science and technology and the construction of a large number of underground projects have made these technologies more sophisticated.
Wang Jianye said that to improve the technical level, it is very important that technical personnel should go to the scene to carry out practical operations, so as to accumulate experience. The accumulation of experience forms a database, which is technology.
In the process of long-term exploration from practice to theory and then from theory to practice, companies in Western countries have gradually established a set of equipment design theory, simulation test methods, and system-based empirical data for their own geological conditions. System technology for installation and commissioning. Wang Jianye said that foreign companies have now been able to design different roadheaders or shield machines based on different geological conditions. For example, the geological engineering of the Shanghai Metro project is mainly soft and silt, so the shield machine is mainly waterproof; the geological conditions in Beijing are hard, so the shield machine is mainly to prevent collapse.
At present, the main companies that can design and manufacture roadheaders or shield machines in the world are Robins of the United States, Herrenknecht of Germany, Welter and Mitsubishi. These companies can produce large-scale equipment with a maximum working area of ​​11 meters.
While the roadheader is doing “bigâ€, it is also developing toward the “small†direction. Under the guidance of the concept of "Ultimate Manufacturing", since the 1980s, the technology of micro-tunnelling machines has been widely applied in some developed countries. In this way, it is no longer necessary to install “zip-locks†on the ground. All work is carried out underground, including underwater, under bridges, excavation, laying, and replacement of various pipelines. In recent years, many cities in Western countries have passed relevant laws that do not permit the use of open-cut methods in the city, thereby further promoting the development of micro-tunnelling machine technology.
According to reports, Japanese companies have the highest level of design and manufacture of small shield machines. They even have a mature plastic tube forming technology that can complete the manufacturing and embedding of underground pipelines while excavating.
D constraints
Three major factors restrict the development of roadheaders
System is the biggest bottleneck
In the interview, Wang Jianye told the reporter about the story of the birth of the world's first 10,000-ton extrusion press: A man from a certain state-owned enterprise in northeast China came to Shandong to establish a private enterprise. The company eventually developed into a famous jungle. The group, the rickshaw, also became a billionaire. One day, the rich suddenly whim to produce 10,000 tons of extruder, so he found a Japanese design company. The Japanese company told him that in the past, only 4,000 tons of extruders were designed. At present, only 8,000 tons of extruders can be designed. So the rich man went to Xi'an Heavy Machinery Research Institute and Shanghai Heavy Machinery Factory. It was not expected that the two units could not only be designed and manufactured, but also the price of its 10,000-ton extrusion press was only half that of the Japanese company's 8,000-ton extrusion press. How is the result? The world’s first 10,000-ton extrusion press was successfully developed at home and won the National Science and Technology Progress Award.
"If this matter is placed in a state-owned enterprise, it may not be possible for it to be approved in two or three years." Wang Jianye said, "The roadheader has innovative properties. Each new set of equipment is an innovation. Our company, especially State-owned enterprises have many obstacles in the innovation mechanism. For example, the encouragement or reward for innovation of scientific and technological personnel is far from enough.
There is a gap between innovative ideas and standards
There is a gap in our innovation philosophy. In the Chinese concept, only success is allowed and no failure is allowed. "Innovation should allow failure and allow tuition fees." Wang Jianye said.
Our science and technology management system also has problems. It is mainly devoted to decentralization and lack of strength. As far as the roadheader is concerned, since many of the projects require such equipment, all departments must insert one. Due to too many management departments, the investment for each project cannot always be put in place.
The standard is another factor that restricts the development of the roadheader. Many standards are outdated and not revised in a timely manner, which exposes the backwardness of China's standard management system. Under the existing standard management system, companies are the object of standard inspection, not the target of standard services. "In the end is the first equipment or the first standard? I think it is the first equipment, followed by standards." Wang Jianye said.
Material and basic parts constraints
Wang Jianye believes that in addition to the constraints of the system and mechanism, the development of large-scale construction equipment such as domestic roadheaders is still facing the constraints of materials and basic components. The constraints of materials are common problems in the equipment industry, but they are even more pronounced in the heavy machinery industry. Although most of the roughs are made by the heavy machinery makers themselves, it is impossible for a heavy machinery factory to do its own thing, and some large steel products need to be purchased on the market. The amount of such procurement is generally not large, a ton, or tens of tons. Due to the small volume of purchases, domestic steel mills are not able to produce for them, so they must go to the international market to purchase. Under the current import and export approval management system, companies often spend a lot of money to purchase a few tons of steel in districts. The domestic seals are not closed, the biggest problem is the hydraulic system. Whether it is a hydraulic press or a hydraulic press, “running, running, dripping, and leaking†are all very serious.
There are also reducers, and the current reducer standard is the 1985 standard. Because the reducer is a universal standard product, the standard does not change for a long time, so it has to be bought abroad. The entry of foreign products has limited the development and progress of the domestic reducer industry. For the mainframe manufacturers, importing parts from foreign countries not only pays customs duties but also pays VAT, thus increasing production costs.
A China situation