"He is the most powerful shoveling master I have ever seen." Zhuo Yongcai, chairman of Shangyin, hand-picked Zhang Zhencai to take off the title of "Machine Master of the Machine Guild". He once took over the maintenance work of a large grinding machine imported from Germany with a price of over 100 million yuan in Sinosteel. He earned a million yuan in 20 days. At this stage, his annual income has exceeded 8 million yuan and his net profit is 4 million yuan, which is the highest gold content. The shoveling master.
Scraping and grinding is called shoveling in Taiwan, China. Scraping and grinding is to use scraper, reference surface, measuring tool and display agent to manually measure and grind points while scraping and grinding, so that the workpiece can reach the size, geometry, surface roughness and tightness specified in the process. A finishing process that requires high precision.
Due to the simple tools used, relatively strong versatility, and low machining allowance, the precision achieved is very high, so scraping is widely used in the manufacture of machines and tools and the repair of mechanical equipment. Usually, the guide rails, carriages and bearing pads of sliding bearings of machine tools are finished by scraping and grinding.
Today we will share a top-level shoveling master: Zhang Zhencai.
On a solid mechanical track, you can use hand tools to sculpt 0.01 to 0.001 centimeters as you like, and the accuracy can be achieved 10,000 times. Correctly pinching to a precision thinner than a hair is the basic skill of master shoveling master Zhang Zhencai.
Shoveling is a metal processing technology that has been passed down from the industrial revolution two hundred years ago and cannot be replaced by machines. The first machine in the world was produced by this technology. Huang Jianzhong, director-general of the Taiwan Machine Tool and Components Association, described shoveling as a "mechanical sculptor". The main principle is to remove the substances that affect the precision of the machine with a single knife by hand, so as to correct the error of machining and affect the output value of hundreds of billions of yuan. The competitiveness of the machine tool industry.
Zhan Bingchi, general manager of the Precision Machinery Research and Development Center, added that scraping is to straighten, flatten, and evenly shovel the two moving surfaces of the machine. When the track slides, the point-line surface formed by the scraping helps the machine to move accurately and also allows the lubricating oil to play a role. Intermediary function to avoid premature wear and reduce mechanical life. He believes that the key to the quality of machinery lies in reliability, the key to reliability is precision, and the key to precision is scraping.
1
Pick up a shovel knife and learn from scratch, one shovel lasts for thirty years
In 1980, he studied art, and his first job was in a Taipei design company. He decorated eight out of ten hotels on Linsen North Road. After retiring from the army, he returned to Taichung to open a coffee shop. Once, I visited the factory with my elder brother, who was eight years older than him, and it was the first time I came into contact with shoveling. The more I observed, the more interested I became. Know how to use a shovel knife", Zhang Zhencai thought to himself, if the elder brother who graduated from elementary school can do it, he must be able to do it too, so he left the coffee shop business that earns 100,000 yuan a month, and changed to an apprenticeship with one-tenth of the salary in the first year. It takes thirty years to learn a shovel knife from scratch.
But what awaits him at the first level is the difficulty of manual shoveling. A shovel knife is no sharper than ordinary blades, and it is useless to rely on brute force to face it head-on. Even if a 90-kg tough guy exhausts his whole body, as long as he fails to get the point, the surface of the machine will still remain motionless. Only by learning the correct center of gravity, posture, and coordination of hands and feet can you shovel down.
It takes less than three days for the learning process, and the palms will peel and blisters due to the backlash of exertion. In the first month, the hands are swollen and painful. At least nine out of ten apprentices will give up. The learning process of facing the cold machine again and again was lonely and speechless. After at least tens of thousands of failures, Zhang Zhencai figured out that he could shovel every knife, and then precisely controlled the force and shoveled at the correct point. Through thousands of repetitions of fine-tuning posture movements every day, he has mastered the waist strength to control the length and width, the pressure path of the left hand to determine the depth, the right hand to control the shoveling point, and the center of gravity of the feet to coordinate more smoothly "body memory" .
For example, the gap between the highest and lowest track may be a tiny 0.001 cm, or it may be 0.1 cm. The strength is different." Zhang Zhencai explained that shoveling is not like ordinary art sculptures, as long as one place is not accurate, it will affect the precision of other places.
In addition, not only one plane, but four or more planes must be shoveled accurately at the same time. The difficulty of one more plane is not addition, but multiplication. “Shoveling can only be dug out, not repaired. , everything else is in vain, and the difficulty lies in this.” He revealed.
Only accuracy is not enough, speed is another level.
In the early days, he worked as an apprentice in Fuyu, the largest grinding machine factory in Taiwan. He produced 300 to 500 machines a month, exceeding the annual output of ordinary machinery factories. It became the best training room for Zhang Zhencai to prove himself. Practice hard, so that his craft is three times faster than others. "The movements of my hands can match my eyes, and I can shovel as fast as my eyes can see." For the work of shoveling flowers, which mainly accepts cases, the faster the speed, the faster the accumulation of wealth. Also let him magnify his own value.
2
To do handicrafts, technology is to practice the first
"To be a handicraft industry, you need to be number one in your skills. There is no problem with being second, because if you are second, you will never be able to beat others!" He forced himself to practice speed and devoted himself to work, only thinking Keep repeating the same action for improvement. In order to increase the speed, through repeated actions, find out that the interval between picking up and shoveling after each shovel is applied is less than one second, and the height from the mechanical contact surface is not more than 0.1 cm, he even learned to make the spade knife a part of his body, and practiced the habit of not thinking about every movement. "When I see the point with my eyes, my hands and waist react naturally. This one is five bars higher (0.005 cm), and I will shovel it down with five bars of shoveling power. This side is one bar higher (0.001 cm), and I will use a shovel." power." Zhang Zhencai said, he said that if you want to think about how to apply force, you will definitely not be able to do it quickly.
After studying the shoveling skills deeply, he refused to admit defeat and began to study other factors that affect the mechanical precision.
"As long as there is a problem with the machine that cannot be solved, I will not make the next one." Zhang Zhencai admitted that when the parts produced by the machine are inaccurate, he will be questioned for inaccurate shoveling, unlike other masters who follow suit , Let it go, and don’t actively think about the reasons and solutions behind the problem. He will check the mechanical principles such as the material, hardness, track and other mechanical design and the change between heat and temperature to find out the problem and the most effective solution. "I didn't find the real reason, what should I do next? (Skills) stop there and can't move forward. Everyone can shovel accurately if the machine doesn't move. In fact, temperature is the biggest damage to the machine." He emphasized that the reason why shoveling can be done with The key to the precision of the machine is better than that of the machine. The key is that there is no problem of thermal deformation. After knowing the principle, you can prescribe the right medicine and repair the machine.
It is precisely because of this persistence that he has the confidence to say this sentence: If you think it is too expensive, you can find someone else, if someone else can't repair it, come back to me, and the price will double! If you dare to fight, there will be a way. Zhang Zhencai has won the real skill of the master of shoveling by relying on his own continuous hard work.
