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工業(yè)機(jī)器人作為綜合性的高新技術(shù)產(chǎn)品，實(shí)現(xiàn)了數(shù)字控制、驅(qū)動(dòng)制造、精密傳動(dòng)與 IT、傳感和信息等技術(shù)的有效集合。而在當(dāng)前數(shù)字制造時(shí)代背景下，數(shù)控技術(shù)與人工智能推進(jìn)了工業(yè)機(jī)器人與金屬成形機(jī)床的迅速融合。并通過(guò)高效組合形成了自動(dòng)化極強(qiáng)的集成單元，可以為工業(yè)生產(chǎn)提供更為多元的的智能解決方案。基于此，文章立足于當(dāng)前工業(yè)機(jī)器人與金屬成形機(jī)床集成的常見(jiàn)應(yīng)用類型，分析了其主要形式。進(jìn)而探討了二者集成應(yīng)用中存在的問(wèn)題，并提出了相應(yīng)發(fā)展途徑。

關(guān)鍵詞 ：工業(yè)機(jī)器人 ；金屬 ；成形機(jī)床 ；集成應(yīng)用
當(dāng)前，我國(guó)已成為全球最大的工業(yè)機(jī)器人市場(chǎng)。據(jù)國(guó)際機(jī)器人聯(lián)盟 (IFR) 統(tǒng)計(jì)數(shù)據(jù)顯示， 2015 年，我國(guó)工業(yè)機(jī)器人的用量共為 6.7 萬(wàn)臺(tái)，已成為全球工業(yè)機(jī)器人的第一大市場(chǎng)。并且，我國(guó)先后發(fā)布的《中國(guó)制造 2025》、2016-2020年機(jī)器人產(chǎn)業(yè)發(fā)展規(guī)劃中均提出，到 2020 年，實(shí)現(xiàn)我國(guó)自主品牌工業(yè)機(jī)器人年產(chǎn)量 10 萬(wàn)臺(tái)。其中，六軸及以上工業(yè)機(jī)器人年產(chǎn)量超過(guò) 5 萬(wàn)臺(tái)。在工業(yè)機(jī)器人制造業(yè)不斷發(fā)展的同時(shí)，我國(guó)裝備制造業(yè)也在逐步轉(zhuǎn)型升級(jí)。近年來(lái)，在先進(jìn)技術(shù)進(jìn)步與市場(chǎng)需求多元化的雙重作用下，考慮用工業(yè)機(jī)器人代替人力勞動(dòng)的企業(yè)逐漸增多。而長(zhǎng)期以來(lái)，汽車制造行業(yè)作為工業(yè)機(jī)器人應(yīng)用的主要領(lǐng)域，受消費(fèi)者自動(dòng)化需求的提升，進(jìn)一步擴(kuò)大了工業(yè)機(jī)器人的應(yīng)用范圍。包括除焊接外的其他大部分領(lǐng)域，如汽車機(jī)床噴涂、打磨、物料搬運(yùn)碼垛、上下料與裝配等。在機(jī)床工具的組成部分當(dāng)中，金屬成形機(jī)床所處的位置即為重要。其成形加工中通常伴有金屬粉塵、噪聲污染、高溫高濕與高勞動(dòng)強(qiáng)度等，工作對(duì)工作人員身體健康的傷害程度較大，且簡(jiǎn)單枯燥，因此企業(yè)招工較為困難。而將工業(yè)機(jī)器人與金屬成形機(jī)床相集成，既能有效提高汽車加工的精度、安全性與工作效率，又可以解決企業(yè)用工難問(wèn)題，發(fā)展空間較大。由此，需對(duì)工業(yè)機(jī)器人與金屬成形機(jī)床集成應(yīng)用進(jìn)行研究，為汽車制造業(yè)發(fā)展提供借鑒 [1]。

1 、工業(yè)機(jī)器人與金屬成形機(jī)床集成的應(yīng)用類型

1.1 工業(yè)機(jī)器人的激光切割

工業(yè)機(jī)器人定位精度高，因此，應(yīng)用其進(jìn)行激光切割已成為激光切割與工業(yè)機(jī)器人應(yīng)用領(lǐng)域的主要熱點(diǎn)。在工業(yè)機(jī)器人手臂中集成激光束引導(dǎo)裝置，當(dāng)工業(yè)機(jī)器人跟蹤工件輪廓的同時(shí)，激光束也在工作，從而實(shí)現(xiàn)切削。此類型應(yīng)用的主要特點(diǎn)包括 ：工業(yè)機(jī)器人運(yùn)動(dòng)靈活、柔性高 ；激光切割質(zhì)量好、速度快且切縫窄，極大地滿足了現(xiàn)代制造業(yè)的發(fā)展需要。

1.2 熱模鍛集成

熱模鍛生產(chǎn)線通常由切邊與沖壓兩臺(tái)模鍛壓機(jī)組成。在此生產(chǎn)線上，工業(yè)機(jī)器人集成應(yīng)用通常會(huì)配置兩臺(tái)機(jī)器人，一臺(tái)用于將中頻處理后的高溫物料，移送至沖壓成型模鍛壓機(jī) ；另一臺(tái)負(fù)責(zé)從沖壓成型模鍛壓機(jī)取料后，移送至另一臺(tái)模鍛壓機(jī)進(jìn)行切邊。為了避免模具被粘附與高溫沖壓工件上，每次沖壓后需用石墨對(duì)模具進(jìn)行潤(rùn)滑。而此過(guò)程處于高溫高濕環(huán)境中，既可由專門(mén)機(jī)構(gòu)操作，又可由工業(yè)機(jī)器人完成。如由后者進(jìn)行，可以大幅提升系統(tǒng)安全性于加工效率。但需做好機(jī)器人的維護(hù)工作，提升其抗熱、抗輻射的能力。

1.3 數(shù)控折彎?rùn)C(jī)集成

工業(yè)機(jī)器人折彎集成應(yīng)用可分為兩種主要方式，一是工業(yè)機(jī)器人與金屬成形機(jī)床中的各類設(shè)備形成板材柔性加工線，包括真空吸盤(pán)抓手、定位臺(tái)、板料傳輸線、工業(yè)機(jī)器人行走軸與激光設(shè)備或數(shù)控轉(zhuǎn)臺(tái)沖床等 ；二是工業(yè)機(jī)器人以折彎?rùn)C(jī)為中心，配置真空吸盤(pán)，磁力分張上料架、定位臺(tái)、下料臺(tái)、翻轉(zhuǎn)架形成折彎單元。制造商利用自身在工業(yè)機(jī)器人控制系統(tǒng)和機(jī)床數(shù)控系統(tǒng)上的技術(shù)優(yōu)勢(shì)，實(shí)現(xiàn)可實(shí)現(xiàn)二者的無(wú)縫連接。進(jìn)而開(kāi)發(fā)出折彎軟件包，對(duì)折彎過(guò)程中工業(yè)機(jī)器人托料實(shí)現(xiàn)閉環(huán)控制 [2,3]。在不同折彎速度下，工業(yè)機(jī)器人實(shí)現(xiàn)了自動(dòng)匹配的完全跟蹤，使折彎示教實(shí)踐叫從前縮短十倍。

2、 工業(yè)機(jī)器人與金屬成形機(jī)床集成應(yīng)用的主要形式

工業(yè)機(jī)器人在金屬成形機(jī)床中的應(yīng)用領(lǐng)域較為廣泛，包括碼操、搬運(yùn)、焊接與裝配等，但一般被作為輔機(jī)使用。目前，工業(yè)機(jī)器人與金屬成形機(jī)床集成應(yīng)用的主要形式如下。

第一，二者集成柔性生產(chǎn)線。此種形式中，工業(yè)機(jī)器人承擔(dān)的工作任務(wù)是轉(zhuǎn)換工件工序，并與多臺(tái)金屬成形機(jī)床組成柔性生產(chǎn)線。其較某種單機(jī)上下料更為復(fù)雜，價(jià)值也更高。在當(dāng)前工業(yè)轉(zhuǎn)型升級(jí)時(shí)代背景下，市場(chǎng)需求的旺盛程度不斷增加。因此，現(xiàn)場(chǎng)條件與工藝路線等因素對(duì)金屬成形機(jī)床的布局起著決定性因素。常見(jiàn)類型包括對(duì)面布置型、有直線型、U 型和 L 型等。其中，由三臺(tái)金屬成形機(jī)床構(gòu)成的 U型布局，主要由一臺(tái)工業(yè)機(jī)器人在場(chǎng)地中間進(jìn)行工件轉(zhuǎn)換，布局特別緊湊。

第二，單機(jī)上下料。此種形式中，工業(yè)機(jī)器人在金屬成形機(jī)床中的應(yīng)用最為成熟與典型。其對(duì)需要吊裝的笨重工件，以及加工時(shí)間短且生產(chǎn)批量大的中小零件加工來(lái)說(shuō)，明顯優(yōu)勢(shì)是比人工上下料更為安全、速度快且準(zhǔn)確。工業(yè)機(jī)器人與金屬成形機(jī)床的結(jié)構(gòu)關(guān)系可分為兩種形式，即與金屬成形機(jī)床構(gòu)成一體和工業(yè)機(jī)器人安裝于機(jī)床外部。其中，后者又可分為銜架式、移動(dòng)式和固定式等 [4]。

第三，獨(dú)立完成加工工序。此種形式中，為工業(yè)機(jī)器人裝上專用手爪，其便可完成機(jī)床清洗、拋光、切割與打磨等工藝。甚至可以直接夾持切削工具，對(duì)工件進(jìn)行切削加工、鉚接、攻絲與打孔等。此外，可將其用于高溫環(huán)境下，進(jìn)行人工難以直接完成的工作，包括更換熱態(tài)模具、上下熱毛坯、澆注、機(jī)械鍛造與鑄造與取鐵液等。在此情形下，工業(yè)機(jī)器人本身便可視為一臺(tái)金屬成形機(jī)床。并且，具備觸覺(jué)與視覺(jué)的工業(yè)機(jī)器人，可以被用于復(fù)雜工序中，如零件分選、上下料與組裝等，且無(wú)需攜帶專用工位器具。

第四，共同完成加工工藝。此種形式中，工業(yè)機(jī)器人在沖剪、折彎?rùn)C(jī)上夾持工件，從而實(shí)現(xiàn)加工操作。此工作不僅是簡(jiǎn)單的上下料，而是替代全部的傳統(tǒng)人工作業(yè)。此形式的主要優(yōu)勢(shì)是較人工操作更為快速、準(zhǔn)確，可以大幅提升提高生產(chǎn)效率與產(chǎn)品質(zhì)量，甚至有利于徹底解決沖壓類機(jī)床工作中的工傷隱患。

上億庫(kù)存，國(guó)內(nèi)外近千個(gè)倉(cāng)庫(kù)，公司部分產(chǎn)品型號(hào)如下，歡迎聯(lián)系哦~！

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IC693CBL312 Cable, I/O Expansion, 0.15 Meters, Shielded

QSI2D100L2P QUICKSTART KIT 10.5" MONO LCD

TRM-21006664 7point screw terminal connector for 4.3/5/7.2 amp S2K controller extended digital I/O

20BC8P7A0AYNAND0 PowerFlex 700 AC Drive 8.7 A 4 kW 20B

20F1ANF046JN0NNNNN PowerFlex 753 AC Packaged Drive

22B-E019N104 PowerFlex 40- 11 kW (15 HP) AC Drive

140ACO02000C Quantum 模擬量輸出, 4通道, 4-20mA, 通道隔離, CC

284E-FVD7P6Z-25-CR-3-DB-SB EtherNet Variable Frequency Drive

E2E-X10D1-N NEW 10mm, 電感式,兩線,常開(kāi)100mA 電源:10-30VDC圓M30

1492-SPM1C130-N MCB Supplementary Protector 13 A

通用型變頻器 6SE6 430-2UD31-8DB0 18.5 KW,275 x 520 x 245

電機(jī)啟動(dòng)器 3VU13401MP00

150-C16NBD SMC-3 16A Smart Motor Controller

1608P-100A400V3E 100 A Pro DySC Sag Corrector

1769-RTBN10 CompactLogix 10 Pin Terminal Block

191S-ANEJ3-CC10C-KN 6.3-10.0 A Compact Rev Starter W/Ckt-Bkr

194R-R3 Operating Shaft

2090-CPBM7E7-08AF02 2 m Length SpeedTec Extension Cable

2090-XXTPMP-16S09 MP-Series 9 m Length Power Cable

CP3B-0WPB-0140-AZ Power cable for B8/3000is motor. 14 meters

GF-905409/SW Connecting FlashCable to Mitutoyo Caliper with Data Read Switch (all e xcept 500-15x/ 500-17x, 551 & 552 series).

IC200UEO108 VersaMax Micro Expansion 8 Output Expansion 24VDC Sink Output, 24VDC Power Supply (includes IC200CBL501)

IC647ACL001 PA Redundant Key

IC647PBBFT0 PPS Boiler Bookshelf - Fire Tube

IC693CBL302 I/O Base expansion 50 feet (15 meters), continuous shield with built in terminator.

IC754ACC06GASE Gasket for 6-Inch Euro QP-View & Control

IMC-313P-X-D 3 amp IMC enhanced servo motor controller with Devicenet

SLC/1746 System 9399-APSMAN SLC 500 APS MANUAL SET

Open Automation Systems 1746-BAS BASIC MODULE FOR PROGRAMMABLE CONTROLLER

Application-specific products 1404-M605B-ENT 1404-M6 ETHERNET PM3000

Operator Interface 2711-K10G12L1 PV1000 GRAYSCALE KEY, PBUS & RS232 PRINT

Support 9301-2SE3300FRR SUPT REINSTATEMENT CONTRACT FOR 93012SE3300FR

Support 9380-RSBVS SUPT RENEWAL CONTRACT FOR 9380RSBV

DeviceNet Products 1792D-CB18JP MAXUM ROUND MEDIA 18MM BASE, PASSTHRU FOR DNET

RSI Software Products 9301-2SE3300ESU2 RSVIEW32 RUNTIME 150-1500 UPGRADE IN-SUPT (ES)

RSI Software Products 9358-EP10U1R UPGRADE: OUT-SUPT: RSBIZWARE EPROCEDURE 03 TO 10

Motion Control MPL-B4530K-SK22AA MOTOR,SERVO,8.36 NM,4000RPM,SINGL,460V

Motion Control 2090-XXLF-X330B AC LINE FILTER,ROXBURGH MIF330

GQPI2D101S2P 10.5" STN COLOR 24VDC WITH CE MARK GE LABEL

IC646MRA159 View 1500 Tag Runtime System

MTR-1N31-N-A-S-0 Replaced by MTR-1N31-I-N-A-S-0

QPM3D200B2P/B 6 inch Blue Monochrome Mini/ Blank Label/ 24VDC

20BC043A3AYNANC0 PowerFlex 700 AC Drive 43 A at 22 kW 20B

20F11ND034AA0NNNNN PowerFlex 753 AC Packaged Drive

22-RF025-CL PowerFlex EMC Filter

2711P-RN0 PanelView Plus Communication Module

280S-RT35 ArmorStart Three-Phase Power Media

C200H-IA121 輸入單元, 8點(diǎn), 100 -120 VAC

1492-PDLM2 Marking Strip

通訊處理器 6GK7443-1EX40-0XE0 CP443-1 高級(jí)以太網(wǎng)處理器，ISO，TCP/IP，UDP TCP，S7-通信

變送器 3RS10201DW10

1497-C-AXJK-0-N Control Circuit Transber

1585J-M8VBJM-1 RJ45 Ethernet Media

1761-NET-ENI MicroLogix and SLC Communication Adaptor

188-K3C080 Miniature Circuit Breaker 8 A

194L-E40-1756 40 A 194L Load Switch

2090-CPBM7DF-02AA15 15 m Length DIN Power and Brake Cable

2090-XXNFT-S03 Kinetix Drives 03m Standard Cable

BC647PSC200 Proficy Process Systems 2000 I/O with CIMPLICITY with Global Care

GC647PCM050 GlobalCare Complete for Proficy Change Management Server - 50 Concurrent Users

IC200MDL244 Input 240VAC isolated 8 point

IC646NUU000 HMI Functional Upgrade Transb Processing Fee

IC647MIEC MIE:Mitsubishi Melsec-A Ethernet

IC676CBLPBF050 IP67 Profibus Cordset - 5 Meters - Female Connector w/Leads

IC697MEM733RR Expansion RAM, 256K Bytes, CMOS, 32 Bit (Used w/78X CPUs)

IC800SSI104RD2 4.3 amp 115/230 VAC Devicenet S2K servo controller for MTR series motors

SoftLogix System

Industrial Computers 6182H-15TRH15D VVCE 1500, TOUCH, STD MEM, CNET, DC

Process Control 1757-DNBUPG35 DEVICENET LIC UPG 35 DNB

Operator Interface 2711-B5A14 PV550 MONO KEY&TOUCH, MBUS & RS232 PRINT

Support 9303-23S0E10R SUPPORT REINSTATEMENT CONTRACT FOR 9303-23S0E10

Support 9371-EJIC3S SUPT RENEWAL CONTRACT FOR 9371EJIC3

ControlNet Products 9230-IOLINXSDK I/OLINX DEVELOPER'S KIT FOR CONTROLNET & DEVICENET

RSI Software Products 9301-2SE2500DEU5 RSVIEW32 WORKS 5K-100K UPGRADE IN-SUPT (DE)

RSI Software Products 9358-BANT30U1 UPGRADE: IN-SUPT: RSBATCH ARCHIVER 03 TO 30

Motion Control MPL-A4520P-SK22AA MOTOR,SERVO,6.10 NM,5000RPM,SINGL,230V,6.8KG

Motion Control 2090-UXNPBMP-14S01 CABLE,460V,NON-FLEX,MOTOR POWER,MP,14 GAUGE,1M

CBL-3C-MP-10 Power Cable, MTR-3S43-G, MTR-3S45, MTR-3S46, & MTR-3S6x-G Series Servo Motors, 10 Ftl

IC641CTL904 CIMPLICITY Control Professional Offline Developer Kit

IC800SLM020N1XE25 200W, 115 VAC SL Servo Motor, Holding Brake, 2.5K Quad Encoder

OC647IPWRSTDVUNLMTM iPower Option - Std Unlmt I/O Dev

20AD8P0A3AYYNNC0 PowerFlex 70 AC Drive 8 A at 5 Hp 20A

20DD065A0NYNANANE PowerFlex 700S AC Drive 65 A 50 Hp 20D

20P41AD250RA0NNN PowerFlex 460V AC 150 HP DC Drive

2711P-B12C4A8 PanelView Plus Terminal

280-PWRM24H-M1 ArmorConnect 3-PH Power Media drop cable

MPT002-G2R-V1 單色LCD 160*32兩行帶RS232端口

1492-MCBA3A0 100 A UL489 Miniature Circuit Breaker

1494V-DSX100 Disconnect Switch

軟啟動(dòng)器 3RW44586BC35

運(yùn)行版軟件 6AV2103-0DA00-0AM0 SIMATIC WinCC 專業(yè)版 512 PowerTags (Compact Edition)

1585D-M8UGJM-40 Gigabit Ethernet Media

1756-M02AS ControlLogix Analog SSI Motion Module

180040-A01 KIT BUS CONTROL CARD

194E-FA40E 194E Load switch

2090-CFBM7DD-CEAF07 Kinetix 7m Flexible Cable

2090-U3BB-DM12 Ultra 3000 Breakout Board Kit

BC646MRA000 View Runtime 8000 I/O with Proficy GlobalCare Complete

GC647ARC050 GC Reporting Client 50 Pak

I5T/2 Proficy Process Systems Tuning Tools from ControlSoft for 10 Loops

IC646APS30005 CSense Predictive Soft Sensor 5 KPI's

IC647IFPLRN00075C iFIX Plus SCADA 75 I/O Runtime (M1Component Part)

IC660HHC005 Hand-Held Monitor Cable

IC697ACC805 I/O Cable (64 conductor) for IC697Vxxxxx modules. Ten feet long

IC756XDV010E-925 "DV-Draw Development on Solarisx86 Op Sys, English v9.25"

FlexLogix System 1794-TB3S FLEX I/O TERMINAL BASE WITH SPRING CLAMPS

GuardPLC Systems 1753-L28BBBM GUARDPLC 1600 - SAFETY PLC W/MODBUS, 28 I/O

Process Control 1757-UPGSIFG UPGRADE HW UDC 3000/5000/6300 QUICKBUILDER I/F

Operator Interface 2711P-K12C4D1 PV PLUS 1250, KEYPAD, RIO/DH, DC PS, STD MEM

Support 6008-SQS1S SUPT RENEWAL CONTRACT FOR 6008SQS1

Support 1400-SPR 1400-SP SOFTWARE SUPPORT REINSTATEMENT

Support F1785-L80C15SERE FIRMWARE UPGRADE FOR 1785-L80C15 PLC5 PROCESSOR MO

RSI Software Products 9301-2SE2350ESE RSVIEW32 WORKS 5K (SPANISH)

RSI Software Products 9701-VWSS250AJPE RSVIEW SE SERVER 250 DISPLAY (JAPANESE)

RSI Software Products 9399-WAB32CSDKPG RSLINX C SDK PROGRAMMER'S GUIDE

Motion Control 8720MC -B042-AA- 42 AMP B CHASSIS DRIVE, ENCLOSURE, LESS OPTIONS

BC646MPSS99 Logic Developer - PLC Standard Unlimited Seat Site License