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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?；诖耍恼铝⒆阌诋?dāng)前工業(yè)機(jī)器人與金屬成形機(jī)床集成的常見應(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，我國已成為全球最大的工業(yè)機(jī)器人市場(chǎng)。據(jù)國際機(jī)器人聯(lián)盟 (IFR) 統(tǒng)計(jì)數(shù)據(jù)顯示， 2015 年，我國工業(yè)機(jī)器人的用量共為 6.7 萬臺(tái)，已成為全球工業(yè)機(jī)器人的第一大市場(chǎng)。并且，我國先后發(fā)布的《中國制造 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)我國自主品牌工業(yè)機(jī)器人年產(chǎn)量 10 萬臺(tái)。其中，六軸及以上工業(yè)機(jī)器人年產(chǎn)量超過 5 萬臺(tái)。在工業(yè)機(jī)器人制造業(yè)不斷發(fā)展的同時(shí)，我國裝備制造業(yè)也在逐步轉(zhuǎn)型升級(jí)。近年來，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。而長期以來，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)行潤滑。而此過程處于高溫高濕環(huán)境中，既可由專門機(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)控折彎機(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)器人以折彎機(jī)為中心，配置真空吸盤，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)二者的無縫連接。進(jìn)而開發(fā)出折彎軟件包，對(duì)折彎過程中工業(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說，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，具備觸覺與視覺的工業(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、折彎機(jī)上夾持工件，從而實(shí)現(xiàn)加工操作。此工作不僅是簡單的上下料，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。

 

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194L-E12-3262 12A 194L Load Switch

2090-CNSSPSS-AA07 Kinetix 6000M network cable

2090-XXLF-TC3200 Kinetix Drives Line Filter

BC647OEM0111B OEM Edge Renewal Add't Key - iFIX

GC647IPWRSTRNUNLMTM iPower Option - Std Unlmt I/O Run Globalcare Complete part

IC200ERM001CA EXPANSION RECEIVER ISOLATED CONFORMAL COATED

IC646NGS000 Sharp TCP/IP Communications

IC647IPCC IPC:Honeywell IPC 620

IC670MDL643RR 5/12Vdc Pos/Neg Logic Input 16 pt. Grouped

IC697MDL341RR 120/240 Vac Isolated Output, 2 Amp (12 Points)

IC800SLCIZ010 Interface cable to connect any 30 Watt to 750 Watt SL series amplifier to terminal block. 1 meter

ControlLogix/1756 System 1756-DHRIO DH+/RIO BRIDGE/SCANNER MODULE

Industrial Computers 6182H-12TEH4B VVCE 1250, TOUCH, EXT MEM, ENET, AC

Process Control 1757-PFBUL100 PROFIBUS INTERFACE MODULE USAGE LICENSE

Operator Interface 2711P-RVAC REPLACMENT AC POWER TERMINAL BLOCK, QTY 10

Support 9357-DNETMDAD3S SUPT RENEWAL CONTRACT FOR 9357DNETMDAD3E

Support 9363-MAILMANR SUPT REINSTATEMENT CONTRACT FOR 9363MAILMAN

ControlNet Products 1734-232ASC POINT I/O RS232 ASCII INTERFACE

RSI Software Products 9301-2SE2403KOE RSVIEW32 WORKS 32K WITH RSLINX (KOREAN)

RSI Software Products 9358-B10U1 UPGRADE: IN-SUPT: RSBIZWARE BATCH 03 TO 10

Motion Control MPL-A430H-MJ24AA MOTOR,SERVO,6.55 NM,3500RPM,MULTI,230V,BRK,8.2KG

Motion Control 2090-UXNFBN-S30 CABLE,ULGRF50ON-FLEX,MOTOR FEEDBACK,N,30M

CBL-149 Cable.SIMATIC T.I. 535 Port 2 (RS-232)

IC610MDL111RR 24Vac/dc Source Input (8 points)

IC800SLA0752 750W, 230 VAC SL Servo Amplifier

OC647IFGLBLCLN020M-50 iFIX WebSpace 20 Additional Users (M4 key)

PXI-2544

W26361-W10-Z2-02-36

Hivertec HPCI-CPD534A

PCI-1756

FI-RBXAT-PEL02Z/4 FI-RBXAT-PEL02/3

PCI-9016

1492-MCAA220 20 A UL489 Miniature Circuit Breaker

1494U-LA36 1494U 30A-60A Aluminum Lugs

軟啟動(dòng)器 3RW44552BC45

Safety Advanced V14 6ES7833-1FA14-0YK5 STEP 7 Safety Adv. V14 SP1 Upgrade SW DL

1585D-M4UBDM-5 Micro D-Code, QD Style Ethernet Media

1756-IT6I ControlLogix 6 Pt Isolated TC In Module

1797-OE8H FlexEx 8 Point Analog Output Module

194E-E40-3753 40 A 194E Load switch

2090-CFBM6DD-CCAA04 TL-Series 4m Feedback Cable

2090-SCEP0-2 Kinetix 0.2-0.2m Fiber Optic Cable

BC646MDA300 View Development/Runtime 300 I/O with Proficy GlobalCare Complete

GC647ADC001 GC PA Dashboard Client

HMI-CAB-C49 DOWNLOAD CABLE PROG TTL TO RS232

IC641SWP042 Series 90 Protocol (SNP) Driver, DOS, Multi-Use License

IC647IFCLNTSRO001K iFIX iClientTS Read Only 1 PK (M1 Kit Part)

IC660EBA105 Electronic Assembly for IC660BBA105

IC695PSA140 120/240VAC, 125VDC Multipurpose Power Supply is suitable for use in load -sharing and redundancy application. It must be installed in a PACsystems RX3i (IC695catalog number) Universal Backplane. It can be used as the only power supply in the backplan

IC756WRE049K-99 DataViews Runtime for Windows 25-49, Per User, Korean, Version 9.9

FlexLogix System 1794-OA8 85-132 VAC OUTPUT MODULE, 8 POINT

PLC-5/1771 System D1785-6.5.12 PLC5 ETHERNET PROGRAMMABLE CONTROLERS USERS MANUAL

Process Control 1757-PLXSIFQ PLX SIEMENS S5 & TI PLC VIA H1/TF QUICKBUILDER I/F

Operator Interface 2711P-K10C15B1 PV PLUS 1000, KEYPAD, CNET, AC PS, STD MEM

Support 9310-WE0200S SUPT RENEWAL CONTRACT FOR 9310WE0200

Support 2706-MB1R SUPT REINSTATEMENT CONTRACT FOR 2706MB1

Support F1785-L40BSERE FIRMWARE UPGRADE FOR 1785-L40B PLC5 PROCESSOR MODU

RSI Software Products 9301-2SE2300PTE RSVIEW32 WORKS 1500 (PORTUGUESE)

RSI Software Products 9701-VWSCRAENE RSVIEW SE VIEW CLIENT

RSI Software Products 9399-PROPAK5GR PROCESSPAK5 GETTING RESULTS GUIDE

Motion Control 2098-DSD-HV100-SE HIGH VOLTAGE DRIVE, 23A/46A, ULTRA3000 W/SERCOS

BC646MDC075 Logic Developer - PC & View Development/Runtime 75 I/O

IC300MIX906 8 DC Inputs (12/24vdc), 8 DC Outputs (5/12/24vdc, 0.5A pos. logic with ESCP) & 4 channels Analog Inputs, current (0-20mA, 4-20ma), 12 bit; 2 channels Analog Outputs, current sourcing (4-20ma)

IC752SKT005 Mature, order QuickPanel instead. DataPanel 320T MEG Starter Kit: Includes Datapanel 320T Mono Expansion with 2 MB & Genius (CBT020), download & communication cables, WinCfg, user & programming manuals

MTR-3S86-G-R-B-E-SRR Servo Motor 24V Brake, Seal

PCI-6034E

GPC-8450-LA-SH

TCM-MC2-v89.80

X8DTL-3F

ADM-682

MB820S

1492-KWC IEC Wire Cutting Tool

1492-XIM20120-8R Connection Products

軟啟動(dòng)器 3RW44243BC34

通信模塊 6GK7 542-5FX00-0XE0 CP 1542-5；RS485，PROFIBUS 通訊模塊

1585-C8CB-S300 Cable Spool Ethernet Media

1746-OX8 SLC 8 Point Digital Output Module

1790-16BV0X CompactBlock LDX 16 Expansion Block

194E-A100-1753 100 A 194E Load switch

20-PP09102 CABLE,OUT PH NON-REGENERATIVE FRONT ENDF

2090-CSBM1DF-18AA10 Kinetix Cable Single DSL 2090-Series

20AC037A3AYNACC0 PowerFlex 70 AC Drive 20A

GC-8459-UP-MT Workbench Upgrade to Latest Version (works with any license type)

HE300GEN150 Genius card for GE Drive G11 and P11

IC600KD515RR Mini OIT

IC647HSTES1KM Historian Enterprise Server 1000 Points (M4 Key)

IC648MNT076 Annual Software Maintenance for LM 90-70 Standard Serial Communication s

IC694ALG442CA Conbal Coated Analog Input module, 4 in and 2 out. Voltage and current supported.

IC756SDV000J-98 DV Development - Solaris Op Sys, Japanese, Version 9.8

MicroLogix 1200 System 1762-RPLDIN2 REPLACEMENT DIN LATCHES FOR 1762 I/O

PLC-5/1771 System 1771-WB FIELD WIRING ARM, 12 TERMINALS, GOLD PLATED

Distributed I/O 1794-IF2XOF2I ISOLATED ANALOG COMBO MODULE

Communications 9399-WAB32LUGES RSLINX LITE USER GUIDE (SPANISH)

Support 6223-5VDLR SUPT REINSTATEMENT CONTRACT FOR 62235VDL

Support 9358-BPC10R SUPT REINSTATEMENT CONTRACT FOR 9358BPC10ENE

Support F1771-ILSERB FIRMWARE UPGRADE FOR 1771-IFE I/O MODULE

RSI Software Products 9324-RLD000PTE RSLOGIX 5000 SERVICE EDITION, PTG

RSI Software Products 9301-2SE350JPU4R RSVIEW32 RUNTIME 150-100K UPGRADE OUT-SUPT (JP)

RSI Software Products 9358-HSTS2500U3 UPGRADE: IN-SUPT: HISTORIAN 1500 TO 70K TAG

Motion Control 8720SM-015S2ECS1 15 KW/48 AMP, 380 VAC, AC MOTOR WITH SRS60 ENC.

829-1-AC Thumbwheel Assembly. 1 Digit, AC Logic. Dust Seal

IC200MDL330 OUTPUT 120VAC 0.5A PER PT ISOLATED 16PT

IC697CMM799RR Replacement Part, MAP 30 Modem, Broadband, All Channels

MTR-1324-E-D-E-0RR Stepping Motor Nema34 Encoder

ExpressCard-8420/2

HSC-1462CLDN

UDIOCODES TRUNKPACK-100

ESX180

WY580-T4

NOVA MC8043P

MELEC 運(yùn)動(dòng)控制卡 C-871

1492-SPM3B100 MCB Supplementary Protector 10 A

軟啟動(dòng)器 3RW40271BB04

電機(jī)啟動(dòng)器 3VU16403CR00

150-F60NBR SMC Flex Smart Motor Controller

1734-IA2 POINT I/O 2 Point Digital Input Module

1783-BMS10CL Stratix 5700 10 Port Managed Switch

193-EIOGP-22-240 E300/E200 240V AC Control Module

20-750-DB1-D2 PowerFlex 750 Frame 2 DB Resistor Kit