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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?；诖?，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，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。

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140CRP93200 Quantum RIO 處理器接口, S908 Head, 雙電纜，本地（總站）

285-BRC25-M12D Source Brake Patchcord Cable, 12M, M25

計(jì)數(shù):0-999999c,計(jì)數(shù)速度:1Kcps,計(jì)時(shí)時(shí)間:0.00s-99999.9h

1492-SPM1D150 MCB Supplementary Protector 15 A

通用型變頻器 6SE6 440-2UD31-5DB1 "15 KW,275 x 520 x 245"

電機(jī)啟動(dòng)器 3VU13403MS00

150-C480NCD SMC-3 480A Smart Motor Controller

1609-SPD UPS Surge Replacement Module

1771-IC DC INPUT 48V

193-EC3CB E3 Plus 5-25 A Overload Relay

198-MT2 IEC Enclosure Accessory

2090-CPBM7E7-16AF30 MP-Series 30 m Length Cable

2094-AM05-S Kinetix 6000 Axis Module

CW0DT128M/UGR 128M RAM Upgrade Kit for DuraTouch Industrial PC

GFK-0585 Series 90 PLC SNP Communications Driver User's Manual

IC200UEX734 RTD expansion module for VersaMax Micro Pt 100, -100 to +600 C-150 to +1050 F 2 and 3 wire support. Channel update is 141/563 ms (selectable) for all channels

IC647AQC005 PA Quality Client 5 Pak

IC647PLSEDTR Proficy Pulse Editor (WebSpace Enabled)

IC693CHS399LT Base, Remote Expansion, 5 Slots (700 ft.) (LT)

IC754UPGRD01VLOAD QP View Loaded OS Upgrade Qty-1

ME51-M-SC 10/100 baseT to multi-mode SC fiber converter

SLC/1746 System D1785-6.8.10 REF.GUIDE CONNEC. SLC SYS

Distributed I/O 1734-APB POINT PROFIBUS W/24VDC PS

Application-specific products 1803-EEM03 EEM,24 ANALOG, 4 TO 20 MA

Operator Interface 2711-T10G14L1 PV1000 GRAYSCALE TOUCH, MBUS & RS232 PRINT

Support 9301-2SE3500R SUPT REINSTATEMENT CONTRACT FOR 93012SE3500

Support 9381-PEDRCPENS SUPT RENEWAL CONTRACT FOR 9381PEDRCPEN

DeviceNet Products 1790D-N4V0 DNET LDX, 4 INPUT VOLTAGE ANALOG BSE,D-SHELL CONN

RSI Software Products 9301-2SE330JPU2R RSVIEW32 RUNTIME 150-1500 UPGRADE OUT-SUPT (JP)

RSI Software Products 9358-PBNT10ENE RSBATCH NT FOR PROCESSLOGIX 10 UNITS

Motion Control MPL-B660F-MJ22AA MOTOR,SERVO,48.0NM,3000RPM,MULTI,460V

Miscellaneous 1771-AR REMOTE I/O ADAPTER MODULE FOR 1774PLC

GQSK3D200C2P QUICKSTART KIT 6" TFT COLOR GE LABEL

IC646NSL005 CIMPLICITY SQL - 5 Client License

MTR-5T57-H-R-0-M-0 MTR-Series Servo Motor, Resolver, Metric

ST-2314 STXi output module 4 points, Negative Logic, 24VDC/ 0.5A

20BC085A3ANNANC0 PowerFlex 700 AC Drive 85 A 45 kW 20B

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22A-A6P8N103 PowerFlex 4- 1.5 kW (2 HP) AC Drive

TSXMCPC002M Quantum Unity V2 PCMCIA存儲(chǔ)擴(kuò)展卡，程序存儲(chǔ)2x1024K（Flash），數(shù)據(jù)存儲(chǔ)1024K（RAM)

284-MTRS22-M6 ArmorStart 90 Degree M22 Motor Cordset

C200H-BAT09 鋰電池 3V

1492-RCDA4C63 Residual Current Device 63 A

有源導(dǎo)軌 6ES7195-1GF30-0XA0 有源導(dǎo)軌/530mm

變送器 3RS11 40-2GW60

1497-K-BASX-0-N Control Circuit Transber

1606-XLE240F Power Supply XLE 240 W Power Supply

1763-L16BWA MicroLogix 1100 16 Point Controller

188-K3D250 Miniature Circuit Breaker 25 A

194L-HE4A-825 IEC Control And Load Sw Actuator Type A

2090-CPBM7DF-08AA30 MP-Series 30m Power and Brake Cable

2090-XXNPMF-14S40 Kinetix Drives 40m Standard Cable

BC647TRT300 CIMPLICITY HMI Server 300 I/O Runtime System with Proficy GlobalCare

GC647PSC500 "GlobalCare,####CIMPLICITY# Proficy##### 5000# I/O"

IC200MDL940CA OUTPUT RELAY 2A ISO FORM A 16PT MODULE CONFORMAL COATED

IC646PME050 Proficy Change Management for ME 50 user pack

IC647MX1M MX1:Leeds and Northrup Max1

IC687BEM713 Half Slot Bus Transmitter Module

IC697VAL324 Discontinued, replacement is Embedded VME-6550. Contact GE IP Embedded for details.

IC800SSI407RS1 7.2 amp 480 VAC S2K servo controller for MTR series motors

SLC/1746 System 1747-M2 EEPROM MEMORY, 4K FOR PROGRAMMABLE CONTROLLER

Industrial Computers 6181P-15NP2KH VERSAVIEW INTEGRATED DISPLAY COMPUTER 15-INCH

Application-specific products 9358-PBEBNT60ENE RSBATCH NT & EPROCEDURE BNDLE PROCESLGIX 60 UNITS

Operator Interface 2711-K5A15L1 PV550 MONOCHROME KEY, CNET & RS232 PRINT

Support 9306-4PXP01S SUPT RENEWAL CONTRACT FOR 93064PXP01ENE

Support 9393-RSTLX500R SUPT REINSTATEMENT CONTRACT FOR 9393RSLTX500

ControlNet Products 2711P-K7C15D1 PV PLUS 700, KEYPAD, CNET, DC PS, STD MEM

RSI Software Products 9301-2SE2500U3 UPGRADE: IN-SUPT: RSVIEW32 WORKS 300 TO 100K

RSI Software Products 9358-BEPB60U1R UPGRADE: OUT-SUPT: RSBW BATCH & EPROCEDURE 03 TO60

Motion Control MPL-A4540F-HK24AA MOTOR,SERVO,10.2NM,3000RPM,ENCDR,230V,BRK,13KG

Motion Control 2090-XXNFY-S12 CABLE,NON-FLEX,MOTOR FEEDBACK,Y,12M

GABI31200C2P/AR QUICKPANEL 10.5" TFT W/AB RIO GE LABEL

IC641PCC804 Annual Maintenance for IC641PCC004

IC800SSI104RD2 4.3A, 115/230V, DeviceNet S2K Servo Controller for MTR Series Motors

PR-PAT-RX-1.2 Proficy PAT - Process Analytical Software Suite, Pharmaceutical

20BB015A3AYNBNC0 PowerFlex 700 AC Drive 20B

20DD8P0A0NYNANGNE PowerFlex 700S AC Drive 8 A 5 Hp 20D

21-49-1 Photoelectric Accessories

2711P-K12C4A9 PanelView Plus Terminal

280-PWRM35D-M1 ArmorStart Three-Phase Power Media

CPM2A-40CDR-A 40點(diǎn)主機(jī) AC100-220V 24點(diǎn)入16點(diǎn)繼電器輸出 自帶RS232C口

1492-MS5X9H1-10 Connection Products

1495-N68 Protective Fuse Cover

行程開(kāi)關(guān) 3SE53120SG12

運(yùn)行版軟件 6AV2105-0MA14-0AA0 SIMATIC WinCC Runtime 專業(yè)版 65536 PowerTags ASIA V14

1585J-M4UBJM-1 RJ45 Ethernet Media

1756-OV32E ControlLogix 32 Point D/O Module

188-K1C160 Miniature Circuit Breaker 16 A

194E-KA16E-P11 194E Load switch

2090-CFBM7DF-CEAA60 MP-Series 60m Servo Feedback Cable

2090-UXLF-HV330 Ultra Series 30A AC Line Filter

BC646SPB365 Solution Provider Additional Seat - Euro

GC647IFCLNTSRO010 GCC iFIX iClientTS Read Only 25 PK Runtime Version

IC200ALG325 Analog output 13 bit voltage 8 channel

IC646MBP001 Machine Edition Professional Development Suite

IC647IFPRDV00900M iFIX Profsnl SCADA 900 I/O Development (M4 Part)

IC660SLA104 Red Safety Label Kit for IC660BBA104 Genius Blocks

IC697CGR772 Hot Standby Genius Dual Bus CPU, 486DX4, 2K Discrete I/O, 512K byte fi xed user memory, Floating Pt.

IC800CBL022 Encoder cable for B0.5/3000 motor. 14 meters

ControlLogix/1756 System 1756-M22 LOGIX5555 750K NV MEMORY MODULE

Industrial Computers 6182H-7KEH6B VVCE 700, KEYPAD, EXT MEM, RIO/DH, AC

Process Control 9358-PBANT03ENE RSBATCH NT FOR PROCESSLOGIX ARCHIVER 03 UNITS

Operator Interface 2711P-K15C6D2 PV PLUS 1500, KEYPAD, RIO/DH, DC PS, EXT MEM

Support 9352-WDN100R SUPT REINSTATEMENT CONTRACT FOR 9352WDN100

Support 9324-RSECSENR SUPT REINSTATEMENT CONTRACT FOR 9324RSECSEN

ControlNet Products 1786-BNC IMPROVED CONTROLNET RG6 COAXIAL CONNECTOR

RSI Software Products 9301-2SE2353ZHE RSVIEW32 WORKS 5K WITH RSLINX (CHINESE)

RSI Software Products 9352-WAB300D WINTELLIGENT LINX

RSI Software Products 9399-WTDGR RSTREND GETTING RESULTS GUIDE

Motion Control 2090-DAIO-D5003 CABLE, NON-FLEX, CN1 CONTROL, 03M

BC646MVSU01 View Standard Edition with SAFE - Upgrade from QuickDesigner

IC300TRM006 Spring-clamp style I/O plug, 6-terminal

IC800ABK001 Battery Backup Kit, Alpha SVU Series Amplifiers

MTR-3T67-G-R-B-M-0RR Servo Motor Metric 24V Brake

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