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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。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，已成為全球工業(yè)機(jī)器人的第一大市場。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。其中，六軸及以上工業(yè)機(jī)器人年產(chǎn)量超過 5 萬臺。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。近年來，在先進(jìn)技術(shù)進(jìn)步與市場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)配置兩臺機(jī)器人，一臺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) ；另一臺負(fù)責(zé)從沖壓成型模鍛壓機(jī)取料后，移送至另一臺模鍛壓機(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、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、下料臺、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，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)型升級時(shí)代背景下，市場需求的旺盛程度不斷增加。因此，現(xiàn)場條件與工藝路線等因素對金屬成形機(jī)床的布局起著決定性因素。常見類型包括對面布置型、有直線型、U 型和 L 型等。其中，由三臺金屬成形機(jī)床構(gòu)成的 U型布局，主要由一臺工業(yè)機(jī)器人在場地中間進(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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IC647IFGLBLSRVRM-50 iFIX WebSpace Server including iClient Dev and 2 Web Users(M4 Key)

IC660EBR101RR Electronic Assembly Normally Open

IC697ACC715 Kit, VME Integrator, J2 Backplane Mounting

IC756WRE499J-23 DataViews Runtime for Windows 100+, Per User, Japanese, Version 2.3

FlexLogix System 1794-IR8 RTD INPUT MODULE, 8 POINT

PLC-5/1771 System D6200-6.4.18DE PLC-5 STRUCTURED TEXT REL 1.0 USER MANUAL (GERMAN)

Process Control 1757-SRC3 1757 REDUNANCY MODULE CABLE - 3 METER, 9.84 FT

Operator Interface 2711P-T10C6B2 PV PLUS 1000, TOUCH, ENET, AC PS, EXT MEM

Support 6001-A1DCR SUPT REINSTATEMENT CONTRACT FOR 6001A1DC

Support 2711-END1S SUPT RENEWAL CONTRACT FOR 2711END1

Support F1785-L46C15SERF FIRMWARE UPGRADE FOR 1785-L46C15 PLC5 PROCESSOR MO

RSI Software Products 9301-2SE230DEU2R RSVIEW32 WORKS 150-1500 UPGRADE OUT-SUPT (DE)

RSI Software Products 9701-VWSS000JPU2 RSVIEW SE 100 TO UNLTD UPG JAPANESE

RSI Software Products 9399-RSBPCDRG RSBATCH PCD PROGRAMMER'S REFERENCE GUIDE

Motion Control 1394C-SJT10-C-RL MODULE,SYSTEM,10KW,IMCS,W/RIO,W/AXIS LINK

BC646MOSS99 QuickPanel Control Development Software Site License with Proficy GlobalCare Complete. Supports QuickPanel, QuickPanel View, and QuickPanel Control.

IC300OCS062 OCS with 2x20 LCD Display and with 16 keypad. Built in I/O no expansion. 8 DC Inputs (12/24vdc), 8 DC Outputs (5/12/24vdc, 0.5A neg. logic with ESCP). Built-in network

IC752WFB253 Display Station 2020 Series - w/ touch - 12.1" SVGA (800x600), Pentium 350 MHz, 128 MB RAM, 6.4 GB HD, expansion slots, Ethernet, floppy drive, CD ROM front access, built-in keypad, with unlimited point count CIMPLICITY HMI R&D and Win '95

MTR-3T22-G-R-0-M-S MTR series metric servo motor with resolver and shaft seal

ZA06B-6150-H018 PSM-18HVi 18 kW high voltage power supply module for Alpha servos

20D-P2-CKE1 PowerFlex 700S Expanded Control Cassette

20G1AGE192JA0NNNNN PowerFlex 755 AC Packaged Drive

25B-A011N104 PowerFlex 525 2.2kW (3Hp) AC Drive

2711P-T7C4D9 PanelView Plus Terminal

6SE6430-2UD33-0DB0 30KW

1492-L3Q IEC Term Blck 5.1x79x31.3mm Spr Clp

1494C-CM5 Cable Mechanism

軟啟動(dòng)器 3RW44261BC45

附件 6ES7 954-8LT03-0AA0 存儲(chǔ)卡：32GB

1585BP-F8BF 1585 Ethernet Media Accessory

1746-RT32 SLC Replacement Terminal Block

1790D-T0V16 CompactBlock LDX 16 Point O/P Base Block

194E-A32-1753-Q 32 A 194E Load switch

20-PP13000 WIRE SET ASSY FI13

2090-CSBM1DF-18AF14 Kinetix Cable Single DSL 2090-Series

20AC060A0AYNANC0 PowerFlex 70 AC Drive 60 A at 30 kW 20A

GC646MBSS99 Proficy GlobalCare Complete for ME Standard Development Suite - Site License

HE690PGM100 Programmable Memory for HPL

IC600PM502RR Standard I/O Rack Power Supply, 115-230Vac

IC647HSTESEO1250KM eSignature Option for Historian - Enterprise Server 1,250,000 Points (M4 Key)

IC655CHS508RR Base Unit, 8 Slots

IC694MDL240 Input module 120 VAC, 16 points.

IC756SDV010E-925 "DV-Draw Development on Solaris Op Sys, English v9.20"

MicroLogix 1500/1769 System 1769-IQ6XOW4 COMBO 6PT 24 VDC SNK/SRC IN, 4PT VAC/VDC RELAY OUT

PLC-5/1771 System 1785-TAS THIN-WIRE TRANSCEIVER CABLE KIT, 49.2FT/15M, STD

Distributed I/O 1794-TB3K CONFORMALLY COATED, TERMINAL BASE 3-WIRE

Communications 9399-WGSUG RSSERVER FOR GE FANUC SERIES 90 USER'S GUIDE

Support 9311-PLC2R SUPT REINSTATEMENT CONTRACT FOR 9311PLC2

Support 9358-BTDS60S SUPT RENEWAL CONTRACT FOR 9358BTDS60ENE

Support F1771-OFE1SERA FIRMWARE UPGRADE FOR 1771-OFE1 I/O MODULE

RSI Software Products 9324-RLD200ESE RSLOGIX 5000 MINI, ESP

RSI Software Products 9301-RSVWSENE RSVIEW32 WEBSERVER

RSI Software Products 9358-PLTM2300ENE RSBIZ PLNTMET SEV 25 CELL

Motion Control 8720SM-022S3GAS3 22 KW/48 AMP, 750 VDC, AC MOTOR WITH SNS60 ENC.

840-RC-48 48" Ribbon Cable. Term Both Ends W/16 Pin DIP Plugs

IC200NDR001 10 point (6) DC In, (4) Relay Out, DC Power Supply

IC697VAL328 Analog Output, isolated, 8 channel, 12 bit, Voltage - polar 0-10VDC, 0-5VDC. Removable terminal block, no cable required

MTR-1337-0-D-E-0RR Stepping Motor Nema34 Dble Shft

ZA06B-0063-B203#0100 B4/4000is Servo Motor with Straight Shaft, Key and IP67 Sealing

20BD156A3AYNAEC0 PowerFlex 700 AC Drive 20B

20G11NE022AA0NNNNN PowerFlex 755 AC Packaged Drive

23C-D038A103NNBANN-LR Fan/Pump Packaged Drive 23C

140CFU00600 Quantum CABLEFAST 保險(xiǎn), 1/16 AMP

294E-FD2P5Z-G1-SB Variable Frequency Drive

HL-5100 觸點(diǎn):1開/1閉,5A 250VAC機(jī)械壽命:1000萬次?撞壓式?頂部柱塞型

1492-SPM3B630-N MCB Supplementary Protector 63 A

軟啟動(dòng)器 3RW40371BB05

中央處理單元 6ES7 214-1AG40-0XB0 CPU 1214C AC/DC/RLY

150-F86L SMC Accessory

1734-IV8 POINT I/O 8 Point Digital Input Module

1783-HMS4EG8CGN Stratix 5400 12 Port Managed Switch

193-ERID E1 Plus Remote Indication Display

20-750-EMCSSM1-F8 PF755,FR8-10,SAFE SPEED MONITOR EMC CORE

2090-CPWM7DF-14AA07 MP-Series 7m SpeedTec Standard Cable

2098-DSD-150 Ultra 3000 Servo Drive

GA646PCM005 GlobalCare Assist for Change Management 5 user pack

GFK-2314 PACSystems RX3i System Manual

IC220TBK203 TERMINAL STRIP SET, SPRING STYLE, ANALOG OUT/HSC

IC647GEFM GEF:GE Fanuc

IC647SHR001 Scheduler Hour rate

IC693MDL648 48VDC Input, Neg/Pos Logic, 1 msec filter, Neg/Pos Logic (16 points)

IC756HDV000CT-99 DV Development - HP/UX Op Sys, Traditional Chinese, Version 9.9

MSI-ROLL Roll Map Base Application

PLC-5/1771 System 1771-IAD INPUT MODULE, 120V AC, 16 INPUT

Distributed I/O 1790D-N4V0 DNET LDX, 4 INPUT VOLTAGE ANALOG BSE,D-SHELL CONN

Communications 1771-KE DATA HWY RS-232C INTERFACE MODULE

Operator Interface 2727-MRJB1 MOBILEVIEW JUNCTION BOX

Support 9305-RSVADFCZHS SUPT RENEWAL CONTRACT FOR 9305RSVADFCZH

Support 9515-RSCHM010R SUPT REINSTATEMENT CONTRACT FOR 9515RSCHM010ENE

EtherNet/IP Products 2706-P74CN1 INVIEW MESSAGE DISPLAY. 1 TO 4 LINE

RSI Software Products 9301-2SE3400U2 RSVIEW RUNTIME 300 TO 32K UPGRADE:IN-SUPPORT

RSI Software Products 9515-RSEOL016ENE RSMACC CONDITION MONITOR, 16XM & 2 ENWATCH

Motion Control 1326AB-B515E-M2L MOTOR,SERVO,460V,10.4NM,3000RPM,MULTI,IP67

4161-3-24 BCD To 7 SEG Display . 3 Digit, 24VDC. Dust Seal

HMI-CAB-A02-25X CABLE ADAPTER HAND HELD 25'

IC693CBL301 Cable, I/O Expansion, 2 Meters

QPL-DEM-C02 QUICKPANEL DEMO COLOR 12.1'

TGT-S000-1-0 Target series system module