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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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IC647HWP322 Series 90 Workstation Intf. (PS/2) w/LM 90-30/20, Serial

QPH2D100S2P/B QUICKPANEL 6" STN HAND HELD BLANK

ST-3808 STXi analog b module 8 Channels, Thermocouple Connector Type

20BC140A3AYNANC0 PowerFlex 700 AC Drive 20B

20F1AGC140JN0NNNNN PowerFlex 753 AC Packaged Drive

22A-D6P0H204 PowerFlex 4- 2.2 kW (3 HP) AC Drive

140DAI35300C Quantum 開關(guān)量AC輸入,32點(diǎn),24VAC,8點(diǎn)成組隔離,CC

284D-FVD1P4B-N-R-3-DB-EMI Cntl Mod. Variable Frequency Drive

CJ1W-SRM21 COMPOBUS/S遠(yuǎn)程I/O主單元，最多256點(diǎn)

1492-RTB20N 20 Pole RTB Plug Assembly

WinCC 上位監(jiān)控軟件 6AV6381-1BD06-0DV0 "WinCC?V6.0 RT?256?（256 個(gè)外部變量）"

變送器 3RS17202ET00

1497A-A5-M6-1-N Control Power Transber

1606-XLP90E-2 Power Supply XLP 90 W Power Supply

1768-L45 CompactLogix L45 3MB Memory Controller

188-K4C400 Miniature Circuit Breaker 40 A

194R-60-NJ 194R 60 Ampere 4th Power Pole Module

2090-CPBM7DF-10AF05 MP-Series 5 m Length Pwr and Brake Cable

2090-XXNPMP-14S03 MP-Series 3 m Length Power Cable

CBL-13-ET-20 Encoder cable for MTR-1300 or MTR-1N series stepping motor. 20 feet

GC647TRT915 Proficy GlobalCare Complete for CIMPLICITY HMI Server 1500 I/O Runtime System

IC200PWR201 POWER SUPPLY 12VDC INPUT

IC646TBLSS2500 Proficy Troubleshooter for Inbligent Historian for Hist 2500 Points

IC647NGV000 CIMPLICITY GlobalView - 1 Concurrent user.

IC693ACC301 Replacement Battery, CPU & PCM (qty 2)

IC698PSA100 RX7i Power Supply 100Watt 85-264VAC

IC800VMCB1200 Motor power and brake power cable for 1 kW VersaMotion servo motor- 20 meter

SLC/1746 System 1746-ITV16 FAST RESPONSE DC SOURCING INPUT CARD (24V DC)

Industrial Computers 6180W-7PXPHDC VERSAVIEW 6180W NON-DISPLAY COMPUTER, 7 SLOT

Application-specific products 6556-PSH0M CLUTCH/BRAKE KIT W/STROKE AND A HALF ON THE HOP

Operator Interface 2711-T5A1L1 PV550 MONO TOUCH, RIO & RS232 PRINT

Support 9301-2SE2200ZHR SUPT REINSTATEMENT CONTRACT FOR 93012SE2200ZH

Support 9307-10KMGDBCR SUPT REINSTATEMENT CONTRACT FOR 930710KMGDBCENE

DeviceNet Products 1732D-8CFGM12 DEVICENET 24VDC 8 SELECTABLE POINTS W/M12

RSI Software Products 9301-2SE250FRU5R RSVIEW32 WORKS 5K-100K UPGRADE OUT-SUPT (FR)

RSI Software Products 9358-BIZUC2PENE RSBIZWARE UNLIM RUNTIME CLIENT + 2 CPU SQL SERVER

Motion Control MPL-B310P-RK22AA MOTOR,SERVO,1.58 NM,5000RPM,RSLVR,460V

Motion Control 2090-XXNPY-16S03 CABLE,NON-FLEX,MOTOR POWER,Y,16 GAUGE,3M

GEK-90486-2 Genius I/O Discrete Analog Blocks User's Manual - Volume 2

IC641SWP703 Logicmaster 90-70 Demonstration Software Pkg., 3.5" & 5.25" Format

IMC-313P-X-D IMC-D Series Servo Motor Controller, Enhanced, DeviceNet, 3 Amp

PSPC-DC100/E-220L Prof Shop Floor SPC DC 100 Usr eSig 220v

20BC011A0AYNANA0 PowerFlex 700 AC Drive 20B

20DM1K12CNNNBCANE PowerFlex 700S AC Drive 20D

2198-H040-DP-T K5500 FR1,2 DC control conn

2711P-RAAT12 PanelView Plus 7 Series Accessory

280-PWRM35G-M015 ArmorStart Three-Phase Power Media

CQM1H-CPU21 主機(jī)，最大I/O點(diǎn)；256點(diǎn)，程序容量；3.2K字 帶RS232C口,不支持內(nèi)裝板

1492-MS8X12V51-60 Connection Products

模擬量輸入/輸出模塊SM 6ES7 331-7NF00-0AB0 AI/8 電壓、電流，光電隔離，40pin 前連接器

行程開關(guān) 3SE53220SF23

運(yùn)行版軟件 6AV2105-4MM04-0AE0 SIMATIC WinCC Runtime 專業(yè)版 V14 Upgrade WinCC V7.0..V7.3 Runtime 65536 PowerTags ->WinCC Runtime 專業(yè)版 65536 PowerTags V14

1585J-M8CC-H 1585 Ethernet Media Accessory

1756-RMC1 ControlLogix 1 m RM Fiber Optic Cable

188-K1D200 Miniature Circuit Breaker 20 A

194E-Y32-1753-6N 32 A 194E Load switch

2090-CFBM7E7-CEAF04 4 m Length SpeedTec Extension Cable

2090-UXNFM-S01 Ultra Series 1 m Feedback Cable

BC646TRT150 Server 150 I/O Runtime System with Proficy GlobalCare

GC647IFPLRN00300 GCC iFIX Plus SCADA 300 I/O Run

IC200CBL555 CABLE TO DATAPANEL 45/65/85

IC646MPPS50 Logic Developer PLC Professional 50 Seat Site License

IC647IFSCTSSPRT01C iFIX TS SCADA Support on SCADA - 1 Client (M1Component Part)

IC670ACC001 Base to Base Connection Cable, Qty 12 of IC670CBL001

IC697CPU731RR CPU, 8 MHz, 512 Discrete I/O, Fixed Memory (32 KBytes)

IC800PCUBC04S030 Powercube flying lead interface cable configured for 400 steps/revolution and power save enabled. 3 meters

ControlLogix/1756 System 1756-OB16IS 10-30VDC ISOLATED OUTPUT CAM 16 PTS (36 PIN)

Industrial Computers 6182H-10KEH4B VVCE 1000, KEYPAD, EXT MEM, ENET, AC

Process Control 9380-RSBCNS2 2-DAYS MISCELLANEOUS SERVICES FOR RSBATCH

Operator Interface 2711P-RBT10 PV PLUS 1000 TOUCH REPLACEMENT BEZEL

Support 9355-WAB1ENS SUPT RENEWAL CONTRACT FOR 9355WAB1EN

Support 9351-SLRSRTS SUPT RENEWAL CONTRACT FOR 9351SLRSRT

ControlNet Products 1788-MCHKR NETWORK MEDIACHECKER (ENET, CNET, DNET, DH+/RIO)

RSI Software Products 9301-2SE2400ESU3 RSVIEW32 WORKS 150-32K UPGRADE IN-SUPT (ES)

RSI Software Products 9355-WABGWITE RSLINX GATEWAY - ITALIAN

Motion Control MPL-A320H-MJ24AA MOTOR,SERVO,2.26 NM,3500RPM,MULTI,230V,BRK,5.1KG

Motion Control 2090-DANPT-16S25 CABLE, NON-FLEX, MTR PWR, CABLE-MTD CONN, 16AWG, 2

CB6N-5WPM-0140-AZ Brake Cable, BM Series Servo Motors, 14 Meters

IC5008TAX0000 18" Unbundled Inbligence Industrial Computer with WIN XP Standard Series

IC800MCUB12310XN Stepping Motor Cube, 175 oz-in with Pulse/Direction, NEMA 23

OC647IFESGCLNTCRNM iFIX Optn: ESig & ERec iClient Runtime (M4 Part)

20AD022F0AYNANC0 PowerFlex 70 AC Drive 22 A at 15 Hp 20A

20DC2P1A0EYNANANE PowerFlex 700S AC Drive 20D

20G1ANF171JN0NNNNN PowerFlex 755 AC Packaged Drive

25C-E032N104 PowerFlex 527 22kW (30Hp) AC Drive

280-PWRM22B-M3 ArmorStart Three-Phase Power Media

FX2N-80MR-001 主機(jī)40入/40出?繼電器輸出

1492-M5X5V1-20S Connection Products

1494H-EA3N Heavy Duty Non-Fus Safety Discon Switch

軟啟動(dòng)器 3RW44462BC45

ET 200SP 6ES7193-6BP00-0BA1 基座單元 BU15-P16+A0+2B/T，類型A1，直插式端子，帶有溫度測(cè)量，15mm寬

1585D-M4TBJM-1 Micro D-Code, QD Style Ethernet Media

1756-ESMCAPXT L7XT Energy Storage Module-Capacitor

1794-OM16 Flex 16 Point Digital Output Module

194E-CA80E 194E Load switch

2090-CCMDSDS-48AAP3 Comms Cable Kinetix 3 Drv to Drv 0.3m

2090-DANPT-16S05 TL-Series 5m Power Cable

ABKCTDE0000/DVN 6 inch TFT QuickPanel TCP w/DeviceNet 24VDC/ No Agency Approvals

GC646PCMSCH GlobalCare Complete for Change Management Scheduler

HE800ACC014 Cage-clamp (screw) style I/O plug, 14-terminal. (Qty 1)

IC630PWR314RR 24Vdc Power Supply Unit

IC647HSTSSEO100KM eSignature Option for Historian - Standard Server 100000 Points (M4 Key)

IC660BLD025 Cover w/Label for IC660BBD025

IC695CHS012CA RX3i 12 slot universal backplane. Conbal Coated.

IC756WET100E-99 Custom Editor Toolkit, English, Version 9.9

CompactLogix System 1769-PA4 120/240 VAC INPT. PWR SUPPLY 4A @ 5VDC, 2A @ 24VDC

PLC-5/1771 System D1771-6.5.108 TEMPERATURE CONTROL MODULE USER MANUAL

Process Control 1757-ABRIO PROCESS RIO SCANNER MODULE

Operator Interface 2711P-B7C15D2 PV PLUS 700, KEY/TOUCH, CNET, DC PS, EXT MEM

Support 6500-DSUTR SUPT REINSTATEMENT CONTRACT FOR 6500DSUT

Support 9358-PLTM2400S SUPT RENEWAL CONTRACT FOR 9358PLTM2400ENE

Support F1785-BCMSERA FIRMWARE UPGRADE FOR 1785-BCM COMMUNICATION MODULE

RSI Software Products 9301-2SE2200JPE RSVIEW32 WORKS 300 (JAPANESE)