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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，實現(xiàn)了數(shù)字控制、驅(qū)動制造、精密傳動與 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，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，受消費者自動化需求的提升，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。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，激光束也在工作，從而實現(xiàn)切削。此類型應(yīng)用的主要特點包括 ：工業(yè)機(jī)器人運(yùn)動靈活、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，實現(xiàn)可實現(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)器人實現(xiàn)了自動匹配的完全跟蹤，使折彎示教實踐叫從前縮短十倍。

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，價值也更高。在當(dāng)前工業(yè)轉(zhuǎn)型升級時代背景下，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、移動式和固定式等 [4]。

第三，獨立完成加工工序。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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RSI Software Products 9301-2SE3403 RSVIEW32 RUNTIME 32K WITH RSLINX

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Motion Control 1326AB-B520F-M2L MOTOR,SERVO,460V,13.1NM,3500RPM,MULTI,IP67

4161-4-24-N4 BCD To 7 SEG Display . 4 Digit, 24VDC, NEMA 4

HMI-CAB-C97 CABLE TOSHIBA T2

IC693CBL327 Cable, Left Side, One - 24 Pin 90 Degree Connector, 3 Meter

QSJ2D100S2P QUICKSTART KIT 5" STN

TRM-21006669 Motor power connector for 4.3/5/7.2 amp 115/230 VAC S2K models

20BC8P7A3AYNAEC1 PowerFlex 700 AC Drive 8.7 A 4 kW 20B

20F1ANF082JN0NNNNN PowerFlex 753 AC Packaged Drive

22B-E3P0C104 PowerFlex 40 1.5 kW (2 Hp) AC Drive

140AVO02000 Quantum 模擬量輸出, 4通道, 電壓

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

E2E-X1R5Y1 1.5mm,電感式,二線,常開 100mA 電源:24-240VAC圓M8

1492-SPM1C200 MCB Supplementary Protector 20 A

通用型變頻器 6SE6 430-2UD35-5FB0 "55 KW,350 x 850 x 320"

電機(jī)啟動器 3VU13402MB00

150-C19NBR SMC-3 19A Smart Motor Controller

1608P-200A415V4S-NX ProDySC 200 Amp Voltage Sag Protector

1770-CD1 Data Highway 100-100 ft Length Cable

193-CBCT3 E3 Plus Ground Fault Current Sensor

194R-R7 DISCONNECT OPERATING SHAFT

2090-CPBM7E7-08AF09 9 m Length SpeedTec Extension Cable

2090-XXTPMP-16S30 MP-Series 30 m Length Power Cable

CP4I-0WEB-0070-AZ Shielded motor power cable for B22HVis/A22HVi/A22HVis/A30HVis/A40HVis motors. (straight connector) 7 meters

GF-937332 Connecting FlashCable to Mitutoyo, Chatillon, Mecmesin.

IC200UEX009 14 point expansion. (8) 120VAC In, (6) Relay Out (2 at 10 amp and 4 a t 2 amp), 120/240VAC Power Supply. (includes IC200CBL501)

IC647ADC005 PA Dashboard Client 5 Pak

IC647PCL100 Proficy Process Systems Standard Edition 1000 I/O with CIMPLICITY

IC693CBL312 I/O rack expansion cable, 0.15 Meters, Shielded

IC754ACC12GAS Gasket for 12 inch QuickPanel View & Control

IMC-316E-X-D 6 amp IMC enhanced servo motor controller

SLC/1746 System 9399-EMMAN PLC-2,-5,-500 PROCESSOR EMULATION GUIDE

Open Automation Systems 1789-STRT1FR SOFTLOGIX 5800 STARTER KIT FRENCH

Application-specific products 1404-M805A-CNT 1404-M8 CONTROLNET PM3000 120/240V P.S.

Operator Interface 2711-K10G16 PV1000 GRAYSCALE KEY, DF1 & RS232 PRINT

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Support 9381-P1KENR SUPT REINSTATEMENT CONTRACT FOR 9381P1KEN

DeviceNet Products 1792D-KPLT KEMPF INTERFACE PLATE

RSI Software Products 9301-2SE3300ITU1 RSVIEW32 RUNTIME 300-1500 UPGRADE IN-SUPT (IT)

RSI Software Products 9358-EP30U2R UPGRADE: OUT-SUPT: RSBIZWARE EPROCEDURE 10 TO 30

Motion Control MPL-B4540F-MK24AA MOTOR,SERVO,10.2 NM,3000RPM,MULTI,460V,BRK

Motion Control 9101-0327 CONNECTOR KIT, MOTOR POWER, F/H-6X, STRAIGHT

GQPI3D200E2P QUICKPANEL 9" EL GE LABEL

IC646MRB150 Logic PC 150 Tag Runtime System

MTR-1N42-H-E-A-E-S Steping Motor Nema42, Parallel Wdg, Encoder

SA07-020 MATRIX Basic Training (3.5 days)

20BC056A0AYNACD1 PowerFlex 700 AC Drive 56 A 30 kW 20B

20F11ND096AA0NNNNN PowerFlex 753 AC Packaged Drive

22-RF5P7-AL PowerFlex EMC Filter

2711P-RN6 PV Plus 700 to 1500 DH Plus RIO Module

281D-F12B-10B-CR ArmorStart Direct Online RVSG Starter

C200H-IM212 輸入單元,16點, 12 - 24 VAC/DC

1492-PLOTADPT IEC X-Y Plotter Ultra Fine Pen Adapter

定位模塊 6ES7 451-3AL00-0AE0 FM451 定位，rapid traverse/creep speed,3 軸

變送器 3RS10301DD20

1497-C-M2-0-N Control Circuit Transber

1606-XL120E-3 Power Supply XL 120 W Power Supply

1762-IF4 MicroLogix 4 Point Analog Input Module

188-K3C130-N Miniature Circuit Breaker 13 A

194L-G2864R Control Knob Red

2090-CPBM7DF-04AA03 MP-Series 3 m Length Pwr and Brake Cable

2090-XXNFT-S15 Kinetix Drives 15m Standard Cable

BC647PSF050 Proficy Process Systems 500 I/O with iFIX with Global Care

GC647PME005 GlobalCare Complete for Proficy Change Management Server Machine Edition Version - 5 Concurrent Users

IC200MDL330LT OUTPUT 120VAC 0.5A PER PT ISOLATED 16PT (LT)

IC646NWV010 WebView - 10 Pack License

IC647MMPM MMP:Modicon Modbus Plus

IC676CBLPWB003 IP67 Power Cordset - 0.3 Meters

IC697MSC800 GMR Redundancy System, 386, 100 TMR I/O, (Rack, P/S, CPU, RAM, 3-GBC)

IC800SSI104RS1MOD1 Custom modified 4.3 amp 115/230 VAC S2K servo controller for MTR series motors

SoftLogix System 1789-STRT1 SOFTLOGIX 5800 STARTER KIT ENGLISH

Industrial Computers 6189-RDB10C VVCE 1000, KEY/TOUCH DISPLAY MODULE

Process Control 9399-RSBACLUG RSBATCH ACTIVEX CONTROLS LIBRARY USER'S GUIDE

Operator Interface 2711-B5A16 PV550 MONO KEY&TOUCH, DF1 & RS232 PRINT

Support 9303-23S0E40S SUPPORT RENEWAL CONTRACT FOR 9303-23S0E40

Support 9371-EPNE3R SUPT REINSTATEMENT CONTRACT FOR 9371EPNE3

ControlNet Products 9355-WABOEMENE RSLINX OEM - ENGLISH

RSI Software Products 9301-2SE2500ESU4 RSVIEW32 WORKS 150-100K UPGRADE IN-SUPT (ES)

RSI Software Products 9358-BANT60U1 UPGRADE: IN-SUPT: RSBATCH ARCHIVER 03 TO 60

Motion Control MPL-A4530F-HK24AA MOTOR,SERVO,8.36NM,2800RPM,ENCDR,230V,BRK,11KG

Motion Control 2090-UXNPBMP-16S01 CABLE,460V,NON-FLEX,MOTOR POWER,MP,16 GAUGE,1M

CBL-3C-RD-30 Resolver Cable, MTR-3S & MTR-3N Series Servo Motors, 30 Ft.

IC641CTL937 CIMPLICITY Control Programmer Tooolkit

IC800SLM040N2KE25 400W, 230 VAC SL Servo Motor, 2.5K Quad Encoder

OC647IPWRTS1CLN-50 iPower Option - TS per Client

20AE017C3AYNNNC0 PowerFlex 70 AC Drive 17 A at 15 Hp 20A

20DD077A3ENNACANE PowerFlex 700S AC Drive 77 A 60 Hp 20D

20P41AD667RA0NNN PowerFlex 460V AC 400 HP DC Drive

2711P-B15C22A9P-B PanelView Plus 7 Graphic Terminal

280-PWRM35A-M025 ArmorStart Three-Phase Power Media

MPT-CN300-CH 通訊電纜 3M

1492-MCEA140 Gfep 40 A Circ Brkr, 30 Ma , 1 Pole

1494V-FS200 Fuse Block