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A02B-0168-B042,

A02B-0168-B042

工業(yè)機器人作為綜合性的高新技術產(chǎn)品，實現(xiàn)了數(shù)字控制、驅動制造、精密傳動與 IT、傳感和信息等技術的有效集合。而在當前數(shù)字制造時代背景下，數(shù)控技術與人工智能推進了工業(yè)機器人與金屬成形機床的迅速融合。并通過高效組合形成了自動化極強的集成單元，可以為工業(yè)生產(chǎn)提供更為多元的的智能解決方案?；诖?，文章立足于當前工業(yè)機器人與金屬成形機床集成的常見應用類型，分析了其主要形式。進而探討了二者集成應用中存在的問題，并提出了相應發(fā)展途徑。

關鍵詞 ：工業(yè)機器人 ；金屬 ；成形機床 ；集成應用
當前，我國已成為全球最大的工業(yè)機器人市場。據(jù)國際機器人聯(lián)盟 (IFR) 統(tǒng)計數(shù)據(jù)顯示， 2015 年，我國工業(yè)機器人的用量共為 6.7 萬臺，已成為全球工業(yè)機器人的第一大市場。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)機器人年產(chǎn)量 10 萬臺。其中，六軸及以上工業(yè)機器人年產(chǎn)量超過 5 萬臺。在工業(yè)機器人制造業(yè)不斷發(fā)展的同時，我國裝備制造業(yè)也在逐步轉型升級。近年來，在先進技術進步與市場需求多元化的雙重作用下，考慮用工業(yè)機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)機器人應用的主要領域，受消費者自動化需求的提升，進一步擴大了工業(yè)機器人的應用范圍。包括除焊接外的其他大部分領域，如汽車機床噴涂、打磨、物料搬運碼垛、上下料與裝配等。在機床工具的組成部分當中，金屬成形機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)機器人與金屬成形機床相集成，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)機器人與金屬成形機床集成應用進行研究，為汽車制造業(yè)發(fā)展提供借鑒 [1]。

1 、工業(yè)機器人與金屬成形機床集成的應用類型

1.1 工業(yè)機器人的激光切割

工業(yè)機器人定位精度高，因此，應用其進行激光切割已成為激光切割與工業(yè)機器人應用領域的主要熱點。在工業(yè)機器人手臂中集成激光束引導裝置，當工業(yè)機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。此類型應用的主要特點包括 ：工業(yè)機器人運動靈活、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組成。在此生產(chǎn)線上，工業(yè)機器人集成應用通常會配置兩臺機器人，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 ；另一臺負責從沖壓成型模鍛壓機取料后，移送至另一臺模鍛壓機進行切邊。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行潤滑。而此過程處于高溫高濕環(huán)境中，既可由專門機構操作，又可由工業(yè)機器人完成。如由后者進行，可以大幅提升系統(tǒng)安全性于加工效率。但需做好機器人的維護工作，提升其抗熱、抗輻射的能力。

1.3 數(shù)控折彎機集成

工業(yè)機器人折彎集成應用可分為兩種主要方式，一是工業(yè)機器人與金屬成形機床中的各類設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)機器人行走軸與激光設備或數(shù)控轉臺沖床等 ；二是工業(yè)機器人以折彎機為中心，配置真空吸盤，磁力分張上料架、定位臺、下料臺、翻轉架形成折彎單元。制造商利用自身在工業(yè)機器人控制系統(tǒng)和機床數(shù)控系統(tǒng)上的技術優(yōu)勢，實現(xiàn)可實現(xiàn)二者的無縫連接。進而開發(fā)出折彎軟件包，對折彎過程中工業(yè)機器人托料實現(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)機器人與金屬成形機床集成應用的主要形式

工業(yè)機器人在金屬成形機床中的應用領域較為廣泛，包括碼操、搬運、焊接與裝配等，但一般被作為輔機使用。目前，工業(yè)機器人與金屬成形機床集成應用的主要形式如下。

第一，二者集成柔性生產(chǎn)線。此種形式中，工業(yè)機器人承擔的工作任務是轉換工件工序，并與多臺金屬成形機床組成柔性生產(chǎn)線。其較某種單機上下料更為復雜，價值也更高。在當前工業(yè)轉型升級時代背景下，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，由三臺金屬成形機床構成的 U型布局，主要由一臺工業(yè)機器人在場地中間進行工件轉換，布局特別緊湊。

第二，單機上下料。此種形式中，工業(yè)機器人在金屬成形機床中的應用最為成熟與典型。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、速度快且準確。工業(yè)機器人與金屬成形機床的結構關系可分為兩種形式，即與金屬成形機床構成一體和工業(yè)機器人安裝于機床外部。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)機器人裝上專用手爪，其便可完成機床清洗、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、機械鍛造與鑄造與取鐵液等。在此情形下，工業(yè)機器人本身便可視為一臺金屬成形機床。并且，具備觸覺與視覺的工業(yè)機器人，可以被用于復雜工序中，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)機器人在沖剪、折彎機上夾持工件，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床工作中的工傷隱患。

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PLC-5/1771 System 1771-N2 EMPTY SLOT FILLER CARD

Distributed I/O 1799-COV20 CLEAR PLASTIC COVER, 4 STAND-OFFS/SCREWS (20 PT)

Operator Interface 2711P-K6M20D PV PLUS 600 GRAYSCALE, KEYPAD, ETHERNET, DC PS

Support 9325-L3140R SUPT REINSTATEMENT CONTRACT FOR 9325L3140

Support 9358-PBBK30S SUPT RENEWAL CONTRACT FOR 9358PBBK30ENE

Support F1775-S4ASERB FIRMWARE UPGRADE FOR 1775-S4A PLC3 PROCESSOR MODUL

RSI Software Products 1789-L30 SOFTLOGIX5830 CONTROLLER W/5 USABLE CHASSIS SLOTS

RSI Software Products 9701-VWMR030ADEE RSVIEW ME STATION RT 30 DISP-WINDOWS 2000 (GERMAN)

RSI Software Products 9330-GC300U2 UPGRADE: IN-SUPT: RSGUARDIAN CORE 24 TO 4096 NODE

Motion Control 2094-PRS8 POWER RAIL, SLIM, 230V OR 460V, 8 AXIS

A06B-6093-H402 Ext. Regen Resistor, 30 Ohm 100 Watt, Beta or I/O Link Amplifiers

IC200UEX211-24 Qty of 24, 28 point expansion. (16) 24VDC In, (12) Relay Out, 120V/240AC Power Supply (includes IC200CBL501)

IC752COM101 Omron 9 pin cable for DataPanel 30/50

MTR-3N32-G-R-0-N-SRR Servo Motor Nema34 with Seal

ZA06B-0153-B175#7076 A30/3000 servo motor with IP67 sealing and brake and 64k serial encoder

20BD8P0A0NYNANC0 PowerFlex 700 AC Drive 8 A 5 Hp 20B

20G14NC302JN0NNNNN PowerFlex 755 AC Packaged Drive

25-PM2-A2P5 PowerFlex 520 0.4kW (0.5Hp) Power Module

TLXCDLTOFS33 Quantum 10 LICENSES LARGE OPC SERVER

FRN0.75C1S-4C 1. 9KVA 2.5A 0.75KW 3相AC380V/50Hz/60Hz

1492-J4 4 square mm Feed-Through Terminal Block

1492-SPM3D160-N MCB Supplementary Protector 16 A

軟啟動器 3RW40552BB44

SIMATIC HMI 系列面板 6AV2124-0UC02-0AX0 TP1900 精智 18.5 寸

150-SPPB4BR SMC-50 POWER POLE ASSEMBLY 180A

1738-IE2CM12 ArmorPoint 2 Point Input Module

1784-PCIC ControlNet PCI PC Comms Card

193-KC12 9.0-12.5 A IEC Bibllic Overload Relay

20-750-PH3-F10 PF755 FR10,IP00,24 VDC WIRE HARNESS

2090-CSBM1DE-10AF30 Kinetix Cable Single DSL 2090-Series

20AB4P2A0AYNNNC0 PowerFlex 70 AC Drive 4.2 A at 1 Hp 20A

GA647IFPRDV00150 GCA iFIX Profsnl SCADA 150 I/O Dev

GP647IFESGDV00900 GCP iFIX Optn: ESig & ERec 900 I/O Dev

IC600BF901RR Remote I/O Driver Module

IC647HSTCCP5M Historian Client Connection Pack 5 Users (M4 Key)

IC647TIDM TID:Texas Instrument Direct

IC693NIU004 Series 90-30 Ethernet NIU (Ethernet I/O)

IC756LDV010E-99 DV Draw Development on Inb/Linux RedHat Op Sys, English, Version 9.9

MicroLogix 1000/1761 System 1761-L10BWB 10 I/O MICROLOGIX 1000

PLC-5/1771 System 1771-OWNA CONTACT OUTPUT MODULE 32 POINT (NORMALLY OPEN)

Distributed I/O 1791-N4V2 BLOCK I/O, 120V AC, 6 POINT ANALOG MODULE

Communications 1786-FSKIT V-PIN CONNECTOR KIT

Operator Interface 9399-RSVSPCGR RSVIEW32 SPC GETTING RESULTS GUIDE

Support 9356-PRO2350S SUPT RENEWAL CONTRACT FOR 9356PRO2350

Support 9324-RL0LDRENR SUPT REINSTATEMENT CONTRACT FOR 9324RL0LDREN

EtherNet/IP Products 9351-DKTS INTERCHANGE FOR MSL-DOS

RSI Software Products 9301-2SE3500FRU1 RSVIEW32 RUNTIME 32K-100K UPGRADE IN-SUPT (FR)

RSI Software Products 9356-PRO2500U2R UPGRADE: OUT-SUPT: RSSQL STD.300 TO PROF.70000 TAG

Motion Control N-4214-2-H00AA MOTOR,NEMA 42,14 LB-IN,4500 RPM

44A731203-G03 Upgrade Kit Genius IC660BBA023

IC200ALG331 Analog Output Module, 16 Bit Voltage/Current, 1500VAC Isolation, 4 Channels

IC693PWR321LT Power Supply, 120/240 Vac, 125 Vdc, Standard (LT)

Silver Series 9500-CPAKMENE CONTROLPAK RT - MEDIUM SYSTEM

VSPC32-ADMIN SP VisualSPC Administration Bundle includes Attributes, Analyst, Designer , Wizard, Importer and Reports.

20BD027A0AYNANC0 PowerFlex 700 AC Drive 27 A at 20 Hp 20B

20G11FD052AA0NNNNN PowerFlex 755 AC Packaged Drive

22C-D260A103 PowerFlex 400- 132 kW (200 HP) AC Drive

MA0329001 Quantum CONNECTOR SET,CASSETTE,W/BOOTS

285-BRCF25-M8 Source Brake Cordset Flex Cable

E6B2-CWZ1X 5VDC,線性驅動輸出.600P/R

1492-SPM2B010 MCB Supplementary Protector 1 A

變頻器選件 6SE6 400-1PC00-0AA0 PC 至變頻器連接組件 MM420/440

電機啟動器 3VU16401CH00

150-F85NCD SMC Flex Smart Motor Controller

1746-F2 SLC Power Supply Fuse

1797-BIC FlexEx Accessories

193-DNCT DeviceNet Configuration Terminal

194R-J60-1753 194R Disconnect Switch