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A06B-0572-B004

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(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 萬臺(tái)。其中，六軸及以上工業(yè)機(jī)器人年產(chǎn)量超過 5 萬臺(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，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，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)二者的無縫連接。進(jìn)而開發(fā)出折彎軟件包，對(duì)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(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說，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?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。

上億庫存，國(guó)內(nèi)外近千個(gè)倉庫，公司部分產(chǎn)品型號(hào)如下，歡迎聯(lián)系哦~！

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ABKSTDN0000/ABD 6" Color STN, TCP Label, 24Vdc, with AB DH Plus,UL,cUL,CE,UL1604

IC220TBK203 TERMINAL STRIP SET, SPRING STYLE, ANALOG OUT

IC752DPJ000 Mature Product, Order Datapanel 160, IC752DSX000. DataPanel J+, 256x64 LCD with EL backlight. Various sizes of text, bitmaps, bar graphs, real time clock. Includes an integrated keypad for data entry. No touch capability.

MTR-3S34-G-R-0-E-ERR Servo Motor Nema34 Flg Explosion-Proof

ZA06B-6073-K214 AHVi Amplifier Motor Encoder Feedback Connector (JF1)

20BE062A0ANNAND0 PowerFlex 700 AC Drive 62 A 60 Hp 20B

20G14NF082JA0NNNNN PowerFlex 755 AC Packaged Drive

25-RF014-BL PowerFlex 520 13.8A 480V EMC Filter Kit

2711P-RTBDC2 PanelView Plus DC 2 Pin Terminal Block

FRN110G11S-4CX 160KVA 210A 110KW 3相AC380V/50Hz/60Hz

1492-JC3 2.5 square mm Comb Style Terminal Block

1492-W10 IEC Term Blck 8x47.6x41mm Screw

軟啟動(dòng)器 3RW40742BB35

CPU 模塊 6ES7 677-2AA41-0FL0 CPU 1515SP PC，4 GB RAM，16 GB CFAST，Windows 7 嵌入版 64 位 + HMI 512PT

153H-C43FBD-45 43 A Encl. Smart Mtr Ctrlr CB

1746-A4 SLC 4 Slots Chassis

1786-BNCP CNet Media Barrel Plug-to-Plug TNC

193-T1AA63 0.45-.63 A IEC Bibllic Overload Relay

20-DA1-A0 PowerFlex 700 24V AC-DC IO Kit

2090-CSBM1DF-10AF14 Kinetix Cable Single DSL 2090-Series

20AC011A3AYYAEC0 PowerFlex 70 AC Drive 20A

GA647TDV000 Proficy GlobalCare Assist for CIMPLICITY HMI Server No Limit Development and Runtime System

GP647IFPLSR00900 GCP iFIX Plus SCADA 900 I/O Srv

IC600BF944RR 12K ASCII/Basic I/O Module

IC647HSTCR750KM Collector Redundancy Option for Historian - Standard Server 750,000 Points (M4 Key)

IC647TRT000 CIMPLICITY HMI Server NO LIMIT Runtime System

IC693PTM101CA Conbal Coated Power Transducer Module

IC756MDV001J-99 DV Development - Alpha OpenVMS Addt'l User, Japanese, Version 9.9

MicroLogix 1000/1761 System 1761-SIM-B16 MICROLOGIX 1000 INPUT SIMULATOR

PLC-5/1771 System 1771-NC15 HIGH RESOLUTION ISOLATED ANALOG SERIES CABLE

Distributed I/O 1792D-CB18PT MAXUM ROUND MEDIA 18MM BASE,

Communications 9351-OSF INTERCHANGE FOR DIGIAL UNIX

Operator Interface D6190-6.5.25FR CONTROLVIEW & CONTROLVIEW 300 INSTALL. MNL(FRENCH)

Support 9358-B10R SUPT REINSTATEMENT CONTRACT FOR 9358B10ENE

Support 9392-CDRSITU UPGRADE TO ENGLISH/ITALIAN BUNDLE

RSI Software Products 9323-L3300DUR UPGRADE: OUT-SUPT: 6200-3 BOTH TO AI-3 BOTH

RSI Software Products 9301-2SE3500PTU2 RSVIEW32 RUNTIME 1500-100K UPGRADE IN-SUPT (PT)

RSI Software Products 9356-SQLSAPSVENE RSSQL FOR SAP SOLUTIONS SERVER

Motion Control TL-A2530P-BJ34AA MOTOR, SERVO, 2.6NM, 5000RPM, 17BIT SERIAL FEEDBAC

44A751125-022R01 Mounting Clips, Set of 8

IC200CHS006 COMMUNICATIONS CARRIER

IC694MDL634 INPUT MODULE 24 VDC 8 POINT POS/NEG LOGIC

MSI-UNIV-WEB-5 Universal Web Client(RTIP / Dashboard / Web / Excel Addin) 5 Pak

VSPC32-SF SP VisualSPC ShopFloor Spanish edition includes Attribute Data Collection , Measurement Systems Analysis and A-681 interface cable.

20BD040A3AYNAEB0 PowerFlex 700 AC Drive 40 A at 30 Hp 20B

20G11JC910JN0NNNNN PowerFlex 755 AC Packaged Drive

22D-D017F104 PowerFlex 40P 7.5 kW (10 Hp) AC Drive

140NOE77111C Quantum TSX Quantum FactoryCast Web Server Modul

290E-FAP-G2 Direct Online Starter

MY2NJ 24VDC，110VAC，220VAC，2開2閉，觸點(diǎn) 5A LED燈

1492-SPM2C060 MCB Supplementary Protector 6 A

軟啟動(dòng)器 3RW30262BB04

電機(jī)啟動(dòng)器 3VU16402MR00

150-F201NBD SMC Flex Smart Motor Controller

1732D-IB16M12MINI ArmorBlock 16 Point Input Block

1771-OM 1771 8 Point Digital Output Module

193-ED1DP E1 Plus 3.2-16 A IEC Overload Relay

199-FSMA1 Industrial Relay R-C Surge Suppressor

2090-CPWM7DF-08AA02 MP-Series 2m Standard Power Cable

2094-SE02F-M00-S1 Kinetix 6200/6500 Control Module

DT1009 Industrial Keyboard (for environments with industrial solvents)

GFK-1062 Series 90-70 High Speed Counter Manual (IC697HSC700)

IC210NDR024 24V DC Power Source, (12) 24VDC in/8 out (Relay, 8 Amp), (4) analog bs. Not expandable,no LCD/Keypad, no cover.

IC647BSP010 Batch Small Server Pak (10 Units)

IC647PRTHE010M Proficy Portal Historian Edition Client Pack 10 Users (M4 Key)

IC693CPU363CA CPU363 conbal coated. CPU supports 240K of memory, 2 serial ports and up to 4,096 I/O.

IC756ADV000E-99 DV Development - AIX Op Sys, English, Version 9.9

MSI-EFF-25-43 Efficiency Mang Clients 25 Pack-43

SLC/1746 System 1746-RL71 REPLACEMENT OCTAL LABEL KIT FOR CTLG # 1746-OV32

Distributed I/O 1734-EP24DC 24V DC POWER/BUS EXTENSION MODULE

Application-specific products 9307-RSP32WENE RSPOWER32 WORKS

Operator Interface 2711-NF5 FUNCTION KEY STRIP PV1400 COLOR

Support 9302-NETS SUPT RENEWAL CONTRACT FOR 9302NET

Support 9510-PPKCENS SUPT RENEWAL CONTRACT FOR 9510PPKCEN

DeviceNet Products 1787-PLUG10R DEVICENET 10 POSITION CONNECTOR WITH JACK SCREWS

RSI Software Products 9301-2SE3350ZHU1 RSVIEW32 RUNTIME 150-5K UPGRADE IN-SUPT (NZ)

RSI Software Products 9326-AD10UENE RSAUTOMATION DESKTOP 10 USER

Motion Control MPG-A004-031S24 MOTOR,SERVO,GEAR RATIO 31,14NM,194RPM,SINGL,BRK

Silver Series 1756-L1M3 LOGIX5550 PROCESSOR WITH 2MBYTE EXPANSION MEMORY

HE693IBMOIU-57B Personal Computer Programming Utility for all Release 3.0 OIUs

IC648MNT101 InfoLink CD-ROM (IC690CDR002) One Year Subbion Renewal

QPI31200E2P QUICKPANEL MONOCHROME 9"

ST-4491 STXi analog output module 1 Channel, 0~10V, 12bit, Manual type

20BC170A0AYNANC1 PowerFlex 700 AC Drive 20B

20F1AGC302JN0NNNNN PowerFlex 753 AC Packaged Drive

22A-V2P3N104 PowerFlex 4- 0.4 kW (0.5 HP) AC Drive

140DAI55300 Quantum 開關(guān)量AC輸入,32點(diǎn),115VAC,8點(diǎn)成組隔離

284D-FVD2P3B-N-R-3-DB-EMI Cntl Mod. Variable Frequency Drive

E3JK-DS30M1 30cm,擴(kuò)散反射式,觸點(diǎn)輸出3A 電源:24-240V AC/DC

1492-RXIMTS4024-32R Solid State Relay Dgtl Interface Module

人機(jī)界面 6ES7810-4CC07-0YA5 "STEP7 V5.3"

6ES78221AA030YC5

1497B-A11-M12-0-N Control Power Transber

1606-XLS240-UPSC 1606 Power Supply

1769-BA CompactLogix 3V Battery Assembly

188-K4D080 Miniature Circuit Breaker 8 A

194R-C30-FC 30A CC Fuse Carrier Rotary Disconnect

2090-CPBM7DF-10AF50 MP-Series 50 m Length Cable

2090-XXNPMP-14S30 MP-Series 30 m Length Power Cable

CBL-14-ET-20 Encoder cable for MTR-1300 or MTR-1N series splashproof stepping motor. 20 feet

GF-0188 Connecting FlashCable to Federal Micro Maxum Indicator.

IC200TBX014 Tool box, 14 point, (IC200UDR001) 24VDC In/Relay Out, AC Powered. (requires AC power) Programming software, manuals and cables (IC640VPS002 and IC646MPM001) provided.

IC646TBPAS010 Production Accounting Server 10 mass balance streams

IC647NMKJAP CIMPLICITY HMI Japanese Media Kit

IC693ACC311 Terminal Blocks (qty 6)

IC750LCD420RR PANELWARE 4-Line x 20-Character LCD Dislplay

IC800VMCB3200 Motor power and brake power cable for 3 kW VersaMotion servo motor- 20 meter

SLC/1746 System 1746-OB32 DC OUTPUT MODULE FOR PROGRAMMABLE CONTROLLER

Industrial Computers 6155R-NP2KH VERSAVIEW NON-DISPLAY COMPUTER

Application-specific products 6556-SCBM34 SLC 5/03, 5/04 PROGRAMMABLE PRESS CONTROL KIT

Operator Interface 2711-B6C10L1 PV600 COLOR KEY&TOUCH, DNET & RS232 PRINT

Support 9301-2SE2300ITS SUPT RENEWAL CONTRACT FOR 93012SE2300IT

Support 9307-8MGDBPR SUPT REINSTATEMENT CONTRACT FOR 93078MGDBPENE

DeviceNet Products 1734D-IA16 120 VAC 16 IN, DNET COMMS, SCREW

RSI Software Products 9301-2SE250JPU4R RSVIEW32 WORKS 150-100K UPGRADE OUT-SUPT(JP)

RSI Software Products 9358-BNT10UB1R UPGRADE: OUT-SUPT: RSBATCH 10 UNITS TO BUNDLE

Motion Control MPL-B320P-MK24AA MOTOR,SERVO,2.94 NM,5000RPM,MULTI,460V,BRK

Motion Control 2090-XXNPY-16S30 CABLE,NON-FLEX,MOTOR POWER,Y,16 GAUGE,30M

GFK-0467 Series 90-30/90-20 Programmable Controllers Reference Manual

IC641VPP999 VersaPro Professional Edition Unlimited Seat Site License - Windows Programming Software for Series 90-70, Series 90-30 and VersaMax PLCs