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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(mén)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(pán)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(pán)，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(kāi)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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IC647HSTCCP25M Historian Client Connection Pack 25 Users (M4 Key)

IC647TIAC TIA:Texas Instrument Unib PC Adapter

IC693MDR390RR Mixed I/O, 24Vdc Input (8 points), Relay Output (8 points)

IC756LDV010E-925 "DV-Draw Development on Inb Linux/Red Hat, English v9.25"

Pico Controllers D1760-UM001BENP PICO CONTROLLER USER MANUAL

PLC-5/1771 System 1771-OW16K CONFORMALLY COATED, CHNL-ISOL. CONTACT OUTPUT MDL.

Distributed I/O 1791-IOVW BLOCK I/O, 24V DC, 64 PT MODULE

Communications 1786-FS300 200 MICRON CABLE ASSEMBLY 300 METERS (984.2 FT)

Operator Interface 9399-2SE32UG RSVIEW32 USER GUIDE

Support 9356-PRO2300R SUPT REINSTATEMENT CONTRACT FOR 9356PRO2300

Support 9324-RL0300PTS SUPT RENEWAL CONTRACT FOR 9324RL0300PT

EtherNet/IP Products 1403-NENET COMMUNICATION MODULE (ETHERNET)

RSI Software Products 9301-2SE3500ESU4 RSVIEW32 RUNTIME 150-100K UPGRADE IN-SUPT (ES)

RSI Software Products 9356-PRO2500U1 UPGRADE: IN-SUPT: RSSQL STD.150 TO PROF.70000 TAG

Motion Control N-3406-2-H04AA SERV MTR,0.8NM,6000RPM,2000 LN ENCDR,BRK

44A730464-G24 Connector Kit, AC12, A12, A22, A30 & A40 Motor Encoder

IC200ALG326 ANALOG OUTPUT 13 BIT CURRENT 8 Channel

IC693PIF400 High Perbance PC/AT Interface (PCIF) to Series 90-30 I/O with software

Silver Series 9323-L2300D PLC-2/1774-PLC OFFLINE/ONLINE PROGRAMMING

VSPC-SRV/OR VisualSPC Oracle Server Interface (Version 8.1.7 or greater).

20BD027A0AYNACD1 PowerFlex 700 AC Drive 27 A at 20 Hp 20B

20G11FD027AA0NNNNN PowerFlex 755 AC Packaged Drive

22C-D142A103 PowerFlex 400- 75 kW (100 HP) AC Drive

MA0331000 Quantum REMOTE I/O TRUNK SPLITTER

285-BRCF25-M20 ArmorConnect Brake and Motor Cable

E6B2-CWZ6C 5-24VDC,集電極開(kāi)路輸出30VDC 35mA,3相,100P/R,360P/R,500P/R,600P/R

1492-SPM1D630 MCB Supplementary Protector 63 A

變頻器選件 6SE6 400-0AP00-0AB0 中文 AOP 高級(jí)操作面板 420/440

電機(jī)啟動(dòng)器 3VU16400MK00

150-CA11 Smart Motor Controller Accessory

1715-AENTR 1715 EtherNet/IP Comms Adaptor Module

1771-IV Driver Logic Input Module

193-EC4CB E3 Plus 5-25 A Current Relay

198-W112 ModCenter IEC Wiring Kit

2090-CPWM4DF-16AF05 MP-Series 5m Power Cable

2094-BL25S Kinetix Line Interface Module

DEMOCD00012 Proficy PlantTV DEMO CD

GFK-0771 C Programmer's Toolkit for Series 90 PCMs User's Manual

IC210CBL001 Programming Cable, PC to Durus Controller

IC647ASC002 PA SDK 2 Pak

IC647PPSOCC Proficy Process Systems Operator Console with CIMPLICITY

IC693CPU311LT 5-Slot Base With CPU in base (6K Bytes User Program) (LT)

IC754VGB06CTD VIEW BASIC 6IN TFTTOUCH DC FLAT GEF

MSI-DASH-UNL-43 Unlimited Dashboard Clients-43

SLC/1746 System 1746-R14 REPLACEMENT COVERS FOR SLC5/03,04,05 PROCESSOR MOD

Distributed I/O 1734-OW2 24 VDC COIL N.O. DPST RELAY MODULE

Application-specific products 1803-EEM21 EEM,32 PULSES,24V DC, 8 ANALOG, 4 TO 20 MA

Operator Interface 2711E-K10C6 PANELVIEW 1000E KEYPAD TERMINAL, 10.4" FLAT PANEL

Support 9302-BATS SUPT RENEWAL CONTRACT FOR 9302BAT

Support 9381-PP250ENR SUPT REINSTATEMENT CONTRACT FOR 9381PP250EN

DeviceNet Products 1791D-8B8P DNET 24VDC CBLOCK I/O,8 IN SINK 8 OUT SOURCE, BASE

RSI Software Products 9301-2SE3350ESU3 RSVIEW32 RUNTIME 1500-5K UPGRADE IN-SUPT (ES)

RSI Software Products 9358-PBRENT01ENE RSBATCH NT FOR PROCESSLOGIX REPORT EDITOR

Motion Control MPL-B860D-SJ24AA MOTOR,SERVO,83.0NM,2000RPM,SINGL,460V,BRK

Silver Series 1398-DDM-009-DN DRIVE,15A PEAK, ULTRA 100 W/DNET

HE660BGM424 Genius BASIC Prog. Co-processor with RS-232 and RS-422/485 ports

IC646TJV000 CIMPLICITY?Tracker Display-Inb

QDA-EDT-001/L QuickDesigner Lite (download cable NOT included)

ST-3114 STXi analog b module 4 Channels, 0~20mA, 12-bit

20BC105A0AYNANC0 PowerFlex 700 AC Drive 20B

20F14NC260AN0NNNNN PowerFlex 753 AC Packaged Drive

22A-B2P3F104 PowerFlex 4 0.4 kW (0.5 Hp) AC Drive

140CPS12420C Quantum LMS AC PS 115/230V RED CC

284D-FHD2P3B-10-CR-DB-SB DeviceNet Variable Frequency Drive

CJ1W-PA205R 電源單元100-240VAC,輸出能力：5A,5VDC

1492-RIFM20F-F120-2 Connection Products

上位網(wǎng)卡 6GK1561-1AA01 CP5611,PCI 卡，用于臺(tái)式機(jī)

變送器 3RS17001AD00

1497A-A10-M6-0-N Control Power Transber

1606-XLP100F Power Supply XLP 100 W Power Supply

1764-MM3 MicroLogix 1500 Memory Module

188-K4B200 Miniature Circuit Breaker 20 A

194L-HE6E-175I 194L Control and Load Switch Actuator

2090-CPBM7DF-08AF40 40 m Length SpeedTec Flexible Cable

2090-XXNPMF-16S40 Kinetix Drives 40m Standard Cable

CA-870-2 Adapter for True Position probe to GP-3102NT GagePort.

GC647SES010 GCScheduler Server Medium

IC200PKG103 I/O starter kit DeviceNet NIU

IC646TBLCLT002 Proficy Troubleshooter for Inbligent Historian Standard, Enterprise and Corporate Clients Access 2 Users

IC647NCN020 CIMPLICITY HMI for CNC Additional Connection

IC690CBL714 Cable, Dual-port, Multi-drop SNP

IC698ACC720 Shielded double slot faceplate, package of six.

IC800VMA042 400 W VersaMotion servo amplifier

SLC/1746 System 1746-C9 36-INCH RACK INTERCONNECT CABLE

Industrial Computers 6181P-17TS2KH VERSAVIEW INTEGRATED DISPLAY COMPUTER 17-INCH TFT

Application-specific products 9358-PBPC60ENE RSBIZWARE BATCH FOR PLX PC BASED PHASE 60 UNITS

Operator Interface 2711-K5A3L2 PV550 MONOCHROME KEY, DH485 & RS232 PRINT

Support 9301-2SE2100PTS SUPT RENEWAL CONTRACT FOR 93012SE2100PT

Support 9500-CPAKPSENR SUPT REINSTATEMENT CONTRACT FOR 9500CPAKPSEN

ControlNet Products 9904-CNA10T CONTROLNET CNA10T ASIC (BOX OF 90)

RSI Software Products 9301-2SE2503ITE RSVIEW32 WORKS 100K WITH RSLINX (ITALIAN)

RSI Software Products 9358-BEPNT60U1R UPGRADE: OUT-SUPT: EPROCEDURE FOR NT 03 TO 60

Motion Control MPL-A520K-SK24AA MOTOR,SERVO,10.7 NM,4000RPM,SINGL,230V,BRK,13.9KG

Motion Control 2090-XXNPMP-14S30 CABLE,NON-FLEX,MOTOR POWER,MP/1326AB,14 GAUGE,30M

GC646MDA159 Proficy GlobalCare Complete for View Development /Runtime 1,500 I/O""

IC641SWM701 Logicmaster 90-70 S/W Dev. Pkg., 3.5"/5.25" disks + paper docs.

IC800SSI228RD2 28A, 230V, DeviceNet S2K Servo Controller for MTR Series Motors

PSPC-DC-220 Prof Shop Floor SPC DC 1 User 220v

20BB154A0AYNANC0 PowerFlex 700 AC Drive 20B

20DH105A0ENNANANE PowerFlex 700S AC Drive 20D

2198-DB20-F Kinetix 5500 20A Line Filter

2711P-K6C20A9 PanelView Plus 6 Graphic Terminal

280-PWRM35E-M12 ArmorStart Three-Phase Power Media

C20P-EDR-A C20P擴(kuò)展，12點(diǎn)入， 8點(diǎn)出?（繼電器）.已停產(chǎn)，替換品：CPM1A-20EDR1

1492-MS6X12V21-30 Connection Products

數(shù)字量輸入/輸出模塊SM 6ES7 321-1FF01-0AA0 DI/8 110/230VAC，光電隔離，20pin 前連接器

行程開(kāi)關(guān) 3SE53122SG12

運(yùn)行版軟件 6AV2105-2HH04-0AC0 SIMATIC WinCC Runtime 專業(yè)版 Powerpack Runtime Advanced 4096 PowerTags -> Runtime 專業(yè)版 4096 PowerTags V14

1585J-M8CBJM-10 RJ45 Ethernet Media

1756-PB75 ControlLogix 24V DC Power Supply

188-K1D010 Miniature Circuit Breaker 1 A

194E-Y100M-1753-6N 100 A 194E Load switch

2090-CFBM7DF-CEAF60 Kinetix 60m Flexible Cable