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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。基于此，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(fèi)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(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，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(diǎn)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(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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通用型變頻器 6SE6 420-2UD21-5AA1 "1.5 KW，73 x 173 x 149"

電機(jī)啟動器 3VU13401MD00

1497D-A9-M21-0-N Gen Purpose Transber

1608N-BP050A240V2 MiniDySC 50 Amp Bypass

1769-PA2 CompactLogix AC 2A/0.8A Power Supply

190S-FND3-FC32S 23-32 A Compact Comb Starter W/Ckt-Bkr

194R-NU600-1753 Disconnect Non-Fused Nema 3 Poles 600A

2090-CPBM7DF-16AF15 MP-Series 15m Cable

2090-XXTPMP-14S07 MP-Series 7 m Length Power Cable

CIMPONNODE500M CIMPLICITY Upgrade to On-Node 500 Tag Standard Edition Historian with Alarm & Event Option ??

GF-5008R Connecting FlashCable to Metronics QC 3000/ QC 1000.

IC200UDR440 VersaMax Micro 40 point PLC,(24) 24VDC In, (16) Relay Out, 12/24VDC Power Supply. (1) serial port and (1)optional communication port. Requires Machine Edition 5.7 or higher. Battery (IC200ACC414) is required for data retention. Battery not inclu

IC647ABCC ABC:Allen Bradley Cyberlogic DHX

IC647PATOSI0 Proficy PAT - Pi Interface: Provides The Capability To Interface Proficy Rx To The Osisof Pisyste Data Historian

IC693BEM331 Genius Bus Controller (supports I/O and Datagrams)

IC752SKT004RR Datapanel 320T MB Starter Kit: Includes Datapanel 320T Mono Base (CBT 000), download & communication cables, WinCfg, user & programming manu als

IMC-200E-X-D IMC ampless servo motor controller/ enhanced

SLC/1746 System 1747-FC FERRITE COLLAR FOR PROGRAMMABLE CONTROLLER

Industrial Computers 6189V-MWA WALL MOUNTING ADAPTER FOR ALL PLATFORMS

Application-specific products 1404-M605A-CNT-02 1404-M6 CONTOLNET PM 3000 CLASS 0.2 120/240V P.S.

Operator Interface 2711-K10C3L1 PV1000 COLOR KEY, DH485 & RS232 PRINT

Support 9301-2SE3200PTS SUPT RENEWAL CONTRACT FOR 93012SE3200PT

Support 9380-RSBVB250R SUPT REINSTATEMENT CONTRACT FOR 9380RSBVB250

DeviceNet Products 1792D-88HC 8 SINK/SOURCE INPUTS, 8 SOURCING 5-10 AMP OUTPUTS

RSI Software Products 9301-2SE320KOU1R RSVIEW32 RUNTIME 150-300 UPGRADE OUT-SUPT (KO)

RSI Software Products 9358-BTDS30U2R UPGRADE: OUT-SUPT: RSBW TNG & SIMULATION 10 TO 30

Motion Control MPL-B4530K-MJ24AA MOTOR,SERVO,8.36 NM,4000RPM,MULTI,460V,BRK,11KG

Motion Control 2090-SCVP5-0 SERCOS FBR CABL,CONN,STANDARD PVC JKT,PLASTIC 5.0M

GQDA-EDT-001 QUICKDESIGNER ADV GE VERSION

IC646MPS010 Logic Developer - PLC Standard 10 Pack

MTR-1350-E-D-E-0 Stepping Motor Nema34, Series Wdg, Encoder

QPKSBDN0000 6 inch Color STN/ Blank Label/ No Ethernet/ CF/ 24VDC/ UL/ cUL/ CE/ UL1604

PXIe-6365

RocketRAID 2680A

MB865-R

i945GMx-FX

DELTA TAU PMAC-PC(DSP)

PNC-TOUCH2 PC-07009A-00

1492-PDL31124 335 A Power Distribution Block

模擬量輸入/輸出模塊 6ES7431-1KF20-0AB0 AI/8 14BIT，光隔離，U/I，0.416MS 掃描計時

變送器 3RS10101CD10

1497-A-M1-3-N Control Circuit Transber

1585J-M8UBJM-3 RJ45 Ethernet Media

1761-L20AWA-5A MicroLogix 1000 20 Point Controller

188-K3C010-N Miniature Circuit Breaker 1 A

194L-E25-1753-6N 25 A 194L Load Switch

2090-CPBM6DF-16AA09 TL-Series 9m Power and Brake Cable

2090-XXNFMP-S20 MP-Series 20 m Length Feedback Cable

BC647PPSEWC Proficy Process Systems Engineering Workstation with CIMPLICITY with Global Care

GC647PATSCFT Proficy PAT - Driver For Spectranet-Coupled Hamilton Sundstrand Analect Ftir Spectrometers - Assist Support

IC200MDL141 Input 240VAC (1 group of 8) 8 point.

IC646NSL900 Proficy SQL 2000 Processor License

IC647MGM001 Enterprise Adaptor for Maximo 5.2

IC676ACC004 Profibus Network Termination Resistor

IC697MEM717 Expansion RAM, 256K Bytes, CMOS (Used w/77X CPUs and PCM)

IC800SSD228S1 28 amp 230 VAC S2K servo drive for S-series motors

ControlLogix/1756 System D1775-6.5.3 I/O SCANNER-MESSAGE HANDLING MOD.(1775-S4B)MNL

Industrial Computers 6182H-15KRH6B VVCE 1500, KEYPAD, STD MEM, RIO/DH, AC

Process Control 1757-DNBUL65 DEVICENET USAGE LICENSE, 65 DNB MAX

Operator Interface 2711-START300ES START KIT PV300,SPANISH(PV300, PB32 CABLES)

Support 9326-AD5APS SUPT RENEWAL CONTRACT FOR 9326AD5APENE

Support 9371-EDETJACR SUPT REINSTATEMENT CONTRACT FOR 9371EDETJAC

ControlNet Products 1797-TPR CONTROLNET EX T-TAP RIGHT ANGLE

RSI Software Products 9301-2SE240ZHU1R RSVIEW32 WORKS 1500-32K UPGRADE OUT-SUPT (ZH)

RSI Software Products 9358-BA60U1R UPGRADE: OUT-SUPT: RSBIZWARE ARCHIVER 03 TO 60

Motion Control MPL-A4520P-HJ22AA MOTOR,SERVO,6.10NM,5000RPM,ENCDR,230V,6.8KG

Motion Control 2090-UXNPAN-16R01 CABLE,NON-FLEX, MOTOR POWER, N,R/A,16AWG,1M

CBL-30-JP-06 AC Power Cord with 3-Prong Plug, 6 Ft.

IC640MWS901RR Workmaster System, 1-35" Disk Drive

IC800SLCS020 Cable, SL Amplifier Serial Communication, 2 Meters

OC647IPWRCLNRNM iPower Option - Run Client

PXI-2599

RUBY-9713VG2AR

W26361-W64-Z2-06-36

COSMO PCPG-46

FB2502

MT6101I-2416-10

1492-MCBA2HA0 100A Miniature Circuit Breaker

1494V-DJX622 NEMA Flange Mtd Rod Switch Disconnect Sw

軟啟動器 3RW44576BC36

運(yùn)行版軟件 6AV2103-4KX04-0AE5 SIMATIC WinCC V7.0..V7.3 RC 8192 ->WinCC 專業(yè)版 max. PowerTags V14 Combo 和 WinCC RT 專業(yè)版 8192 PowerTags

1585D-M8UGDM-40 Gigabit Ethernet Media

1756-L75 ControlLogix 32 MB Controller

1799-DNETSCON DeviceNet I/O Accessories

194E-FA32E 194E Load switch

2090-CFBM7DD-CEAA25 MP-Series 25m Servo Feedback Cable

2090-SCVP8-0 Kinetix 8-8m Fiber Optic Cable

BC646MPS050 Logic Developer PLC Standard 50 Pack with Proficy GlobalCare Complete

GC647AQC025 GC Quality Client 25 Pak

HMI-COV-203 FRONT SHEET COVER FOR 5 inch (QPJ2xxxx-L2P/ -S2P)/ 20 per pack

IC641VPS350 VersaPro Standard Edition 50 Pack - Windows Programming Software for S eries 90-30 and VersaMax PLCs

IC647IFPLDV00150M iFIX Plus SCADA 150 I/O Development (M4 Part)

IC660ELB910RR GENI B Genius Interface

IC697ACC730 Spare Slot Terminal Strip Retainer (Quantity 1)

IC756WRT499E-27 DV-Tools Runtime Windows, Eng v2.7

FlexLogix System 1794-IP4 4-CHANNEL 12/24V PULSE COUNTER INPUT MODULE

PLC-5/1771 System D6200-6.5.18 PLC5 VOLMTC FLOW CARS/TURBINE+DISPL.METERING UR.ML

Process Control 1757-UPGNX UPGRADE APPLICATION TOOLKIT

Operator Interface 2711P-B12C6B1 PV PLUS 1250, KEY/TOUCH, RIO/DH, AC PS, STD MEM

Support 6001-G1DBS SUPT RENEWAL CONTRACT FOR 6001G1DB