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工業(yè)機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(dāng)前工業(yè)機器人與金屬成形機床集成的常見應(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)機器人 ；金屬 ；成形機床 ；集成應(yīng)用
當(dāng)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(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(yīng)用的主要領(lǐng)域，受消費者自動化需求的提升，進(jìn)一步擴大了工業(yè)機器人的應(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(dāng)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(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)機器人與金屬成形機床集成的應(yīng)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(yīng)用其進(jìn)行激光切割已成為激光切割與工業(yè)機器人應(yīng)用領(lǐng)域的主要熱點。在工業(yè)機器人手臂中集成激光束引導(dǎo)裝置，當(dāng)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(yīng)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(yīng)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(fù)責(zé)從沖壓成型模鍛壓機取料后，移送至另一臺模鍛壓機進(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，既可由專門機構(gòu)操作，又可由工業(yè)機器人完成。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(yīng)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(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(zhuǎn)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(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(yīng)用的主要形式

工業(yè)機器人在金屬成形機床中的應(yīng)用領(lǐng)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(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床組成柔性生產(chǎn)線。其較某種單機上下料更為復(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(gòu)成的 U型布局，主要由一臺工業(yè)機器人在場地中間進(jìn)行工件轉(zhuǎn)換，布局特別緊湊。

第二，單機上下料。此種形式中，工業(yè)機器人在金屬成形機床中的應(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)機器人與金屬成形機床的結(jié)構(gòu)關(guān)系可分為兩種形式，即與金屬成形機床構(gòu)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(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(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(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床工作中的工傷隱患。

 

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RSI Software Products 9701-VWMR075DEU2 RSVIEW ME STATION RT 30 TO 75 DISP UPGRADE(GERMAN)

RSI Software Products 9399-2SE32GRDE RSVIEW32 GETTING RESULTS GUIDE (GERMAN)

Motion Control 2098-DSD-150 DRIVE, 65A/150A, ULTRA3000

ABI31200C2P/ABR QUICKPANEL 10.5" TFT W/AB RIO

IC200USB001 VersaMax Micro 64, RS-232 communications option board with (2) 0 - 10VDCanalog b channels built-in. The option board also supports program storage memory module. Compatible with VersaMax Micro 64 only.

IC752DNMU11 DeviceNet Master/Scanner for ControlStation CE Iix

MTR-3S32-G-R-0-E-ERR Servo Motor Nema34 Flg Explosion-Proof

NI 9501

JUKI-3711P

ADAM-4572

NCCH-DL 875P 604

FSC-1612V2N

Equinox SST-16P 910277-001/F

1492-J50-B IEC 1-Ckt Feed-Through Blk 50mm

1492-SPM3D630 MCB Supplementary Protector 63 A

軟啟動器 3RW40566BB35

CPU 模塊 6ES7 515-2AM01-0AB0 CPU 1515-2 PN，500 KB 程序，3 MB 數(shù)據(jù)；30 ns；集成 X1: 2x PN 接口，X2: 1x PN 接口

152H-C201XBD-52 SMC-3 Enclosed Motor Starter

1738-OB8EM23 ArmorPoint 8 Point Output Module

1785-ACC5LB PLC-5 Accessory Kit

193-NREEHZ E1 Plus Replacement Overload Relay

20-COMM-B PF ARCH. CLASS BACNET/MSTP ADAPTER

2090-CSBM1DE-18AA09 Kinetix Cable Single DSL 2090-Series

20AB9P6C3AYNANC0 PowerFlex 70 AC Drive 9.6 A at 3 Hp 20A

GA647IFPRSRUNLMT GCA iFIX Profsnl SCADA Unlmt Srv

GP647IFPLDV00075 GCP iFIX Plus SCADA 75 I/O Dev

IC600BF913RR 10-50Vdc Sink Output Module

IC647HSTCR20000KM Collector Redundancy Option for Historian - Standard Server 20,000,000 Points (M4 Key)

IC647TPD910 CIMPLICITY HMI ProServer 10000 I/O Development and Runtime

IC693PCM301RR Programmable Coprocessor Mod, 85K, w/Port Expansion Cable

IC756MDV000E-98 DV Development - Alpha OpenVMS Op Sys, English, Version 9.8

MicroLogix 1000/1761 System 1761-L32AWA 32 I/O MICROLOGIX 1000

PLC-5/1771 System 1771-ILK CONFORMALLY COATED, ANALOG INPUT MODULE

Distributed I/O 1792D-4BV4D 4 SINK/SOURCE INPUTS, 4 SOURCING 0.5 AMP OUTPUTS

Communications 9300-RAPMKIT UNIVERSAL PAGING MODEM KIT

Operator Interface D6190-6.5.16 CONTROLVIEW MODBUS DRIVER(6190-MOD)USER MANUAL

Support 9356-SQLSAP250S SUPT RENEWAL CONTRACT FOR 9356SQLSAP250

Support 1789-L10UL30 SOFTLOGIX 5800 1789L10 TO 1789L30 UPGRADE

EtherNet/IP Products 9351-WKTS INTERCHANGE FOR WINDOWS

RSI Software Products 9301-2SE3500JPU1 RSVIEW32 RUNTIME 32K-100K UPGRADE IN-SUPT (JP)

RSI Software Products 9356-PRO2500U8R UPGRADE: OUT-SUPT: RSSQL PROF.5000 TO 70000 TAG

Motion Control 0041-5070 N-4200 SHAFT SEAL KIT

44A735709-001 Failure Analysis - PLC

IC200CBL110 CABLE I/O NON-SHIELDED 2 CONNECTORS 1.0M

IC694ALG392 OUTPUT MODULE ANALOG CURRENT VOLTAGE 8 POINT

MSI-SERVICES-43 Professional services (Billed/Hour)-43

cFP-CTR-500

PCM-9577F

PCI-1240U

KON MODEL 10115C

SOM-5892FG-T03A1E

IOI FWB-PCIE1X21A

MH005-000016-2A

1492-SPM2B200 MCB Supplementary Protector 20 A

軟啟動器 3RW30161BB14

電機啟動器 3VU16401MP00

150-F108NBR SMC Flex Smart Motor Controller

1715-TASOF8 1715 8 Simplex A/O Termination Assembly

1771-NT1 1771 Analog Module

193-EC5JG E3 Plus 84-420 A Overload Relay

198E-DF1286 TYPE 3, 3R, 4, 12 Metal Hinged Enclosure

2090-CPWM6DF-16AA02 TL-Series 2m Standard Power Cable

2094-EN02D-M01-S0 Kinetix 6200/6500 Control Module

DNR120AS12-I 12V, 10A POWER SUPPLY

GFK-0868 MMS-Ethernet Communications for the Series 90-70 PLC User's Manual

IC210EDS001 DeviceNet slave communications expansion module, 24V DC power source

IC647AUR010 PA Universal Reporting Client 10 Pak

IC647PRTEE010M Proficy Portal Enterprise Edition Client Pack 10 Users (M4 Key)

IC693CPU341RR CPU 341 Module, (80K Bytes user memory), 10K Reg., 3 msec/K

IC754VSB06CTD VIEW BASIC 6IN TFT TOUCH DC

MSI-DEMO Proficy Plant Apps Demo Software

SLC/1746 System 1746-RL51 REPLACEMENT OCTAL LABEL KIT FOR CTLG # 1746-OB16

Distributed I/O 1734-VHSC5 5 VDC VERY HIGH SPEED COUNTER WITH SOURCE OUTPUTS

Application-specific products 9307-8MGDBPENE RSEMETRIX MGR(0-8 METERS),W/1MSSQL PROCESSOR LIC

Operator Interface 2711-NC13 5METER RS232 OPERATING/PROGRAMMING CABLE

Support 9302-H1S SUPT RENEWAL CONTRACT FOR 9302H1

Support 9510-PB1000ENS SUPT RENEWAL CONTRACT FOR 9510PB1000EN

DeviceNet Products 1799-DNETSCON 5-POSITION OPEN STYLE PLUG/LOCKING SCREWS FOR DN

RSI Software Products 9301-2SE3350KOU3 RSVIEW32 RUNTIME 1500-5K UPGRADE IN-SUPT (KO)

RSI Software Products 9307-EMDB1C RSEMETRIX ONE CLIENT LICENSE

Motion Control MPL-B980C-MJ24AA MOTOR,SERVO,122.0NM,1500RPM,MULTI,460V,BRK

Silver Series 1398-DDM-150X DRIVE,150A,PEAK,ULTRA 200 W/INDEXING

HE693ADC415 4ch., 4-20mA/0-20mA Analog Input, 700Vac Isolation, 14-bit resolution

IC647CBL703 Cable, Workstation Intf. to Series 90-70 CPU, Parallel, 10 feet