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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。

 

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Motion Control MPL-B980C-MJ22AA MOTOR,SERVO,122.0NM,1500RPM,MULTI,460V

Silver Series 1398-DDM-150 DRIVE,150A,PEAK,ULTRA 200

HE693ADC410 4ch., +/-10Vdc Analog Input Module, 2000Vac Isolation, 14-bit resolution

IC646TRT915 1,500 I/O Point Runtime System

QPGCTDE0000 7/4" Color TFT, Ethernet, CF Card, 24VDC, UL, cUL, CE

ST-3704 STXi analog b module 4 Channels, RTD Connector Type

USB-6210

PC-488

92-005932-XXX

NDMC-035535

CWT-9300TC2

ROCKY-3703EVR

1492-RTB14N 14-Pole Screw Style Rtb Plug

WinCC 上位監(jiān)控軟件 6XV1840-2AH10 FC 標(biāo)準(zhǔn)電纜/每米

變送器 3RS17032AD00

1497A-A3-M8-3-N Control Power Transber

1606-XLP60EQ AC or DC Input 24 to 48VDC Out 60W PS

1768-EWEB CompactLogix Enhanced Web Server Module

188-K4C160 Miniature Circuit Breaker 16 A

194R-30-NJ 194R 30 Ampere 4th Power Pole Module

2090-CPBM7DF-10AA40 MP-Series 40m Standard Cable

2090-XXNPMP-10S60 MP-Series 60 m Length Power Cable

CBL-13-ED-10 Encoder cable for MTR-1235 or MTR-1300 or MTR-1400 or MTR-1N series stepping motors connected to IMC or S2K. 10 feet

GC647SVB001 GCScheduler Visma Business Adapter

IC200PWR101LT POWER SUPPLY 120/240VAC INPUT (LT)

IC646TBLSS10K Proficy Troubleshooter for Inbligent Historian for Hist 10000 Points

IC647NGM000 CIMPLICITY HMI HONEYWELL IPC620 Communications

IC692MDR741RR 16 DC b/ 12 Relay Output 120 Vac PS

IC698CRE030 600mHz CPU, Ethernet, Redundancy

IC800VMCB100 Motor power and brake power cable for 200 W to 750 W VersaMotion servo motors- 10 meter

SLC/1746 System 1746-IO12DC COMBINATION MODULE FOR PROGRAMMABLE CONTROLLER

Industrial Computers 6180W-15KSXPH VERSAVIEW 15-INCH WORKSTATION, KEYPAD

Application-specific products 6556-PA0PM3 CLUTCH/BRAKE KIT W/ARMED CONTINUOUS PUSHBUTTON

Operator Interface 2711-T5A12L1 PV550 MONO TOUCH, PBUS & RS232 PRINT

Support 9301-2SE2200PTR SUPT REINSTATEMENT CONTRACT FOR 93012SE2200PT

Support ABTS-W103R ABT-SW103 PATHFINDER SW SUPPORT REINSTATEMENT

ControlNet Products D9220-6.5.1 DEVELOPERS GUIDE-CONTROL

RSI Software Products 9301-2SE250FRU1R RSVIEW32 WORKS 32K-100K UPGRADE OUT-SUPT (FR)

RSI Software Products 9358-BIZ1C0PENE RSBIZWARE SINGLE-USER RUNTIME CLIENT

Motion Control MPL-B310P-MK22AA MOTOR,SERVO,1.58 NM,5000RPM,MULTI,460V

Motion Control 2090-XXNPMP-16S60 CABLE,NON-FLEX,MOTOR POWER,MP/1326AB,16 GAUGE,60M

GC646TDV700 Proficy GlobalCare Complete for Server 700 I/O Develop/Runtime System

IC641SWP303 LM 90-30/20/Micro Serial Software Demo Version, 3.5", 5.25" Format

IMC-200P-X-D IMC-D Series Ampless Servo Motor Controller, Enhanced, DeviceNet

PSPC-DC100-220L Prof Shop Floor SPC DC 100 User 220v

PXI-6733

PCM-3660

OC-64E0-IPRO0

GW-ERP2U700 (90+)

IAC-H672Z

PCI9054-AC50PI

1492-MS8X12V1-50 Connection Products

模擬量輸入/輸出模塊SM 6ES7 331-7KF02-0AB0 AI/8，電壓、電流、電阻、熱電阻、熱電偶，光電隔離，20pin 前連接器

行程開(kāi)關(guān) 3SE53220SE23

運(yùn)行版軟件 6AV2105-4DD04-0AE0 SIMATIC WinCC Runtime 專業(yè)版 V14 Upgrade WinCC V7.0..V7.3 Runtime 512 PowerTags -> WinCC Runtime 專業(yè)版 512 PowerTags V14

1585J-M8CBJM-60 RJ45 Ethernet Media

1756-RM2 ControlLogix Redundancy Enhanced Module

188-K1D130-N Miniature Circuit Breaker 13 A

194E-Y25M-1756-6G 25 A 194E Load switch

2090-CFBM7E7-CEAF01 1 m Length SpeedTec Extension Cable

2090-UXNFBY-S15 Y-Series 15 m Length Feedback Cable

BC646TRT000 Server Unlimited Runtime System with Proficy GlobalCare

GC647IFPLDVUNLMT GCC iFIX Plus SCADA Unlmt Dev

IC200CBL525 Series 90 SPN port, RS485 Cable to DataPanel 45/65/85

IC646MPP010 Logic Developer PLC Professional 10 pack

IC647IFPRSRUNLMTC iFIX Profsnl SCADA Unlimited Server (M1Component Part)

IC660TSD020 Terminal Assembly for IC660BBD020

IC697CPM915RR CPU, 32 MHz, 12K Discrete I/O, 1024K RAM, 80486DX

IC800MCUB12310XNRR Stepping MotorCube 175 oz-in, Pulse/Direction

ControlLogix/1756 System 1756-OA8E 74-132 VAC ELEC FUSED 2A OUTPUT 8 PTS (20 PIN)

Industrial Computers 6182H-10BRH6B VVCE 1000, KEY/TOUCH, STD MEM, RIO/DH, AC

Process Control 9358-PBPCNT60ENE RSBATCH NT FOR PROCESLGIX PC BASED PHASES 60 UNITS

Operator Interface 2711P-RBK10 PV PLUS 1000 KEYPAD REPLACEMENT BEZEL

Support 9355-TKTOPCS SUPT RENEWAL CONTRACT FOR 9355TKTOPC

Support 9351-OSFRTS SUPT RENEWAL CONTRACT FOR 9351OSFRT

ControlNet Products 1786-RPFM CONTROLNET FIBER REPEATER - MEDIUM

RSI Software Products 9301-2SE2400DEU5 RSVIEW32 WORKS 5K-32K UPGRADE IN-SUPT (DE)

RSI Software Products 9355-WABGWEU3R UPGRADE: OUT-SUPT RSLINX PROF TO RSLINX GW

Motion Control MPL-A320H-HJ24AA MOTOR,SERVO,2.94NM,3500RPM,ENCR,230V,BRK,5.1KG

Motion Control 2090-DANPT-16S07 CABLE, NON-FLEX, MTR PWR, CABLE-MTD CONN, 16AWG, 0

BC647MQP001 View Development for QuickPanels with Proficy GlobalCare Complete and a hardware key

IC5005TBX0000 15" Unbundled Inbligence Industrial Computer with WIN XP Perbance Series

IC800MCUB12210XE Stepping MotorCube 100 oz-in, Pulse/Direction, Encoder Feedback

OC647IFDBTKTM iFIX Optn: Database Dynamo Toolkit (M4 Part)

PCIe-8431/2 (RS485/422)

IB104+ TM5800-800M

ADLINK凌華M-322

AMCC 9590SE-16ML

DH-VRT-CG200

LV-676

1492-M5X5H1-50 Connection Products

1494H-DN3H6 Heavy Duty Fusible Safety Discon Switch

軟啟動(dòng)器 3RW44456BC46

ET 200SP 6ES7193-6BP00-0BA0 基座單元 BU15-P16+A0+2B，類型A0，直插式端子，15mm寬

1585D-M4TBDM-80 Micro D-Code, QD Style Ethernet Media

1756-EN3TR ControlLogix Ethernet Motion Module

1794-OF4I Flex 4 Point Analog Output Module

194E-CA63EX-TN-PE 194E Load switch

2090-CBUSPSS Kinetix 6000M network bulkhead connector

2090-DANPT-16S01 TL-Series 1 m Length Power Cable

ABICTDE0000/DVN 10.5 inch Color TFT/ TCP Label/ 24VDC/ with DeviceNet/ UL/ cUL/ CE/ UL1604

GC646PCMS10 GlobalCare Complete for Change Management Electronic Signature Module 10 Pack

HE697THM160 Series 90-70 Thermocouple Input Module, 16 Channel

IC630MDL375RR 115/230Vac Output Module (16 points)

IC647HSTSS75KM Historian Standard Server 75000 Points (M4 Key)

IC660BLD021 Cover w/Label for IC660BBD021

IC695CBL001 Energy Pack Cable, 3 ft. (0.91m)

IC756WET100E-23 Custom Editor Toolkit, English, Version 2.3

CompactLogix System 1769-CRL3 3.28 FT (1M) RIGHT-TO-LEFT BUS EXPANSION CABLE

PLC-5/1771 System 9399-RL53GRIT RSLOGIX 5 GETTING RESULTS GUIDE(ITALIAN)

Distributed I/O D1794-6.5.7 FLEX I/O THERM'CPL/MILLV'T MOD.1794-IT8 USR MANUAL

Operator Interface 2711P-T6M8D PV PLUS 600 GRAYSCALE, TOUCH, DH+, DC PS

Support 6411-SDSCR 6411-SDSC SOFTWARE SUPPORT REINSTATEMENT

Support 9358-PLTM2200S SUPT RENEWAL CONTRACT FOR 9358PLTM2200ENE

Support F1784-KTCX15SERA FIRMWARE UPGRADE FOR 1784-KTCX15 COMMUNICATION MOD

RSI Software Products 9301-2SE2200FRE RSVIEW32 WORKS 300 (FRENCH)

RSI Software Products 9701-VWSB000DEU3 RSV SE STATION 250 - UNLTD DISP UPGRADE (GERMAN)

RSI Software Products 9399-APSUM APS USER MANUAL FOR REL. 6.01

Motion Control 2098-IPD-010 DRIVE, 5A/15A, ULTRA5000

ABKSTDN0000/ABR 6" Color STN, TCP Label, 24Vdc, with AB Remote I/O,UL,cUL,CE,UL1604

IC300ACM200 Power Control Smart Stack. Input Range 120 three-phase Wye, 208V line to line

IC752DPJ000RR 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-S MTR series servo motor with resolver and shaft seal

NI 9861

SYS7283VGA

ARK-14050

CI-7200