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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(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(jì)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(shí)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(shí)，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(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(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)型升級時(shí)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(shí)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(shí)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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FlexLogix System 1794-IJ2 2-CHANNEL HIGH RESOLUTION FREQUENCY MODULE

PLC-5/1771 System D6200-6.4.7RU PLC5 PROG. SW PROGRAMMING MNL (RUSSIAN)

Process Control 1757-UPGNV UPGRADE OPEN DATA ACCESS - 5

Operator Interface 2711P-B12C4D1 PV PLUS 1250, KEY/TOUCH, ENET DC PS, STD MEM

Support 6001-F3ES SUPT RENEWAL CONTRACT FOR 6001F3E

Support 2711-ND2FRS SUPT RENEWAL CONTRACT FOR 2711ND2F

Support F1785-L60LSERA FIRMWARE UPGRADE FOR 1785-L60L PLC5 PROCESSOR MODU

RSI Software Products 9301-2SE230KOU1R RSVIEW32 WORKS 300-1500 UPGRADE OUT-SUPT (KO)

RSI Software Products 9701-VWSS100AENE RSVIEW SE SERVER 100 DISPLAY

RSI Software Products 9399-RSVADSGR RSVIEW32 ACTIVE DISPLAY SYS GETTING RESULTS GUIDE

Motion Control 1394C-SJT22-D MODULE,SYSTEM,22KW,SERVO,W/SERCOS INTF,NO HIM

BC646MPP050 Logic Developer - PLC Professional w/1 Yr of SAFE - 50 pack

IC300OCS077 14 AC Inputs (120vac), 10 Relay Outsputs (3.0A ea) & CsCAN

IC752WFC585 CONTROLSTATION DS2050 15" 850 MHz/256MB RAM WNT

MTR-3T24-H-R-0-M-SRR Servo Motor Metric with Seal

PCI-6503

SBC-350A

RADIALL R404507000

Teknor Applicom T824/166

PCISA-158V

EB-2131VG2A-CS

1492-L3T-B IEC Term Blck 5.1x64.5x31.3mm Spr Clp

1494C-DJ606-A4-B-D-E 600 A Flange Mtd Cable Switch

軟啟動器 3RW44271BC34

備品備件 6ES7 528-0AA70-7AA0 接口模塊（6ES7 155-5AA00-0AB0）前蓋板 5 片 / 包

1585BT-M8UBBM-15 Ethernet Media Variant 1, Patchcord

1747-C20 SLC Replacement Cable

1790D-T8A0 CompactBlock LDX 8 Point I/P Base Block

194E-A40-1756 40 A 194E Load switch

20-VB00299 PowerFlex 700S-H-AFE Fan Inverter Board

2090-CSWM1DE-14AA01 Kinetix Cable Single DSL 2090-Series

20AC072A3AYNAEC0 PowerFlex 70 AC Drive 72 A at 37 kW 20A

GC646MDA700 Proficy GlobalCare Complete for View Development /Runtime 700 I/O

HE693BEM310 SDS Bus Interface Module

IC600PM544RR Redundant Processor Unit Auxiliary Power Supply, 24Vdc

IC647HSTESEO250KM eSignature Option for Historian - Enterprise Server 250000 Points (M4 Key)

IC655MDL551RR 12-24Vdc Output, Negative Logic (16 points)

IC694MDL340CA Conbal Coated 120/240 Output module, 0.5A,16 points

IC756SDV010K-99 DV Draw Development on Solaris Op Sys, Korean, Version 9.9

MicroLogix 1500/1769 System 1769-OW8 8 POINT VAC/VDC RELAY OUTPUT MODULE

PLC-5/1771 System 1771-CX1 PLC-5 FAMILY LOCAL I/O BUS TERMINATOR CABLE

Distributed I/O 1797-ACNR15 REDUNDANT MEDIA CONTROLNET EX ADAPTER

Communications D1785-6.5.4 BACKUP COMMUNICATION MODULE(CAT.1785-BCM)MANUAL

Support 9313-PLC2S SUPT RENEWAL CONTRACT FOR 9313PLC2

Support 9358-CTDMENR SUPT REINSTATEMENT CONTRACT FOR 9358CTDMEN

Support F1771-QDCSERC FIRMWARE UPGRADE FOR 1771-QDC I/O MODULE

RSI Software Products 9324-RLD2U3DEE RSLOGIX 5000 MINI TO STD UP, DEU

RSI Software Products 9304-WRM300D WINTELLIGENT RECIPE

RSI Software Products 9358-PLTM2400U2R UPGRADE: OUT-SUPT: PLANTMETRICS 10 TO 50 WORKCELL

Motion Control 8720SM-045S5NAS1 45 KW/93 AMP, 750 VDC, AC MOTOR WITH SRS60 ENC

9650-128 Mini Protocol Converter . 128K Memory

IC200TBM005 I/O AUXILIARY SPRING CLAMP STYLE

IC698ACC701 Lithium Battery pack

MTR-1337-N-D-E-0 MTR series NEMA 34 stepping motor with series winding connection

NI 5771

HS5X86HVGA

HAC250P-490(E)

ADVANTECH PCL-818HD-B

GV-VCP3/PCI-1GV-VC

M-322

MC3012-PCI-V1.1

1492-SPM3C040 MCB Supplementary Protector 4 A

軟啟動器 3RW40362BB04

數(shù)字量輸出模 6ES7 222-1HH32-0XB0 SM1222DQ 16 x RLY

150-FPP317C SMC Flex Repair Part

1734-OB8 POINT I/O 8 Point Digital Output Module

1783-HMS8SG4CGR Stratix 5400 12 Port Managed Switch

193-ESM-I-30A-E3T E300/E200 30 Amp Sensing Module

20-750-FLNG1-F4 PowerFlex 750 NEMA 1 Flange Adaptor Kit

2090-CPWM7DF-14AA60 MP-Series 60m SpeedTec Standard Cable

2098-DSD-HV030X-DN Ultra 3000 Servo Drive

GA646PCMS10 GlobalCare Assist for Change Management Electronic Signature Module 10 Pack

GP-0602NT-F1 GagePort LVDT NT (Full Bridge F1 Blocks)

IC5002CAC0000 12in Inbligence PanelClient H/W Only

IC647HSTAE10000KM Alarm and Events Option for Historian - Standard Server 10,000,000 Points (M4 Key)

IC647SI7M SI7:Siemens SIMATIC S7

IC693MDL655LT 24 Vdc Input, Neg/Pos Logic, 1 ms, (32 pts) (LT)

IC756HDV000K-98 DV Development - HP/UX Op Sys, Korean, Version 9.8

MSI-SDK SDK Connections

PLC-5/1771 System 1771-IC INPUT MODULE, 48V DC, 8 INPUT

Distributed I/O 1790P-T4T0 PROFIBUS,4 INPUT THERMOCOUPLE BASE, TERMINAL BLOCK

Communications 1784-CP2 CABLE ASSY, 10 FT/3.20 M, 1784-KTP, -KT, -KT2, -KL

Operator Interface 2727-T7P30D1FEU MOBILEVIEW TABLET T750 - EUROPEAN

Support 9305-RSVADFVCJPS SUPT RENEWAL CONTRACT FOR 9305RSVADFVCJP

Support 9515-RSCHM500R SUPT REINSTATEMENT CONTRACT FOR 9515RSCHM500ENE

EtherNet/IP Products 2711-B5A20 PV550 MONO KEY&TOUCH, ENET & RS232 PRINT

RSI Software Products 9301-2SE3400ZHU2 RSVIEW32 RUNTIME 300-32K UPGRADE IN-SUPT (ZH)

RSI Software Products 9515-RSNHS025ENE RSMACC NETWORK HEALTH FOR 25 NETWORKS

Motion Control 1326AB-B520E-S2K5L MOTOR,SERVO,460V,13.0NM,3000RPM,SINGL,BRK,IP67

4161-4-24-+/- BCD To 7 SEG Display . 3 Numeric Digits & 1 +/- Digit, 24VDC. Dust Seal

HMI-CAB-C58-2 CABLE AEG MODICON SLOT PR

IC693CBL314 Cable, I/O Expansion, 15 Meters, Shielded

QSI31200E2P QUICKSTART KIT 9" EL

TRM-21006666 14 point connector for S2K digital I/O connector TB2

SOM-6763D

a6795-62002

ROCKY-4786EV-RS-R4.1

G31AX-K G31

LGY-852LA

8001-4073

1492-SPM1C150-N MCB Supplementary Protector 15 A

通用型變頻器 6SE6 430-2UD33-0DB0 "30 KW,275 x 520 x 245"

電機(jī)啟動器 3VU13401NJ00

150-C16NCD SMC-3 16A Smart Motor Controller

1608P-100A400V4S 100 A Pro DySC Sag Corrector

1769-SDN CompactLogix DeviceNet Scanner Module

193-CB1 Configuration Terminal Accessory

194R-R4 Operating Shaft

2090-CPBM7E7-08AF04 4 m Length SpeedTec Extension Cable

2090-XXTPMP-16S15 MP-Series 15 m Length Power Cable

CP3I-0WEB-0140-AZ Shielded motor power cable for B8HVis/B12Hvis/A8HVis/A12HVis motors (straight connector). 14 meters

GF-905692 Connecting FlashCable to Mitutoyo Angled Connection (RIGHT).

IC200UER008 VersaMax Micro Expansion 8 Output Expansion (8) Relay Outputs, 24VDC Power Supply (includes IC200CBL501)