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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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Motion Control 2094-PRS7 POWER RAIL, SLIM, 230V OR 460V, 7 AXIS

A06B-6093-H401 Ext. Regen Resistor, 30 Ohm 20 Watt, Beta or I/O Link Amplifiers

IC200UEX211 28 point expansion. (16) 24VDC In, (12) Relay Out, 120V/240AC Power Supply (includes IC200CBL501)

IC752CMO101 Modicon 984 9 pin cable for DataPanel 30/50

MTR-3N32-G-R-0-M-0-MODRR Servo Motor Nema34 Metric Mod=Connector

NI 9411

ROCKY-318

ADLINK NUDAM 亞當(dāng)模塊 ND-6017

D865PEFT2

SAGP-845EV

CONTEC COM-2(PCI)H

1492-J3TW 2.5 square mm Standard Terminal Block

1492-SPM3D160 MCB Supplementary Protector 16 A

軟啟動器 3RW40552BB34

SIMATIC HMI 系列面板 6AV2124-1QC02-0AX0 KP1500 精智 15.4 寸

150-SPPB3UR SMC-50 POWER POLE ASSEMBLY 140A

1738-IB8M8 ArmorPoint 8 Point Input Module

1784-PCD1 DeviceNet Comms Cable for 1784-PCD Card

193-KC10 7.2-10.0 A IEC Bibllic Overload Relay

20-750-PH2-F9 PF755 FR9,IP00,24 VDC WIRE HARNESS

2090-CSBM1DE-10AF15 Kinetix Cable Single DSL 2090-Series

20AB4P2A0AYNANC0 PowerFlex 70 AC Drive 4.2 A at 1 Hp 20A

GA647IFPRDV00075 GCA iFIX Profsnl SCADA 75 I/O Dev

GP647IFESGDV00300 GCP iFIX Optn: ESig & ERec 300 I/O Dev

IC600BF900RR Local I/O Transmitter Module

IC647HSTCCP50M Historian Client Connection Pack 50 Users (M4 Key)

IC647TIDC TID:Texas Instrument Direct

IC693MSC301RR Series 90-30 Demonstration Case

IC756LDV010E-98 DV Draw Development on Inb/Linux RedHat Op Sys, English, Version 9.8

MicroLogix 1000/1761 System 1761-L10BWA 10 I/O MICROLOGIX 1000

PLC-5/1771 System 1771-OWN SELECTABLE CONTACT OUTPUT MODULE 32 POINT

Distributed I/O 1791-N4C2 BLOCK I/O, 120V AC, 6 POINT ANALOG MODULE

Communications 1786-FSB500 200 MICRON BULK CABLE 500 METERS (1640 FT)

Operator Interface 9399-RSVADSGR RSVIEW32 ACTIVE DISPLAY SYS GETTING RESULTS GUIDE

Support 9356-PRO2350R SUPT REINSTATEMENT CONTRACT FOR 9356PRO2350

Support 9324-RL0700NXS SUPT RENEWAL CONTRACT FOR 9324RL0700NXENE

EtherNet/IP Products 9351-AIXRT INTERCHANGE FOR AIX RUNTIME

RSI Software Products 9301-2SE3500FRE RSVIEW32 RUNTIME 100K (FRENCH)

RSI Software Products 9356-PRO2500U2 UPGRADE: IN-SUPT: RSSQL STD.300 TO PROF.70000 TAG

Motion Control N-3412-2-H04AA SERV MTR,1.6NM,6000RPM,2000 LN ENCDR,BRK

44A731202-G03 Upgrade Kit Genius IC660BBA103

IC200ALG328 ANALOG OUTPUT 13 BIT CURRENT 12 Channel

IC693PWR321 Power Supply, 120/240 Vac, 125 Vdc, Standard

Silver Series 9323-PI300D A.I SERIES PLC-5/250 OFFLINE/ONLINE PROGRAMMING

cDAQ-9188XT

MEIDEN IZ48Z

ACL-7130

AIMB-212

AIMB-767

ISO-350PP

3G8F7-DRM21-E

1492-SPM1D630-N MCB Supplementary Protector 63 A

變頻器選件 6SE6 400-0EN00-0AA0 Encoder 脈沖編碼器計(jì)數(shù)模塊

電機(jī)啟動器 3VU16400ML00

150-CA20 Smart Motor Controller Accessory

1715-C2 1715 2 m Length Backplane Extender Cable

1771-IXE 1771 8 Point Input Module

193-EC4DD E3 Plus 9-45 A Current Relay

198-WT1 ModCenter IEC Wiring Kit

2090-CPWM4DF-16AF07 MP-Series 7m Power Cable

2094-BL50S Kinetix Line Interface Module

DEMOCD00013 iWorkinstruction DEMO CD

GFK-0772 PCM C Function Library Reference Manual

IC210CBL002 PDA to Durus Controllers Transfer Cable

IC647ASC005 PA SDK 5 Pak

IC647PPSOCF Proficy Process Systems Operator Console with iFIX

IC693CPU311RR Base 5 - slot with CPU311

IC754VGF08CTD View Loaded 8In Color TFT Touch DC GEF

MSI-DASHBOARD Dashboard Client

SLC/1746 System 1746-R15 REPLACEMENT RETAINER CLIP FOR MODULES

Distributed I/O 1734-OW4 24V DC COIL N.O. DPST 4 RELAY MODULE

Application-specific products 1803-EEM21E4 EEM,32 PULSES,24V DC,8 ANALOG,4 TO 20 MA, NEMA 4

Operator Interface 2711E-T10C6 PANELVIEW 1000E TOUCHSCREEN TERMINAL, 10.4" FLAT

Support 9302-BLDS SUPT RENEWAL CONTRACT FOR 9302BLD

Support 9381-PP250KENR SUPPORT REINSTATEMENT CONTRACT FOR 9381PP250KEN

DeviceNet Products 1791D-0B16PX 24 VDC BLOCK I/O EXPANSION, 16 OUT SOURCE, RTB

RSI Software Products 9301-2SE3350FRU1 RSVIEW32 RUNTIME 150-5K UPGRADE IN-SUPT (FR)

RSI Software Products 9358-PBVNT01ENE RSBATCH NT FOR PLX BATCH VIEW ADDITIONAL CLIENTS

Motion Control MPL-B880C-MJ24AA MOTOR,SERVO,76.0NM,1500RPM,MULTI,460V,BRKE

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

HE660CGM424 Genius "C" Prog. Co-processor with RS-232 and RS-422/485 ports

IC646TPD075 Pro Server 75 I/O Point Development and Run Time System

QDA-EDT-SITE QuickDesigner Site License

ST-3134 STXi analog b module 4 Channels, 0~20mA, 14-bit

USB-485

PCI-7434

92-005721-OX

PMAC2-PC 602404-106

M-302 08GSAQ96501102

E271-2210

1492-RIFM20F-F24-2 Connection Products

微處理器的PCI卡 6GK1561-3AA01 CP5613,有微處理器的 PCI 卡

變送器 3RS17001DD00

1497A-A11-M6-1-N Control Power Transber

1606-XLP15B Power Supply XLP 15 W Power Supply

1764-RPLTB1 MicroLogix Replacement Part

188-K4B320 Miniature Circuit Breaker 32 A

194L-HE6G-175 194L Control and Load Switch Actuator

2090-CPBM7DF-08AF90 90 m Length SpeedTec Flexible Cable

2090-XXNPMF-16S90 Kinetix Drives 90m Standard Cable

CB4N-0WPM-0070-AZ AHVi and AHVis Motor Brake Power Cable with Straight Connector, 7 M

GC647SJM001 GCScheduler Project Module

IC200PNS001 PROFINET Scanner (PNS) module interfaces a remote node of VersaMax modules to a PROFINET IO Controller. Two 10/100 Mbps copper interfaces. Requires Proficy Machine Edition 7.0

IC646TBLCLT010 Proficy Troubleshooter for Inbligent Historian Standard, Enterprise and Corporate Clients Access 10 Users

IC647NDF000 CIMPLICITY HMI AB DF1 COMM Driver

IC690CDR002 InfoLink CD-ROM Documentation, single-user license

IC698CHS009 RX7i 9 Slot Rear Mount Rack