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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。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(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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BC647SPR0X0 "Solution Provider Renewal > 30 keys includes key flashes which could be M4 or M1, Global Care Complete (iGC SP1)

GC647PRTEE005 GlobalCare Complete - Proficy Portal Enterprise Edition Client Pack 5 Users Ver 3.0

IC200MDL644LT INPUT 5/12VDC POS/NEG LOGIC (4 GROUPS OF 8) 32PT (LT)

IC646PCMS10 Proficy Change Management Electronic Signature Module 10 Pack

IC647MPS010 Logic Developer PLC Standard 10 Pack with USB Hardware key

IC676PBI016 IP67 Input Block - 24 VDC Positive Logic - 16 Pt - Profibus

IC697PWR720 Replacement Power Supply Adaptor

IC800SSI107RS1RR 7.2A, 115/230V, S2K Servo Controller for MTR Series Motors

SLC/1746 System 1747-L30B 30 I/O FIXED HARDWARE STYLE

Industrial Computers 6189-RPRH VVCE LOGIC MODULE, 128MB FLASH, 128MB RAM

Process Control D1770-6.5.21 SMART TRANSMITTER TOOLKIT USER MANUAL

Operator Interface 2711-B5A3L2 PV550 MONO KEY&TOUCH, DH485 & RS232 PRINT

Support 9303-3CS0E20UR UPGRADE: OUT-SUPT: DRIVEMONITOR TO DRIVEMONITOR32

Support 9371-RSWDI1S SUPT RENEWAL CONTRACT FOR 9371RSWDI1

ControlNet Products 2706-P92C INVIEW MESSAGE DISPLAYS

RSI Software Products 9301-2SE2500ITU5 RSVIEW32 WORKS 5K-100K UPGRADE IN-SUPT (IT)

RSI Software Products 9358-BBKEY30ENE RSBIZWARE BATCH BACK-UP KEY 30 UNITS

Motion Control MPL-A4530K-MJ22AA MOTOR,SERVO,8.36 NM,4000RPM,MULTI,230V,8.2KG

Motion Control 2090-UXPC-D0915 CABLE,9/9 POS,45 DEG D/STRAIGHT D,15M

CBL-6113 Cable. IBM COMP. To Model 9650, 25 Pin PC COMM. Port

IC641LCN053 Runtime license for DEC VAX/VMS

IC800SLMCONKITVB Connector Kit, 1 kW to 2.5 kW S-Series Servo Motors with Brake

OC647WFLRDB Proficy Workflow - Relational DB SP

PXI-5402

PCE-5B13-08

PDSLA 945G

DSA628/328

IPC-6105P4

SYS7180CVE

1492-MCS5X10 IEC 5 x 10 mm Marker Card

1494V-LL3 DiISCONNECT SWITCH ACCESSORY

軟啟動(dòng)器 3RW44662BC44

運(yùn)行版軟件 6AV2104-3DD04-0AE0 SIMATIC WinCC Runtime Advanced 512 PowerTags V14 Upgrade ： V11..V13 -> V14

1585J-M4TBJM-0M6 RJ45 Ethernet Media

1756-OB16EK ControlLogix 16 Point Digital Output

188-K1B400 Miniature Circuit Breaker 40 A

194E-FA80E-P11 194E Load switch

2090-CFBM7DF-CDAF09 MP-Series 9m Feedback Cable

2090-U5PM-D0909 Ultra 5000 9m Interface Cable

BC646MVSU02 View Standard Edition Upgrade from View for QuickPanel View Standard Edition with Proficy GlobalCare Complete

GC647AUR025 GC Universal Reporting Client 25 pak

IC200ACC414 The ACC414 is a long term battery for the VersaMax Micro 20, 23, 28, 40 and 64 point CPUs. The battery will backup upto 7 years.

IC646CSPR010 Proficy Cause+ for Inbligent HMI/SCADA Runtime Server - 10X monitored KPIs

IC647IFPLSR00075M iFIX Plus SCADA 75 I/O Server (M4 Part)

IC660MLA105 Label for IC660BBA105 (Qty 100)

IC697ALG444 Analog Input Expander, Current, 16 Channels gold plated terminal. WARNING: The IC697ALG444 module must be matched with IC697ACC775 terminal block ONLY. IC697ACC775 is included with the module.

IC760STA100 StationPortal. Stand-alone I/O device supporting Ethernet. Includes universal power supply.

FlexLogix System 1794-STRT1DE FLEXLOGIX STARTER KIT GERMAN

GuardPLC Systems 1753-PCSUSB RSLOGIX GUARD PLUS FOR GUARDPLC - USB HARDLOCK

Process Control 1757-UPGSIFZA UPGRADE APPLICON QUICKBUILDER I/F

Operator Interface 2711P-T12C6D2 PV PLUS 1250, TOUCH, RIO/DH, DC PS, EXT MEM

Support 9220-WINTAR SUPT REINSTATEMENT CONTRACT FOR 9220WINTA

Support 2755-LHS1S SUPT RENEWAL CONTRACT FOR 2755LHS1

Support F1785-V40BSERC FIRMWARE UPGRADE FOR 1785-V40B PLC5 PROCESSOR MODU

RSI Software Products 9301-2SE2350KOU2 RSVIEW32 WORKS 300-5K UPGRADE IN-SUPT (KO)

RSI Software Products 9701-VWSTMENE RSVIEW STUDIO FOR MACHINE EDITION

RSI Software Products 9399-WABOUGDE RSLINX OEM USERS GUIDE (GERMAN)

Motion Control 8720MC -D180-AN- 180 AMP D CHASSIS DRIVE, OPEN ENCL., LESS OPTIONS

BC646MRC000 Logic PC & View Runtime 8,000 I/O

IC300PDA001 OCS Handheld Programmer

IC754CKL12CTD Starter Kit, 12 TFT Ctrl Loaded, 24VDC"

MTR-3T45-I-R-B-M-0RR Servo Motor Metric 24V Brake

PCI-6713

STM-5 R1.5

PCA-6186E2

Allied Telesyn安奈特 AT-2711FX/LC

ARBOR EmCORE-i6419

PIO-16/16B(PCI)

1492-LD4RB822 Terminal Block, Resistor, 8.25K Ohms

1494F-LL4 Door Hardware Kit

軟啟動(dòng)器 3RW44352BC46

ET 200SP 6ES7193-6AP40-0AA0 BA 1×SCRJ光纖/1×FC 快連式

1585D-E4TBDE-0M3 Micro D-Code, QD Style Ethernet Media

1751-SLBA SynchLink Fiber Base Block

1794-IB10XOB6 Flex 10 Input 6 Output Digital Module

194E-AA20E-P11-TN 194E Load switch

2080-LC20-20AWB Micro820 20 I/O ENet/IP Controller

2090-CSWM1DF-14AA19 Kinetix Cable Single DSL 2090-Series

20AC2P1F0AYNANC0 PowerFlex 70 AC Drive 20A

GC646MPP010 Proficy GlobalCare Complete for Logic Developer - PLC Professional - 10 Pack

HE693OIU297 Compact VF Genius w/4-line display, powered by 24VDC

IC610CCM105RR Series One Plus Data Communications Unit (DCU)

IC647HSTSC2000KM Server to Server Collector for Historian - Standard Server 2,000,000 Points (M4 Key)

IC660BBA101RR RTD Input Block, 115Vac/125Vdc Power, 6 Chans, Ph B

IC694MDL753 Output module, 12/24VDC POS logic, 32 points. Interface uses Fujitsu connector.

IC756WDJ009J-22 DV Development Sys VB and Java, Japanese, Version 2.2

MicroLogix 1500/1769 System 9399-RL50GRFR RSLOGIX 500 GETTING RESULTS GUIDE (FRENCH)

PLC-5/1771 System 1771-CP3 1771 I/O CHASSIS CABLE FOR 1771-P7 POWER SUPPLY

Distributed I/O 1797-PS1N AC IN QUAD-EX DC OUT POWER SUPPLY- NPT CONDUIT

Operator Interface 2711P-B6C3D PV PLUS 600 COLOR, KEY/TOUCH, DH485, DC PS

Support 9323-PA1SR SUPT REINSTATEMENT CONTRACT FOR 9323PA1S

Support 9358-HSTSSROLS SUPT RENEWAL CONTRACT FOR 9358HSTSSROL

Support F1772-LXPSERD FIRMWARE UPGRADE FOR 1772-LXP PLC2 PROCESSOR MODUL

RSI Software Products 9324-RLD3U7PTE RSLOGIX 5000 STD. TO PRO UPGRADE, PORTUGUESE

RSI Software Products 9305-RSVADDCITE RSVIEW32 ACTIVE DISPLAY DED. CLIENT (ITALIAN)

RSI Software Products 9358-RTI20E RTI DATA COLLECTOR (20 CONFIGURATION)

Motion Control 2094-AC05-M01 MODULE, INTEGRATED, 200/230V, 3KW CONV. 9A INV.

A06B-0143-B175#7008 A12/3000 Servo Motor, Holding Brake, 64K Serial Encoder

IC200UDD112 14 point PLC,(8) 12VDC In, (6) 12VDC Out at 0.70 A, 12VDC Power Supply

IC752BUU034 VT100 Upgrade for Datapanel 240T

MTR-1480-E-A-E-SRR Stepping Motor Nema42 Encoder Splashproof

NI 9222

ROCKY-3702EV-R4V8

MOTOROLA HA MCP 750

OMRON 3G8F7-CLK21-V1

SP2-4300F

P51-15-K

1492-SPM3C500-N MCB Supplementary Protector 50 A

軟啟動(dòng)器 3RW40461TB05

模擬量輸出信號(hào)板 6ES7 232-4HA30-0XB0 SB 1232 AQ 1x12 位

150-SC3NBD SMC-50 SOLID STATE MOTOR CONTROLLER 320A

1734-VHSC5 POINT I/O Very High Speed Counter Module

1783-SRKIT Stratix 5900 Services Router Kit

193-ESM-VIG-60A-C55 E300/E200 60 Amp Sensing Module

20-750-IP20GI-F2 PF753 & PF755 FR 2 EMC CORES W PLATE

2090-CPWM7DF-16AA25 MP-Series 25m Servo Power Cable

20A-DG01 PowerFlex 70 DriveGuard Board Kit

GA647IFESGDV00300 GCA iFIX Optn: ESig & ERec 300 I/O Dev

GP-2104NT GagePort Digital NT 4-port b

IC5007TBX0030 PanelPC 17 inch Perbance Unit Deluxe with Windows XP

IC647HSTCC100M Calculation Collector for Historian - Standard Server 100 Points (M4 Key)

IC647SVB001 Scheduler Visma Business Adapter

IC693MDL750RR 12/24 Vdc Output, Negative Logic (32 Points)

IC756LDV000E64-925 DataViews Development on Inb Linux/Red Hat 64 bit Op Sys, English v9.25