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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?；诖耍恼铝⒆阌诋?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(hù)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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PLC-5/1771 System 1771-SN SUB I/O SCANNER MODULE

Distributed I/O 1790-T8A0X LDX I/O, 110V AC, 8 INPUT EXPANSION, TERMINAL BLK

Communications 1785-TR10BF AUI TO F.OPTIC ENET TRANS

Operator Interface 2711E-NF3 FUNCTION KEY LEGEND INSERTS, PV1200 & PV1200E

Support 9305-RSVADDCJPR SUPT REINSTATEMENT CONTRACT FOR 9305RSVADDCJP

Support 9324-RLD600S SUPT RENEWAL CONTRACT FOR 9324RLD600ENE

DeviceNet Products 9355-WABOEMENE RSLINX OEM - ENGLISH

RSI Software Products 9301-2SE3400ITU1 RSVIEW32 RUNTIME 1500-32K UPGRADE IN-SUPT (IT)

RSI Software Products 9371-RSWD2 RSWIRE DESIGNER/JIC PROFESSIONAL PACK

Motion Control 1326AB-B410J-M2L MOTOR,SERVO,460V,2.7NM,7250RPM,MULTI,IP67

2224 Greyline OS, 2 Line, (20) 5MM Chars, Backlit Supertwist LCD. ASCII /Serial Interface, NEMA 4

HE800ACC006 Cage-clamp (screw) style I/O plug, 6-terminal. (Qty 1). May be used as an alternative to the standard SmartStack plugs which are spring-clamp style.

IC693ACC302 High capacity battery pack. The new Auxiliary Battery Pack (IC693ACC302) will enable Series 90-30 & Series 90-70 CPUs (except CPU374) to go up to 75 months (shelf life of 10 years ) of RAM memory backup w/no power & the CPU374 backup=15 mo

QPK2D101S2P QUICKPANEL 6" STN COLOR WITH CE MARK

TGT-000A-2-0 Target series 2-axis motion control module

SCC-SG03

TAHOMA TECH 10118B

INTERFACE PCI 8521S

100-79-0810-00

SC I486

MK620-MCT01

1492-SPM1B400 MCB Supplementary Protector 40 A

直流電源 6EP1436-3BA00 3 相 400-500VAC 輸入，24VDC/20A 輸出

電機啟動器 3VU13400MD00

1497D-A15-M21-0-22 GEN PURPOSE TRANSFORMER

1607-XT200D2A ArmorPower Dual 24VDC Output 91W PS

1769-OB16 CompactLogix 16 Pt 24VDC D/O Module

190S-AND2-CB25C-KN-V 1.6-2.5 A Compact Comb Starter W/Ckt-Bkr

194R-N30-1753-PBS1 Non-Fused 194R Disconnect Switch

2090-CPBM7DF-16AA09 MP-Series 9m Standard Cable

2090-XXTFMP-S05 MP-Series 5 m Length Feedback Cable

CBL-T7-MB-20 Power/brake cable for MTR-3T10 or MTR-3T20 or MTR-3T40 series servo motors. 20 feet

GF-3022R Connecting FlashCable to Ametek Accuforce II Cadet.

IC200UDD240 VersaMax Micro 40 point PLC,(24) 24VDC In, (16) 24VDC Sink Outputs, 24VDC Power Supply. (1) serial port and (1)optional communication port. Requires Machine Edition 5.7 or higher. Battery (IC200ACC414) is required for data retention. Battery no

IC646TPR300 ProServer 300 I/O Point Runtime System

IC647PATABB0 Proficy PAT - Driver For Ethernet-Coupled Abb Bomem Ftir Spectrometers

IC693ALG442CA Conbal Coated Analog module, four in and two out.

IC752DSX000RR Datapanel 160 - 240x64 LCD display with LED backlight. Includes integ rated keypad for data entry. No touch capability. Various sizes of t ext, bitmaps, bar graphs, messaging. Supports limited PC/104 capabili ty.

IFIXONNODE100M iFIX Upgrade to On-Node 100 Tag Standard Edition Historian with Alarm & Event Option, M4 Key

SLC/1746 System 1746-BAS BASIC MODULE FOR PROGRAMMABLE CONTROLLER

Industrial Computers 6186-M17SS VERSAVIEW 17 INCH MONITOR, TEMPERED GLASS

Application-specific products 1404-M505A-000 MASTER MODULE - PQ

Operator Interface 2711-T6C8L1 PV600 COLOR TOUCH, DH+ & RS232 PRINT

Support 9301-2SE3100JPS SUPT RENEWAL CONTRACT FOR 93012SE3100JP

Support 9380-RSBARR SUPT REINSTATEMENT CONTRACT FOR 9380RSBAR

DeviceNet Products 1734-TBSQ10 10 MODULES BASES W/ REMOVABLE IEC SPRING TERMINALS

RSI Software Products 9301-2SE3200U1R RSVIEW RUNTIME 150 TO 300 UPGRADE:OUT-OF-SUPPORT

RSI Software Products 9358-BPCNT60ENE RSBATCH PC-BASED PHASES 60 UNITS

Motion Control MPL-B4520P-RK24AA MOTOR,SERVO,6.1 NM,5000RPM,RSLVR,460V,BRK

Motion Control 2090-SCVG100-0 SERCOS FBR CABL,CONN,STNDRD PVC JKT,GLASS,100.0M

GFK-2210 PowerCube with Pulse & Direction Interface, Users Manual

IC646MGRS03 Electronic Signature option for a 3 users Procify Change Management system.

MTR-1235-E-D-E-0 Stepping Motor Nema23, Series Wdg, Encoder

QPICGAE0000 10.4 inch Color TFT/ GE Fanuc/ Ethernet/ CF Card/ 110 VAC

PXIe-5122

147-000047-00

Kontron 18030-0000-17-2

ASC-29320LPE

291300A 291300B

IAC-H669C

1492-PD3C2127 760 A Power Distribution Block

中央處理單元 6ES7414-3XJ04-0AB0 CPU414-3，1.4MB，60ns，電源 24VDC，MPI/PROFIBUS-DP 主站接口，PROFIBUS-DP 主站接口

變送器 3RS17061FW00

TIA 博途數(shù)字化選件 6ES7823-1EA00-0YL5 TIA Portal Teamcenter Gateway SUS

1585J-M8TBJM-2 RJ45 Ethernet Media

1761-CBL-AH02 MicroLogix Cable

188-K3B130-N Miniature Circuit Breaker 13 A

194L-E16-1753-6N 16 A 194L Load Switch

2090-CPBM4DF-16AF09 MP-Series 9m Length Cable

2090-XXNFMF-S09 Kinetix Drives 9m Standard Cable

BC647OEM0410B OEM Edge Program Add't Key - Historian

GC647PATAXIM Proficy PAT - Axiom Multiplexer Interface: Provides The Capability To Control An Axiom Analytical Fmx Series Fiber-Optic Multiplexer

IC200MDD843LT MIXED 24VDC POS LOG INPUT GRP 10PT / OUTPUT RELAY 2.0A PER PT GRP 6PT (LT)

IC646NQD000 Square D SyMax SyNet Communications

IC647MB1M MB1:Modicon Modbus I

IC670PBI001RR Profibus Bus Interface Unit, DP 12M Baud

IC697MDL654RR 48 Vdc Input, Positive/Negative Logic (32 Points)

IC800SLMCONKITZB Connector kit for 30 Watt to 750 Watt S-series servo motor with brake

ControlLogix/1756 System 1756-SYNCH CONTROLLOGIX SYNCHLINK MODULE

Industrial Computers 6182H-15BEH6B VVCE 1500, KEY/TOUCH, EXT MEM, RIO/DH, AC

Process Control 1757-DNBEXP03 DEVICENET MODULE EXPANSION, 2-3 MAX

Operator Interface 2711P-ST4KM PV PLUS 400 GRAYSCALE, KEYPAD STARTER KIT