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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?，文章立足于當(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，在先進技術(shù)進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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25B-A011N104 PowerFlex 525 2.2kW (3Hp) AC Drive

2711P-T7C4D9 PanelView Plus Terminal

6SE6430-2UD33-0DB0 30KW

1492-L3Q IEC Term Blck 5.1x79x31.3mm Spr Clp

1494C-CM5 Cable Mechanism

軟啟動器 3RW44261BC45

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1585BP-F8BF 1585 Ethernet Media Accessory

1746-RT32 SLC Replacement Terminal Block

1790D-T0V16 CompactBlock LDX 16 Point O/P Base Block

194E-A32-1753-Q 32 A 194E Load switch

20-PP13000 WIRE SET ASSY FI13

2090-CSBM1DF-18AF14 Kinetix Cable Single DSL 2090-Series

20AC060A0AYNANC0 PowerFlex 70 AC Drive 60 A at 30 kW 20A

GC646MBSS99 Proficy GlobalCare Complete for ME Standard Development Suite - Site License

HE690PGM100 Programmable Memory for HPL

IC600PM502RR Standard I/O Rack Power Supply, 115-230Vac

IC647HSTESEO1250KM eSignature Option for Historian - Enterprise Server 1,250,000 Points (M4 Key)

IC655CHS508RR Base Unit, 8 Slots

IC694MDL240 Input module 120 VAC, 16 points.

IC756SDV010E-925 "DV-Draw Development on Solaris Op Sys, English v9.20"

MicroLogix 1500/1769 System 1769-IQ6XOW4 COMBO 6PT 24 VDC SNK/SRC IN, 4PT VAC/VDC RELAY OUT

PLC-5/1771 System 1785-TAS THIN-WIRE TRANSCEIVER CABLE KIT, 49.2FT/15M, STD

Distributed I/O 1794-TB3K CONFORMALLY COATED, TERMINAL BASE 3-WIRE

Communications 9399-WGSUG RSSERVER FOR GE FANUC SERIES 90 USER'S GUIDE

Support 9311-PLC2R SUPT REINSTATEMENT CONTRACT FOR 9311PLC2

Support 9358-BTDS60S SUPT RENEWAL CONTRACT FOR 9358BTDS60ENE

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RSI Software Products 9324-RLD200ESE RSLOGIX 5000 MINI, ESP

RSI Software Products 9301-RSVWSENE RSVIEW32 WEBSERVER

RSI Software Products 9358-PLTM2300ENE RSBIZ PLNTMET SEV 25 CELL

Motion Control 8720SM-022S3GAS3 22 KW/48 AMP, 750 VDC, AC MOTOR WITH SNS60 ENC.

840-RC-48 48" Ribbon Cable. Term Both Ends W/16 Pin DIP Plugs

IC200NDR001 10 point (6) DC In, (4) Relay Out, DC Power Supply

IC697VAL328 Analog Output, isolated, 8 channel, 12 bit, Voltage - polar 0-10VDC, 0-5VDC. Removable terminal block, no cable required

MTR-1337-0-D-E-0RR Stepping Motor Nema34 Dble Shft

ZA06B-0063-B203#0100 B4/4000is Servo Motor with Straight Shaft, Key and IP67 Sealing

20BD156A3AYNAEC0 PowerFlex 700 AC Drive 20B

20G11NE022AA0NNNNN PowerFlex 755 AC Packaged Drive

23C-D038A103NNBANN-LR Fan/Pump Packaged Drive 23C

140CFU00600 Quantum CABLEFAST 保險, 1/16 AMP

294E-FD2P5Z-G1-SB Variable Frequency Drive

HL-5100 觸點:1開/1閉,5A 250VAC機械壽命:1000萬次?撞壓式?頂部柱塞型

1492-SPM3B630-N MCB Supplementary Protector 63 A

軟啟動器 3RW40371BB05

中央處理單元 6ES7 214-1AG40-0XB0 CPU 1214C AC/DC/RLY

150-F86L SMC Accessory

1734-IV8 POINT I/O 8 Point Digital Input Module

1783-HMS4EG8CGN Stratix 5400 12 Port Managed Switch

193-ERID E1 Plus Remote Indication Display

20-750-EMCSSM1-F8 PF755,FR8-10,SAFE SPEED MONITOR EMC CORE

2090-CPWM7DF-14AA07 MP-Series 7m SpeedTec Standard Cable

2098-DSD-150 Ultra 3000 Servo Drive

GA646PCM005 GlobalCare Assist for Change Management 5 user pack

GFK-2314 PACSystems RX3i System Manual

IC220TBK203 TERMINAL STRIP SET, SPRING STYLE, ANALOG OUT/HSC

IC647GEFM GEF:GE Fanuc

IC647SHR001 Scheduler Hour rate

IC693MDL648 48VDC Input, Neg/Pos Logic, 1 msec filter, Neg/Pos Logic (16 points)

IC756HDV000CT-99 DV Development - HP/UX Op Sys, Traditional Chinese, Version 9.9

MSI-ROLL Roll Map Base Application

PLC-5/1771 System 1771-IAD INPUT MODULE, 120V AC, 16 INPUT

Distributed I/O 1790D-N4V0 DNET LDX, 4 INPUT VOLTAGE ANALOG BSE,D-SHELL CONN

Communications 1771-KE DATA HWY RS-232C INTERFACE MODULE

Operator Interface 2727-MRJB1 MOBILEVIEW JUNCTION BOX

Support 9305-RSVADFCZHS SUPT RENEWAL CONTRACT FOR 9305RSVADFCZH

Support 9515-RSCHM010R SUPT REINSTATEMENT CONTRACT FOR 9515RSCHM010ENE

EtherNet/IP Products 2706-P74CN1 INVIEW MESSAGE DISPLAY. 1 TO 4 LINE

RSI Software Products 9301-2SE3400U2 RSVIEW RUNTIME 300 TO 32K UPGRADE:IN-SUPPORT

RSI Software Products 9515-RSEOL016ENE RSMACC CONDITION MONITOR, 16XM & 2 ENWATCH

Motion Control 1326AB-B515E-M2L MOTOR,SERVO,460V,10.4NM,3000RPM,MULTI,IP67

4161-3-24 BCD To 7 SEG Display . 3 Digit, 24VDC. Dust Seal

HMI-CAB-A02-25X CABLE ADAPTER HAND HELD 25'

IC693CBL301 Cable, I/O Expansion, 2 Meters

QPL-DEM-C02 QUICKPANEL DEMO COLOR 12.1'

TGT-S000-1-0 Target series system module