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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(tái)，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(tái)。其中，六軸及以上工業(yè)機(jī)器人年產(chǎn)量超過 5 萬臺(tái)。在工業(yè)機(jī)器人制造業(yè)不斷發(fā)展的同時(shí)，我國裝備制造業(yè)也在逐步轉(zhuǎn)型升級(jí)。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(dòng)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(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(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(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)器人以折彎機(jī)為中心，配置真空吸盤，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，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(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(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(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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IC646IFCLNTCRO025K iFIX iClient Read Only 25 PK Keyless (M1 Kit Part)

IC647IFPRDV00075K iFIX Profsnl SCADA 75 I/O Development (M1 Kit Part)

IC660MLS101 Label for IC660BBS101 (Qty 100)

IC697BEM741RR FIP Bus Controller 9070

IC800BIHV010 BSVM1-10HVi Beta HVi 10 amp amplifier kit

ControlLogix/1756 System 1756-L55M23 LOGIX5555 PROCESSOR WITH 1.5MBYTE NV MEMORY

Industrial Computers 6182H-7BRH15B VVCE 700, KEY/TOUCH, STD MEM, CNET, AC

Process Control 9323-ATUNEENE LOOP TUNER FOR LOGIX5000 PIDE FUNCTION BLOCK

Operator Interface 2711P-K15C15B2 PV PLUS 1500, KEYPAD, CNET, AC PS, EXT MEM

Support 9240-WIN16SDKR SUPT REINSTATEMENT CONTRACT FOR 9240WIN16SDK

Support 6723-PCSS SUPPORT RENEWAL CONTRACT FOR 6723-PCS

Support F5130-RM1 FIRMWARE UPGRADE FOR 5130-RM1 PLC5250 PROCESSOR MO

RSI Software Products 9301-2SE2350ZHU1 RSVIEW32 WORKS 150-5K UPGRADE IN-SUPT (ZH)

RSI Software Products 9351-ICDOC INTERCHANGE DOCUMENTATION SET (RELEASE 6.0)

RSI Software Products 9399-WHEELUG RSWHEEL USERS GUIDE

Motion Control 8720MC-RPS190BS SLAVE 460V 190AMP RPS

BC646MRE075 Logic PC & View Runtime (HRT) 75 I/O

IC300RTD100 4 channel RTD Inputs (Pt-100, Pt-200, Pt-500, Pt-1000), 18 bit

IC754VKI10MTD Starter Kit - 10" Monochrome QuickPanel View Intermediate, Touch, 24VDC

MTR-3T57-H-R-0-M-0 MTR series metric servo motor with resolver

PCI-8431/2 (RS485/RS422)

PFM-535I

IPC-606P3(B)

M470-2 D2778-C14

NOVA-7896R

01-03450-00

1492-LG4 IEC Term Blck 6.1x62x35.7mm Spr Clp

1494G-BF3J6-421 NEMA 1494G Enclosed Disconnect

軟啟動(dòng)器 3RW44366BC34

ET 200SP 6ES7132-6BF00-0CA0 DO 8x24VDC/0,5A 高性能型，基座單元類型 A0

1585D-E4UBDE-25 Micro D-Code, QD Style Ethernet Media

1753-OB16 GuardPLC Digital Output Module

1794-IE8 Flex 8 Point Analog Input Module

194E-AA63 194E Load switch

2080-LC30-24QWB Micro830 24 I/O Controller

2090-CSWM1DF-18AA06 Kinetix Cable Single DSL 2090-Series

20AC3P5A3AYNNEG0 PowerFlex 70 AC Drive 20A

GC646MPTS99 Proficy GlobalCare Complete GE Compare

HE693RTD660 6 channel RTD b module for Series 90-30 with 700VDC bus-isolation and 0.05C resolution.

IC610MDL104RR 24Vdc Sink In, Relay Out (4 In/4 Out)

IC647HSTSC75KM Server to Server Collector for Historian - Standard Server 75000 Points (M4 Key)

IC660BBD022 Block 24Vdc Source I/O 16 Circuits, 2/3 Wire Sensor Compatible

IC694PWR330CA Conbal Coated Power Supply 120/240VAC 125VDC, added capacity.

IC756WDN009J-22 DV Development Sys VB, Java, C++, C, Japanese, Version 2.2

MicroLogix 1500/1769 System 1769-RTBN18 REPLACEMENT 18 PIN NEMA TERMINAL BLOCK (1 PER KIT)

PLC-5/1771 System 1771-P6R POWER SUPPLY,REDUNDANT,SLOT,8A,220V AC

Distributed I/O 1798-IE4 FLEXARMOR 4 CHANNEL ANALOG INPUT MODULE

Operator Interface 2711P-B6M8A PV PLUS 600 GRAYSCALE, KEY/TOUCH, DH+, AC PS

Support 9323-PA2SS SUPT RENEWAL CONTRACT FOR 9323PA2S

Support 9358-PB60R SUPT REINSTATEMENT CONTRACT FOR 9358PB60ENE

Support F1772-SD FIRMWARE UPGRADE FOR 1772-SD PLC2 PROCESSOR MODULE

RSI Software Products 9324-RLD6U7PTE RSLOGIX 5000 FULL TO PRO UPGRADE, PORTUGUESE

RSI Software Products 9305-RSVADFVCFRE RSVIEW32 ACTIVE DISPLAY FLOAT. VIEW CLNT (FRENCH)

RSI Software Products 9301-PCI2000ETHP APPLICOM PCI2000ETH ADDITIONAL PROTOCOL

Motion Control 2094-BNCON-1 460V CONVERTER CONNECTORS UP TO 15KW

A06B-6050-K115 Connector Kit, B2, B6 and A6 Motor Encoder

IC200UEX009 14 point expansion. (8) 120VAC In, (6) Relay Out (2 at 10 amp and 4 at 2 amp), 120/240VAC Power Supply. (includes IC200CBL501)

IC752CBT053RR Datapanel 320T CB (Color Base) with Advanced software: 320x240 1/4 VGA Passive Color with 80386SX/40 PC processor. Analog touch screen with text, bitmaps, bar graphs, real time clock. With Real Time Trends & Host Communications.

MTR-1N41-G-N-A-E-0 MTR series NEMA 42 stepping motor with parallel winding connection and encoder

NI 9242

ROCKY-3703EVR-VC

Matrix MRK-1005 ABX-1005(G)

SBC-F757CVGL-RS

SBC-8173

LXE VX4 158637-0001

TM172PDG28R

1492-SPM3D050 MCB Supplementary Protector 5 A

軟啟動(dòng)器 3RW40281BB04

SIMATIC HMI 系列面板 6AV2123-2GB03-0AX0 KTP700 Basic PN 7 寸觸摸 + 按鍵

150-SD3NUR SMC-50 SOLID STATE MOTOR CONTROLLER 520A

1738-AENT ArmorPoint Ethernet Adaptor

1783-ZMS24TA ArmorStratix 5700 24 port managed switch

193-KA40 0.25-.40 A IEC Bibllic Overload Relay

20-750-P5-C770D740 PF750,Fr8,DC Input w Precharge,400/480V

2090-CPWM7DF-16AF20 MP-Series 20m Length Power Cable

20AB022F0AYNANC0 PowerFlex 70 AC Drive 22 A at 7.5 Hp 20A

GA647IFPLDV00150 GCA iFIX Plus SCADA 150 I/O Dev

GP647IFCLNTS001 GCP iFIX iClientTS Each Additional User

IC600BF813RR Type J Thermocouple Input Module (8 points)

IC647HSTCC3KM Calculation Collector for Historian - Standard Server 2500 Points (M4 Key)

IC647TBPM TBP:Texas Instrument Transparent Byte Protocol

IC693MDL930CA Conbal Coated Relay Output module, 4 amp 8 point isolated

IC756LDV001E-99 DV Development - Inb/Linux RedHat Addt'l User, English, Version 9.9

Pico Controllers 1760-CBLPC02 GFX PROGRAMMING CABLE

PLC-5/1771 System 1771-OM 220/240V AC OUTPUT MODULE, 8 DRIVER, SOURCE OUTPUT

Distributed I/O 1791-24A8 BLOCK I/O, 120V AC, 32 POINT MODULE

Communications 1786-TNCL10 CONTROLNET TNC COAXIAL CONNECTOR - PLUG

Operator Interface 2707-MVP232 MICROVIEW, PANEL MOUNT, 2 LINE LCD, RS-232

Support 9701-VWSS250AR SUPT REINSTATEMENT CONTRACT FOR 9701VWSS250AENE

Support 9324-RL0100PTS SUPT RENEWAL CONTRACT FOR 9324RL0100PT

EtherNet/IP Products 1788-MCHKR NETWORK MEDIACHECKER (ENET, CNET, DNET, DH+/RIO)

RSI Software Products 9301-2SE340ZHU5R RSVIEW32 RUNTIME 5K-32K UPGRADE OUT-SUPT (ZH)

RSI Software Products 9356-PRO2450U2R UPGRADE: OUT-SUPT: RSSQL STD.300 TO PROF.32000 TAG

Motion Control F-6100-R-H04AA MOTOR/ENCODER/BRAKE

44A722981-011RR Color Adapter Card (W/M 1)

IC200ACC451 Simulator for VersaMax Micro 8 Inputs

IC693MDL310 120 Vac Output, 0.5 Amp (12 Points)

TRM-21006664 Connector, 7 Point 4.3/5/7.2 Amp S2K Extended Digital I/O (S1 Modules)

cDAQ-9132

PCA-6136

DM280520-CAN

SANGOMA A102

P4PE-X

Melec C-864

MIC-3082A

1492-SPM1D160-N MCB Supplementary Protector 16 A

通用型變頻器 6SE6 440-2UD33-0EB1 "30 KW,275 x 650 x 245"

電機(jī)啟動(dòng)器 3VU13401TD00

150-C60NBR SMC-3 60A Smart Motor Controller

1692-ZG4444 24 V DC Electronic Circuit Protection

1771-IFE Analog Input Module