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A02B-0162-C045

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?；诖耍恼铝⒆阌诋?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，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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Support F1785-L40BSERE FIRMWARE UPGRADE FOR 1785-L40B PLC5 PROCESSOR MODU

RSI Software Products 9301-2SE2300PTE RSVIEW32 WORKS 1500 (PORTUGUESE)

RSI Software Products 9701-VWSCRAENE RSVIEW SE VIEW CLIENT

RSI Software Products 9399-PROPAK5GR PROCESSPAK5 GETTING RESULTS GUIDE

Motion Control 2098-DSD-HV100-SE HIGH VOLTAGE DRIVE, 23A/46A, ULTRA3000 W/SERCOS

BC646MDC075 Logic Developer - PC & View Development/Runtime 75 I/O

IC300MIX906 8 DC Inputs (12/24vdc), 8 DC Outputs (5/12/24vdc, 0.5A pos. logic with ESCP) & 4 channels Analog Inputs, current (0-20mA, 4-20ma), 12 bit; 2 channels Analog Outputs, current sourcing (4-20ma)

IC752SKT005 Mature, order QuickPanel instead. DataPanel 320T MEG Starter Kit: Includes Datapanel 320T Mono Expansion with 2 MB & Genius (CBT020), download & communication cables, WinCfg, user & programming manuals

MTR-3S86-G-R-B-E-SRR Servo Motor 24V Brake, Seal

ZA06B-6124-H106 Alpha SVM1-180HVi FSSB 180 amp amplifier

20CC460A0ANNBNA0 PowerFlex 700H AC Drive 20C

20G1ABF370AN2NNNNN PowerFlex 755 AC Packaged Drive

25A-D2P3N104 PowerFlex 523 0.75kW (1Hp) AC Drive

2711P-T6C20D9 PanelView Plus 6 Graphic Terminal

6SE6440-2UD25-5CA1 5.5KW

1492-KWC IEC Wire Cutting Tool

1492-XIM20120-8R Connection Products

軟啟動(dòng)器 3RW44243BC34

通信模塊 6GK7 542-5FX00-0XE0 CP 1542-5；RS485，PROFIBUS 通訊模塊

1585-C8CB-S300 Cable Spool Ethernet Media

1746-OX8 SLC 8 Point Digital Output Module

1790-16BV0X CompactBlock LDX 16 Expansion Block

194E-A100-1753 100 A 194E Load switch

20-PP09102 CABLE,OUT PH NON-REGENERATIVE FRONT ENDF

2090-CSBM1DF-18AA10 Kinetix Cable Single DSL 2090-Series

20AC037A3AYNACC0 PowerFlex 70 AC Drive 20A

GC-8459-UP-MT Workbench Upgrade to Latest Version (works with any license type)

HE300GEN150 Genius card for GE Drive G11 and P11

IC600KD515RR Mini OIT

IC647HSTES1KM Historian Enterprise Server 1000 Points (M4 Key)

IC648MNT076 Annual Software Maintenance for LM 90-70 Standard Serial Communication s

IC694ALG442CA Conbal Coated Analog Input module, 4 in and 2 out. Voltage and current supported.

IC756SDV000J-98 DV Development - Solaris Op Sys, Japanese, Version 9.8

MicroLogix 1200 System 1762-RPLDIN2 REPLACEMENT DIN LATCHES FOR 1762 I/O

PLC-5/1771 System 1771-WB FIELD WIRING ARM, 12 TERMINALS, GOLD PLATED

Distributed I/O 1794-IF2XOF2I ISOLATED ANALOG COMBO MODULE

Communications 9399-WAB32LUGES RSLINX LITE USER GUIDE (SPANISH)

Support 6223-5VDLR SUPT REINSTATEMENT CONTRACT FOR 62235VDL

Support 9358-BPC10R SUPT REINSTATEMENT CONTRACT FOR 9358BPC10ENE

Support F1771-ILSERB FIRMWARE UPGRADE FOR 1771-IFE I/O MODULE

RSI Software Products 9324-RLD000PTE RSLOGIX 5000 SERVICE EDITION, PTG

RSI Software Products 9301-2SE350JPU4R RSVIEW32 RUNTIME 150-100K UPGRADE OUT-SUPT (JP)

RSI Software Products 9358-HSTS2500U3 UPGRADE: IN-SUPT: HISTORIAN 1500 TO 70K TAG

Motion Control 8720SM-015S2ECS1 15 KW/48 AMP, 380 VAC, AC MOTOR WITH SRS60 ENC.

829-1-AC Thumbwheel Assembly. 1 Digit, AC Logic. Dust Seal

IC200MDL330 OUTPUT 120VAC 0.5A PER PT ISOLATED 16PT

IC697CMM799RR Replacement Part, MAP 30 Modem, Broadband, All Channels

MTR-1324-E-D-E-0RR Stepping Motor Nema34 Encoder

Z44C742433-001 2 meter cable to connect the IC800ABK001 battery pack to a Beta amplifier

20BD096A3AYNADC0 PowerFlex 700 AC Drive 96 A 75 Hp 20B

20G11NC5P0AA0NNNNN PowerFlex 755 AC Packaged Drive

22F-D8P7N103 PowerFlex 4M-3.7 kW (5 HP) AC Drive

TSXCUSB485 Twido USB - RS485 CONVERTER

294E-FD1P5P-G1 Variable Frequency Drive

S8VS-09024 NEW 100-240VAC,容量：90W輸出 3.75A導(dǎo)軌安裝型

1492-SPM3B100 MCB Supplementary Protector 10 A

軟啟動(dòng)器 3RW40271BB04

電機(jī)啟動(dòng)器 3VU16403CR00

150-F60NBR SMC Flex Smart Motor Controller

1734-IA2 POINT I/O 2 Point Digital Input Module

1783-BMS10CL Stratix 5700 10 Port Managed Switch

193-EIOGP-22-240 E300/E200 240V AC Control Module

20-750-DB1-D2 PowerFlex 750 Frame 2 DB Resistor Kit

2090-CPWM7DF-10AF60 MP-Series 60 m Length Power Cable

2098-DSD-005X-NV1 Ultra 3000 Servo Drive

G-0001-A 6 Foot Gage Extension Cable

GFK-2079 PMC IDE Hard Disk Adapter User's Manual

IC220PWR003 POWER TERMINAL, FUSED W/DIAG 24VDC (REQUIRES 1 IC220TBK087)

IC647DNP000 DNP3 Master Protocol for Unlimited points

IC647ROC050M ROC:Fisher Remote Operations Controller for 250 Units

IC693MDL390LT 120/240 Vac Isolated Output, 2 Amp (5 Points) (LT)

IC756CDV010K-99 DV Draw Development on Compaq True64, Korean, Version 9.9

MSI-PROD-UNL Unltd Site Clients - Product Management

PLC-5/1771 System 1771-SDN 2-CHANNEL DEVICENET SCANNER MODULE

Distributed I/O 1790-T16BV0X LDX I/O, 24VDC,16 UNIVERSAL IN EXPANSION, TERM BLK

Communications 1785-TR10B5 AUI TO THICK WIRE ENET TR

Operator Interface 2711-NR1 19-INCH RACK MOUNT KIT

Support 9305-RSVADDCITS SUPT RENEWAL CONTRACT FOR 9305RSVADDCIT

Support 9324-RLD600R SUPT REINSTATEMENT CONTRACT FOR 9324RLD600ENE

DeviceNet Products 9355-WABGWENE RSLINX GATEWAY - ENGLISH

RSI Software Products 9301-2SE3400ITE RSVIEW32 RUNTIME 32K (ITALIAN)

RSI Software Products 9371-RSWD1U2R UPGRADE:OUT-SUPT:RSWIRE DES JIC PROF ACAD TO STDAL

Motion Control 1326AB-B410J-M2K4L MOTOR,SERVO,460V,2.7NM,7250RPM,MULTI,BRK,IP67

2125-LV Greyline OS, 4 Line, (20) 5MM Chars, VFD, Quick Connect, 10-30 VDC, NEMA 40

HE697THM260 8 channel thermocouple b module for Series 90-70 with 0.1癈 resolution and resistance measurement.

IC690CDR004 InfoLink Product Library and Legacy Product CD's

QPK2D101L2P QUICKPANEL 6" MONO LCD WITH CE MARK

TDP-160RR DataPanel 1500 w/Support For Network Interfaces

20BC3P5A3AYNAEC0 PowerFlex 700 AC Drive 20B

20F1AND415AA0NNNNN PowerFlex 753 AC Packaged Drive

22B-D017F104 PowerFlex 40 7.5 kW (10 Hp) AC Drive

140DRC83000 Quantum 繼電器輸出, 8點(diǎn), NO/NC, 2A/點(diǎn)

284E-FVD2P3Z-10-RR-3-DB1-EMI EtherNet Variable Frequency Drive

TL-Q5MC1 5mm,電感式,三線,常開(kāi)200mA NPN方17×17mm電源:10-30VDC

1492-SPM1B320-N MCB Supplementary Protector 32 A

直流電源 6EP1436-2BA00 3 相 400-500VAC 輸入，24VDC/20A 輸出

電機(jī)啟動(dòng)器 3VU13400MC00

1497D-A15-M21-0-2 GEN PURPOSE TRANSFORMER

1607-XT200D1A ArmorPower Single 24VDC Output 192W PS

1769-OA8 CompactLogix 8 Pt 240VAC D/O Module

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

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

2090-CPBM7DF-16AA07 MP-Series 7m Standard Cable

2090-XXTFMP-S04 MP-Series 4 m Length Feedback Cable

CBL-T7-MB-10 Power/brake cable for MTR-3T10 or MTR-3T20 or MTR-3T40 series servo motors. 10 feet

GF-3017R Connecting FlashCable to Chatillon DTG Series.

IC200UDD220 VersaMax Micro 20 point PLC,(12) 24VDC In, (8) 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 not i

IC646TPR150 ProServer 150 I/O Point Runtime System

IC647OPXM OPX:Opto 22 Mistic

IC693ALG442 Analog Combo Module 4IN/2OUT

IC752DSX000 DataPanel 160, GE Fanuc Label, 240x64 LCD display w/ LED backlight. In cludes integrated keypad for data entry. No touch capability. Various sizes of text, bitmaps, bar graphs. Supports limited PC/104 capability . UL, cUL, CE, UL1604

IFIXONNODE100C iFIX Upgrade to On-Node 100 Tag Standard Edition Historian with Alarm & Event Option, M1 Key

SLC/1746 System 1784-CP14 CABLE ASSY, 10 FT/3.2 M

Industrial Computers 6186-M17ALTR VERSAVIEW 17 INCH MONITOR, RESISTIVE TOUCH SCREEN

Application-specific products 1404-M405B-ENT 1404-M4 ETHERNET PM3000

Operator Interface 2711-T6C5L1 PV600 COLOR TOUCH, RS232 (DH485)

Support 9301-2SE3100JPS SUPT RENEWAL CONTRACT FOR 93012SE3100JP