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A20B-1001-0100,

A20B-1001-0100

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?，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。

上億庫(kù)存，國(guó)內(nèi)外近千個(gè)倉(cāng)庫(kù)，公司部分產(chǎn)品型號(hào)如下，歡迎聯(lián)系哦~！

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Support F1785-LTSERB FIRMWARE UPGRADE FOR 1785-LT PLC5 PROCESSOR MODULE

RSI Software Products 9301-2SE2350JPU2 RSVIEW32 WORKS 300-5K UPGRADE IN-SUPT (JP)

RSI Software Products 9701-VWSTFRU1 RSVIEW STUDIO FOR ME - ENT SERIES UPGRADE (FRENCH)

RSI Software Products 9399-WAB32UGPT RSLINX USERS GUIDE (PORTUGUESE)

Motion Control 8720MC -D180-AA- 180 AMP D CHASSIS DRIVE, ENCLOSURE, LESS OPTIONS

BC646MRB150 Logic PC Runtime 150 I/O

IC300OSW001 Cscape PDA Software with Handspring Visor/Visor Deluxe/Prism Cable

IC754ACC12GAS Gasket for 12 QuickPanel View & Control"

MTR-3T45-H-R-B-M-0 MTR series metric servo motor with resolver and brake

20AC8P7A3AYNAEC0 PowerFlex 70 AC Drive 8.7 A at 4 kW 20A

20DC022A0EYNANANE PowerFlex 700S AC Drive 20D

20G1ALF460AN2NNNNN PowerFlex 755 AC Packaged Drive

25B-D2P3N114 PowerFlex 525 0.75kW (1Hp) AC Drive

2715-T10CD PanelView 5500 10.4 in. Graphic Terminal

FR-A740-5.5K 9.1 KVA 12A 5.5KW

1492-LD4DF IEC Term Blck 6.1x76x52.2mm Spr Clp

1494F-L1 Door Hardware Kit

軟啟動(dòng)器 3RW44352BC44

ET 200SP 6ES7193-6AG00-0AA0 BA 2× LC 玻璃光纖，光纖最遠(yuǎn)距離 2 KM

1585D-D4UBJM-2 Micro D-Code, QD Style Ethernet Media

1747-SDN SLC DeviceNet Scanner Module

1794-CJC2 Flex I/O Accessories

194E-AA20-P11 194E Load switch

2080-LC10-12AWA Micro810 12 I/O Smart Relay Controller

2090-CSWM1DF-14AA15 Kinetix 15m Smartb Single Cable

20AC2P1C0AYNANC0 PowerFlex 70 AC Drive 20A

GC646MPM001 Proficy GlobalCare Complete for Logic Developer - PLC Nano/Micro

HE693OIU177 Compact VF OIU powered by 24VDC with Numeric Keypad

IC609SJR121RR Series One Junior 24Vdc Src In/Rly Out, 115Vac Power

IC647HSTSC15KM Server to Server Collector for Historian - Standard Server 15000 Points (M4 Key)

IC660BBA026RR Curr Src Analog Input Block, 24/48Vdc Power, 6 Inputs, Ph B

IC694MDL741CA Conbal Coated Output module 12/24 VDC 0.5 amp 16 points NEG logic.

IC756WDJ009E-23 DV Development Sys VB and Java, English, Version 2.3

MicroLogix 1500/1769 System 1769-ECR RIGHT END CAP/TERMINATOR

PLC-5/1771 System 1771-CE 1771 I/O CHASSIS CABLE FOR 1771-P2 POWER SUPPLY

Distributed I/O 1797-IJ2 2-CHANNEL EX HIGH RESOLUTION FREQUENCY MODULE

Operator Interface 2711P-B6C1D PV PLUS 600 COLOR, KEY/TOUCH, SRIO, DC PS

Support 9323-PA1GR SUPT REINSTATEMENT CONTRACT FOR 9323PA1G

Support 9358-HSTS2400S SUPT RENEWAL CONTRACT FOR 9358HSTS2400

Support F1772-LWSERD FIRMWARE UPGRADE FOR 1772-LW PLC2 PROCESSOR MODULE

RSI Software Products 9324-RLD3U7DEE RSLOGIX 5000 STD. TO PRO UPGRADE, GERMAN

RSI Software Products 9305-ADSGWENE RSVIEW32 ACTIVE DISPLAY SERVER WITH RSLINX GATEWAY

RSI Software Products 9358-PLTMCLTENE RSBIZ PLNTMET RED ONLY CL

Motion Control 2092-DA1 DRIVE, 1.4A/3.4A, ULTRA1500 DIGITAL SERVO DRIVE

A06B-0128-B675#7076 A6/3000 Servo Motor, IP67 Sealing, Holding Brake, 64K Serial Encoder

IC200UAR028 28 point PLC,(16) 120VAC In, (12) Relay Out (2 at 10 amp and 10 at 2 amp) 120V/240AC Power Supply. Battery (IC200ACC403) is required for data retention. Battery not included.

IC752BTS450 Display Station 1085 - 10.4" active matrix VGA (640x480) resistive touch screen with integrated keypad, Pentium 133, 32MB, 2 Gig hard drive, expansion slots, Ethernet, with CIMPLICITY HMI and Win NT

MTR-1362-E-A-E-SRR Stepping Motor Nema34 Encoder Splashproof

ZA06B-0113-B075#7008 B0.5/3000 servo motor with 32k serial encoder

20BD3P4A0AYNANC0 PowerFlex 700 AC Drive 3.4 A at 2 Hp 20B

20G11TC770JN0NNNNN PowerFlex 755 AC Packaged Drive

25-PM1-B011 PowerFlex 520 2.2kW (3Hp) Power Module

990XTS00300 Quantum B200 轉(zhuǎn)換接頭

FRN 2. 2E1S-4C 4. 1KVA 5.5A 2.2KW 3相AC380V/50Hz/60Hz

61F-G2 自動(dòng)供水和排水控制，水位異常高報(bào)警 電源:110/220VAC

1492-SPM3C320 MCB Supplementary Protector 32 A

軟啟動(dòng)器 3RW40462BB04

數(shù)字量輸入 / 輸出信號(hào)板 6ES7 223-3AD30-0XB0 SB 1223 DI 2 x 5 V DC/DQ 2 x 5 V DC，200 kHz

150-SC2NBD SMC-50 SOLID STATE MOTOR CONTROLLER 260A

1734-TOP3 POINT I/O Terminal Base

1783-SFP100FX 100FX SFP Fiber Transceiver

193-ESM-VIG-30A-C55 E300/E200 30 Amp Sensing Module

20-750-I2B-C750D710 PowerFlex 750 Inverter Assembly

2090-CPWM7DF-16AA09 MP-Series 9m Servo Power Cable

2099-BM10-S Kinetix 7000 Servo Drive

GA647IFESGCLNTCRN GCA iFIX Optn: ESig & ERec iClient Run

GP-2102NT/FOWSB GagePort Digital NT 2-port b (Fowler OEM) - Sales BOM.

IC5007TAX0030 PanelPC 17 inch Standard Unit Deluxe with Windows XP

IC647HSTAE75KM Alarm and Events Option for Historian - Standard Server 75000 Points (M4 Key)

IC647SSM005 Scheduler Shop Floor Server 5 users

IC693MDL742 12/24 Vdc Output, 1 Amp, Positive Logic (16 Points), Fused

IC756LDV000E-925 "DataViews Development on Inb Linux/Red Hat Op Sys, English v9.25"

Pico Controllers 1760-IA12XOW6I 18 I/O EXPANSION MODULE, AC

PLC-5/1771 System 1771-OAN OUTPUT MODULE, 120V AC, 32 OUTPUTS

Distributed I/O 1791P-16B0 PROFIBUS 24VDC CBLOCK I/O, 16 IN SINKING, BASE

Communications 2760-RB FLEXIBLE INTERFACE MODULE, 2-SLOT, 1771 I/O RACK

Operator Interface 2706-PDH485P DH-485 COMMUNICATION MODULE FOR 2706-P22R

Support 9701-VWSB000AR SUPT REINSTATEMENT CONTRACT FOR 9701VWSB000AENE

Support 9515-RSNHS250S SUPT RENEWAL CONTRACT FOR 9515RSNHS250ENE

EtherNet/IP Products 2711P-K7C4B2 PV PLUS 700, KEYPAD, ENET, AC PS, EXT MEM

RSI Software Products 9301-2SE340ITU2R RSVIEW32 RUNTIME 300-32K UPGRADE OUT-SUPT (IT)

RSI Software Products 9356-PRO2300U6R UPGRADE: OUT-SUPT: RSSQL PROF.300 TO 1500 TAG

Motion Control 1326AB-B740C-S2L MOTOR,SERVO,460V,53.0NM,2200RPM,SINGL,IP67

4162-L-6 4162 CONTINUOUS LENS KIT. FOR (6) 4162s

HMI-KPN-302 QUICKPANEL KEYPAD FOR 10.5"

IC693CPU360RR CPU 360 Module (240K Bytes configurable user memory, 4K I/O, 8 racks), no built-in Serial Ports

SPS-24W-2 24 VDC PS, 1.0A, 85-265 VAC INPUT

TRM-JAUX-10 S2K auxiliary I/O screw terminal breakout board with 10 foot cable

20BD014A0AYNAND0 PowerFlex 700 AC Drive 14 A at 10 Hp 20B

20G11BD1K2AN0NNNNN PowerFlex 755 AC Packaged Drive

22C-B012N103 PowerFlex 400- 2.2 kW (3 HP) AC Drive

140XBP00400C Quantum 背板, 4槽, CC

284S-MTRS22-M6 ArmorStart Spare Parts

H3BA-N8H DC24/AC220, 1.2S-300H 可調(diào)，瞬時(shí)兩開(kāi)兩閉

1492-SPM1D040 MCB Supplementary Protector 4 A

通用型變頻器 6SE6 440-2UC33-0FA1 "30 KW,350 x 850 x 320"

電機(jī)啟動(dòng)器 3VU13403MG00

150-C361NBR SMC-3 361A Smart Motor Controller

1609-NMC 1609 UPS Accessory

1771-CD 1771-P2 Power Supply Cable

193-EC1PB E3 0.4-2.0 A Overload Relay

198-F1 IEC Mounting Foot Enclosure Accessory

2090-CPBM7E7-14AF15 MP-Series 15 m Length Cable

2093-PRS8S Kinetix 2000 8 Axis Slim Power Rail

CP9I-0MEB-0070-AZ Alpha 50HVis shielded motor power cable (7 meter)

GFK-0263 Logicmaster 90-70 Programming Software User's Manual

IC200UEX213 28 point expansion. (16) 12VDC In, (12) Relay Out, 12VDC Power Supply (included IC200CBL501)

IC647ANS001 PA new SFL allows 1 Production Unit in PA plant model to use 1 of the 11 server functions

IC647PDCH025 Ruggedized PDC Historian Base with 2500 Tags

IC693CHS392RR Base, Expansion, 10 Slots

IC754CSL06CTD 6 inch TFT QuickPanel Control/ Loaded/ 24VDC

KIT-GFS-351-CN QP View & Control Workshop Student Kit

SLC/1746 System D1746-UM010BENP BARREL TEMPERATURE CONTROL MODULE USER MANUAL