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A20B-8001-0970,

A20B-8001-0970

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(lèi)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(chē)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(chē)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(chē)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(chē)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(lèi)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(lèi)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(mǎn)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(zhuān)門(mén)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(lèi)設(shè)備形成板材柔性加工線，包括真空吸盤(pán)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(pán)，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(lèi)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(zhuān)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(zhuān)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(lèi)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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1492-PD3C2127 760 A Power Distribution Block

中央處理單元 6ES7414-2XG04-0AB0 CPU414-2，512KB，60ns，電源 24VDC，MPI/PROFIBUS-DP 主站接口

變送器 3RS17061FD00

TIA 博途數(shù)字化選件 6ES7823-1EA00-0YA5 TIA Portal Teamcenter Gateway V1.0

1585J-M8TBJM-1M9 RJ45 Ethernet Media

1761-CBL-AC00 MicroLogix Cable

188-K3B130 Miniature Circuit Breaker 13 A

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

2090-CPBM4DF-16AF07 MP-Series 7m Length Cable

2090-XXNFMF-S07 Kinetix Drives 7m Standard Cable

BC647OEM0410 OEM Edge Program Additional Key - Historian (Approval Required)

GC647PATASD0 Proficy PAT - Driver For ASD - Assist Support

IC200MDD843 Mixed 24VDC POS LOG b group 10 point / relay output 2 amp output 6 point.

IC646NPG000 Pager

IC647MB1C MB1:Modicon Modbus I

IC670PBI001 Profibus Bus Interface Unit, DP 12M Baud

IC697MDL654 48 Vdc Input, Positive/Negative Logic (32 Points)

IC800SLMCONKITZ Connector kit for 30 Watt to 750 Watt S-series servo motor without brake

ControlLogix/1756 System 1751-SLBP SYNCHLINK FIBER BYPASS SWITCH BLOCK

Industrial Computers 6182H-15BEH4D VVCE 1500, KEY/TOUCH, EXT MEM, ENET, DC

Process Control 1757-DNBEXP02 DEVICENET MODULE EXPANSION, 1-2 MAX

Operator Interface 2711P-ST15T PANELVIEW PLUS 1500 TOUCH STARTER KIT

Support 9326-AD10UR SUPT REINSTATEMENT CONTRACT FOR 9326AD10UENE

Support 9371-EDDL2S SUPT RENEWAL CONTRACT FOR 9371EDDL2

ControlNet Products 1734-TB3SQ10 TEN 12-POSITION IP20 SPRING TERNIMAL BASES

RSI Software Products 9301-2SE240FRU3R RSVIEW32 WORKS 150-32K UPGRADE OUT-SUPT (FR)

RSI Software Products 9358-B60U1R UPGRADE: OUT-SUPT: RSBIZWARE BATCH 03 TO 60

Motion Control MPL-A430P-MK22AA MOTOR,SERVO,5.42 NM,5000RPM,MULTI,230V,6.4KG

Motion Control 2090-UXNFDN23-K09 CABLE,ULTRA,NON-FLEX, MOTOR FEEDBACK,N,SKW,9M

CBL-15-MP-10 Power Cable, MTR-1Nxx SPLASHPROOF Stepping Motors, 10 Ft.

IC610MDL185RR U.L. Listed 115Vac Output (6 points)

IC800SLCEV050 Encoder Cable, 1000 W SL Servo Motor, 5 Meters

OC647IFINTTKTC iFIX Optn: Integration Toolkit (M1Component Part)

20AD5P0A0AYNANC0 PowerFlex 70 AC Drive 5 A at 3 Hp 20A

20DD022A0EYYANANE PowerFlex 700S AC Drive 20D

20P41AB146RA0NNN PowerFlex DC Drive 230V AC 40 HP

2711-NV6K PanelView Accessory

280-PWRM24A-M6 ArmorStart Three-Phase Power Media

SRM1-C02-V2 主單元，輸入：128點(diǎn), 輸出：128點(diǎn)帶RS-232C口，電源：DC24V

1492-MCAA320 20 A UL489 Miniature Circuit Breaker

1494V-DH622-A-D NEMA Flange Mtd Rod Switch Disconnect Sw

軟啟動(dòng)器 3RW44562BC36

工程組態(tài)編程軟件 6AV2103-0AA04-0AA7 SIMATIC WinCC 專(zhuān)業(yè)版 V14, 試用授權(quán)

1585D-M4UBJM-25 Ethernet Media M12 Patchcord

1756-L65 ControlLogix 32 MB Memory Controller

1797-TPYS FlexEx Accessories

194E-FA00E-P11 194E Load switch

2090-CFBM6DF-CBAA05 TL-Series 5m Feedback Cable

2090-SCNP15-0 Kinetix 15-15m Fiber Optic Cable

BC646MPH010 Logic Developer PDA 10 Pack Liscense with SAFE

GC647AEC050 GC Efficiency Client 50 Pak

HMI-CAB-C91 CABLE MITSUBISHI SERIES A, FX, FX0

IC641SWP719 C Toolkit for Series 90 (Professional)

IC647IFCLNTSRO100C iFIX iClientTS Read Only 100 PK (M1Component Part)

IC660EBD101RR 115Vac Low Leakage, 8 Ckt, Electronic Assembly

IC695STK003 RX3i Power PACkage 3 Starter Kit includes RX3i(CPE305)/ motion module (Servo andAmplifier sold seperaby) and QuickPanel View 6 inch STD wi th software

IC756WRE099K-99 DataViews Runtime for Windows 50-99, Per User, Korean, Version 9.9

FlexLogix System 1794-OV16P FLEX I/O 24VDC SINK OUTPUT MODULE, PROTECTED, 16PT

PLC-5/1771 System D1785-7.1 1785 PLC5 PROGRAMMABLE CONTROLLERS QUICK REFERENCE

Process Control 1757-PLXSR50 PLX 50 POINT REDUNDANT SERVER LICENSE

Operator Interface 2711P-T10C15D1 PV PLUS 1000, TOUCH, CNET, DC PS, STD MEM

Support 1787-MGRS SUPT RENEWAL CONTRACT FOR 1787MGR

Support 2707-NP3R SUPT REINSTATEMENT CONTRACT FOR 2707NP3

Support F1785-L40LSERD FIRMWARE UPGRADE FOR 1785-L40L PLC5 PROCESSOR MODU

RSI Software Products 9301-2SE2303ITE RSVIEW32 WORKS 1500 WITH RSLINX (ITALIAN)

RSI Software Products 9701-VWSS000ENU1 RSVIEWSE 25 TO UNLIMITED DISPLAY UPGRADE IN-SUPT

RSI Software Products 9399-RL53GRPT RSLOGIX 5 GETTING RESULTS GUIDE (PORTUGUESE)

Motion Control 1394C-SJT05-D MODULE,SYSTEM,5KW,SERVO,W/SERCOS INTF.NO HIM

BC646MDE159 Logic Developer - PC & View Development/Runtime (HRT) 1,500 I/O

IC300OCS047 14 AC Inputs (120vac), 10 Relay Outputs (3.0A ea)

IC752WBB203 Display Station 2000 Series - 12.1" active matrix SVGA (800x600) resistive touch screen with integrated keypad, Pentium 233 MHz, 64 MB RAM, 6 GB HD, expansion slots, Ethernet, with unlimited point count CIMPLICITY HMI R&D and Win 95

MTR-3T13-G-R-B-M-S MTR series metric servo motor with resolver and brake and shaft seal

ZA06B-6130-K203 CX29 MCC contact connector for BSVM1-20i or BSVM1-40i Beta i series amplifier

20D-DL2-CKE1 PowerFlex 700S DriveLogix Kit

20G1AGC367JN0NNNNN PowerFlex 755 AC Packaged Drive

25A-E4P2N104 PowerFlex 523 2.2kW (3Hp) AC Drive

2711P-T7C22A9P-B PanelView Plus 7 Graphic Terminal

6SE6440-2UD41-6GB1 160KW

1492-L3 IEC Term Blck 5.1x59.5x31.3mm Spr Clp

1492-XIMTS2024-16R Solid State Relay Dgtl Interface Module

軟啟動(dòng)器 3RW44253BC35

附件 6ES7 590-1AJ30-0AA0 S7-1500 安裝導(dǎo)軌：830 mm

1585-C8UB-S300 Cable Spool Ethernet Media

1746-RT25G SLC Replacement Terminal Block

1790D-0W6 CompactBlock LDX Output Block

194E-A25-1753-6N 25 A 194E Load switch

20-PP11005 RECTIFIER - DC LINK CABLE

2090-CSBM1DF-18AF06 Kinetix Cable Single DSL 2090-Series

20AC043A3AYNANC0 PowerFlex 70 AC Drive 43 A at 22 kW 20A

GC646IFCLNTCRO025 GCC iFIX iClient Read Only 50 PK Keyless Runtime Version

HE660SER211 Discontinued Part. Check with GE IP on migration path.

IC600LX605RR 4K Logic/1K Register Memory Module

IC647HSTES5KM Historian Enterprise Server 5000 Points (M4 Key)

IC655APU500RR ASCII/Basic Module, 32K

IC694CHS398 Base Expansion 5 Slots

IC756SDV001J-97 DV Development - Solaris Op Sys Addt'l User, Japanese, Version 9.7

MicroLogix 1500/1769 System 1764-28BXB ML 1500 BASE DC IN / DC FET & RELAY OUT / DC POWER

PLC-5/1771 System 1771-CPR FIBER OPTIC CABLE COUPLER

Distributed I/O 1794-VHSC 2-CHANNEL 1 MHZ VERY HIGH SPEED COUNTER

Communications 9399-WABOUGDE RSLINX OEM USERS GUIDE (GERMAN)

Support 9310-2CV5S SUPT RENEWAL CONTRACT FOR 93102CV5

Support 9358-BRE01S SUPT RENEWAL CONTRACT FOR 9358BRENT01ENE

Support F1771-KGSERA FIRMWARE UPGRADE FOR 1771-KG COMMUNICATION MODULE

RSI Software Products 9324-RLD0U7DEE RSLOGIX 5000 SERVICE ED TO PRO UPG, DEU

RSI Software Products 9301-2SE350ZHU2R RSVIEW32 RUNTIME 1500-100K UPGRADE OUT-SUPT (ZH)

RSI Software Products 9358-MTRCK03U1R UPGRADE: OUT-SUPT: RSBW MATERIALTRACK 1 TO 10

Motion Control 8720SM-018S2FBS3 18.5 KW/47.1 AMP,460 VAC, AC MOTOR WITH SNS60 ENC.

840-RC-04 4" Ribbon Cable. Term Both Ends W/16 Pin DIP Plugs

IC200MDL742 OUTPUT 24VDC POS LOGIC 0.5A PER PT (2 GROUPS OF 16) W/ESCP 32PT

IC697VAL264 Analog Input, 64 Channel, jumper selectable for 0 to 5VDC, 0 to 10VDC, +/-2.5VDC, +/-5VDC, +/-10VDC. 16 bit resolution.

MTR-1331-J-E-D-E-0RR Stepping Motor Nema34 Encoder

ZA06B-0061-B203#0100 B2/4000is Servo Motor with Straight Shaft, Key and IP67 Sealing

20BD125A3AYNANC0 PowerFlex 700 AC Drive 20B

20G11ND096AA0NNNNN PowerFlex 755 AC Packaged Drive

22F-RF9P5-AL PowerFlex 4M EMC Filter Kit

140CFC03200 Quantum CABLEFAST, 數(shù)字輸出塊, 成組保險(xiǎn)

294E-FD2P5P-G1 Variable Frequency Drive

WLCA32-43 觸點(diǎn):1開(kāi)/1閉,10A 250VAC機(jī)械壽命:1500萬(wàn)次?撞壓式?叉式擺桿鎖定型

1492-SPM3B300-N MCB Supplementary Protector 30 A