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工業(yè)機器人作為綜合性的高新技術產品，實現了數字控制、驅動制造、精密傳動與 IT、傳感和信息等技術的有效集合。而在當前數字制造時代背景下，數控技術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)生產提供更為多元的的智能解決方案�；�于此，文章立足于當前工業(yè)機器人與金屬成形機床集成的常見應用類型，分析了其主要形式。進而探討了二者集成應用中存在的問題，并提出了相應發(fā)展途徑。

關鍵詞 ：工業(yè)機器人 ；金屬 ；成形機床 ；集成應用
當前，我國已成為全球最大的工業(yè)機器人市場。據國際機器人聯盟 (IFR) 統(tǒng)計數據顯示， 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年機器人產業(yè)發(fā)展規(guī)劃中均提出，到 2020 年，實現我國自主品牌工業(yè)機器人年產量 10 萬臺。其中，六軸及以上工業(yè)機器人年產量超過 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)也在逐步轉型升級。近年來，在先進技術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)機器人應用的主要領域，受消費者自動化需求的提升，進一步擴大了工業(yè)機器人的應用范圍。包括除焊接外的其他大部分領域，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，應用其進行激光切割已成為激光切割與工業(yè)機器人應用領域的主要熱點。在工業(yè)機器人手臂中集成激光束引導裝置，當工業(yè)機器人跟蹤工件輪廓的同時，激光束也在工作，從而實現切削。此類型應用的主要特點包括 ：工業(yè)機器人運動靈活、柔性高 ；激光切割質量好、速度快且切縫窄，極大地滿足了現代制造業(yè)的發(fā)展需要。

1.2 熱模鍛集成

熱模鍛生產線通常由切邊與沖壓兩臺模鍛壓機組成。在此生產線上，工業(yè)機器人集成應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 數控折彎機集成

工業(yè)機器人折彎集成應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備或數控轉臺沖床等 ；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)和機床數控系統(tǒng)上的技術優(yōu)勢，實現可實現二者的無縫連接。進而開發(fā)出折彎軟件包，對折彎過程中工業(yè)機器人托料實現閉環(huán)控制 [2,3]。在不同折彎速度下，工業(yè)機器人實現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用的主要形式

工業(yè)機器人在金屬成形機床中的應用領域較為廣泛，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用的主要形式如下。

第一，二者集成柔性生產線。此種形式中，工業(yè)機器人承擔的工作任務是轉換工件工序，并與多臺金屬成形機床組成柔性生產線。其較某種單機上下料更為復雜，價值也更高。在當前工業(yè)轉型升級時代背景下，市場需求的旺盛程度不斷增加。因此，現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、速度快且準確。工業(yè)機器人與金屬成形機床的結構關系可分為兩種形式，即與金屬成形機床構成一體和工業(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、準確，可以大幅提升提高生產效率與產品質量，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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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

PCI-6034E

GPC-8450-LA-SH

TCM-MC2-v89.80

X8DTL-3F

ADM-682

MB820S

1492-KWC IEC Wire Cutting Tool

1492-XIM20120-8R Connection Products

軟啟動器 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 Conformal 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

ExpressCard-8420/2

HSC-1462CLDN

UDIOCODES TRUNKPACK-100

ESX180

WY580-T4

NOVA MC8043P

MELEC 運動控制卡 C-871

1492-SPM3B100 MCB Supplementary Protector 10 A

軟啟動器 3RW40271BB04

電機啟動器 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