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A16B-1210-0140,

A16B-1210-0140

工業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，并提出了相應發展途徑。

關鍵詞 ：工業機器人 ；金屬 ；成形機床 ；集成應用
當前，我國已成為全球最大的工業機器人市場。據國際機器人聯盟 (IFR) 統計數據顯示， 2015 年，我國工業機器人的用量共為 6.7 萬臺，已成為全球工業機器人的第一大市場。并且，我國先后發布的《中國制造 2025》、2016-2020年機器人產業發展規劃中均提出，到 2020 年，實現我國自主品牌工業機器人年產量 10 萬臺。其中，六軸及以上工業機器人年產量超過 5 萬臺。在工業機器人制造業不斷發展的同時，我國裝備制造業也在逐步轉型升級。近年來，在先進技術進步與市場需求多元化的雙重作用下，考慮用工業機器人代替人力勞動的企業逐漸增多。而長期以來，汽車制造行業作為工業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，因此企業招工較為困難。而將工業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，又可以解決企業用工難問題，發展空間較大。由此，需對工業機器人與金屬成形機床集成應用進行研究，為汽車制造業發展提供借鑒 [1]。

1 、工業機器人與金屬成形機床集成的應用類型

1.1 工業機器人的激光切割

工業機器人定位精度高，因此，應用其進行激光切割已成為激光切割與工業機器人應用領域的主要熱點。在工業機器人手臂中集成激光束引導裝置，當工業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的發展需要。

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境中，既可由專門機構操作，又可由工業機器人完成。如由后者進行，可以大幅提升系統安全性于加工效率。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

工業機器人折彎集成應用可分為兩種主要方式，一是工業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、工業機器人行走軸與激光設備或數控轉臺沖床等 ；二是工業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機器人控制系統和機床數控系統上的技術優勢，實現可實現二者的無縫連接。進而開發出折彎軟件包，對折彎過程中工業機器人托料實現閉環控制 [2,3]。在不同折彎速度下，工業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、 工業機器人與金屬成形機床集成應用的主要形式

工業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，明顯優勢是比人工上下料更為安全、速度快且準確。工業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，可將其用于高溫環境下，進行人工難以直接完成的工作，包括更換熱態模具、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人工作業。此形式的主要優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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Motion Control 2090-UXNPBMP-14S01 CABLE,460V,NON-FLEX,MOTOR POWER,MP,14 GAUGE,1M

CBL-3C-MP-10 Power Cable, MTR-3S43-G, MTR-3S45, MTR-3S46, & MTR-3S6x-G Series Servo Motors, 10 Ftl

IC641CTL904 CIMPLICITY Control Professional Offline Developer Kit

IC800SLM020N1XE25 200W, 115 VAC SL Servo Motor, Holding Brake, 2.5K Quad Encoder

OC647IPWRSTDVUNLMTM iPower Option - Std Unlmt I/O Dev

20AD8P0A3AYYNNC0 PowerFlex 70 AC Drive 8 A at 5 Hp 20A

20DD065A0NYNANANE PowerFlex 700S AC Drive 65 A 50 Hp 20D

20P41AD250RA0NNN PowerFlex 460V AC 150 HP DC Drive

2711P-B12C4A8 PanelView Plus Terminal

280-PWRM24H-M1 ArmorConnect 3-PH Power Media drop cable

MPT002-G2R-V1 單色LCD 160*32兩行帶RS232端口

1492-MCBA3A0 100 A UL489 Miniature Circuit Breaker

1494V-DSX100 Disconnect Switch

軟啟動器 3RW44586BC35

運行版軟件 6AV2103-0DA00-0AM0 SIMATIC WinCC 專業版 512 PowerTags (Compact Edition)

1585D-M8UGJM-40 Gigabit Ethernet Media

1756-M02AS ControlLogix Analog SSI Motion Module

180040-A01 KIT BUS CONTROL CARD

194E-FA40E 194E Load switch

2090-CFBM7DD-CEAF07 Kinetix 7m Flexible Cable

2090-U3BB-DM12 Ultra 3000 Breakout Board Kit

BC646MRA000 View Runtime 8000 I/O with Proficy GlobalCare Complete

GC647ARC050 GC Reporting Client 50 Pak

I5T/2 Proficy Process Systems Tuning Tools from ControlSoft for 10 Loops

IC646APS30005 CSense Predictive Soft Sensor 5 KPI's

IC647IFPLRN00075C iFIX Plus SCADA 75 I/O Runtime (M1Component Part)

IC660HHC005 Hand-Held Monitor Cable

IC697ACC805 I/O Cable (64 conductor) for IC697Vxxxxx modules. Ten feet long

IC756XDV010E-925 "DV-Draw Development on Solarisx86 Op Sys, English v9.25"

FlexLogix System 1794-TB3S FLEX I/O TERMINAL BASE WITH SPRING CLAMPS

GuardPLC Systems 1753-L28BBBM GUARDPLC 1600 - SAFETY PLC W/MODBUS, 28 I/O

Process Control 1757-UPGSIFG UPGRADE HW UDC 3000/5000/6300 QUICKBUILDER I/F

Operator Interface 2711P-K12C4D1 PV PLUS 1250, KEYPAD, RIO/DH, DC PS, STD MEM

Support 6008-SQS1S SUPT RENEWAL CONTRACT FOR 6008SQS1

Support 1400-SPR 1400-SP SOFTWARE SUPPORT REINSTATEMENT

Support F1785-L80C15SERE FIRMWARE UPGRADE FOR 1785-L80C15 PLC5 PROCESSOR MO

RSI Software Products 9301-2SE2350ESE RSVIEW32 WORKS 5K (SPANISH)

RSI Software Products 9701-VWSS250AJPE RSVIEW SE SERVER 250 DISPLAY (JAPANESE)

RSI Software Products 9399-WAB32CSDKPG RSLINX C SDK PROGRAMMER'S GUIDE

Motion Control 8720MC -B042-AA- 42 AMP B CHASSIS DRIVE, ENCLOSURE, LESS OPTIONS

BC646MPSS99 Logic Developer - PLC Standard Unlimited Seat Site License