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A06B-0856-B100,

A06B-0856-B100

工业机器人作为综合性的高新技术产品，实现了数字控制、驱动制造、精密传动与 IT、传感和信息等技术的有效集合。而在当前数字制造时代背景下，数控技术与人工智能推进了工业机器人与金属成形机床的迅速融合。并通过高效组合形成了自动化极强的集成单元，可以为工业生产提供更为多元的的智能解决方案。基于此，文章立足于当前工业机器人与金属成形机床集成的常见应用类型，分析了其主要形式。进而探讨了二者集成应用中存在的问题，并提出了相应发展途径。

关键词 ：工业机器人 ；金属 ；成形机床 ；集成应用
当前，我国已成为全球最大的工业机器人市场。据国际机器人联盟 (IFR) 统计数据显示， 2015 年，我国工业机器人的用量共为 6.7 万台，已成为全球工业机器人的第一大市场。并且，我国先后发布的《中国制造 2025》、2016-2020年机器人产业发展规划中均提出，到 2020 年，实现我国自主品牌工业机器人年产量 10 万台。其中，六轴及以上工业机器人年产量超过 5 万台。在工业机器人制造业不断发展的同时，我国装备制造业也在逐步转型升级。近年来，在先进技术进步与市场需求多元化的双重作用下，考虑用工业机器人代替人力劳动的企业逐渐增多。而长期以来，汽车制造行业作为工业机器人应用的主要领域，受消费者自动化需求的提升，进一步扩大了工业机器人的应用范围。包括除焊接外的其他大部分领域，如汽车机床喷涂、打磨、物料搬运码垛、上下料与装配等。在机床工具的组成部分当中，金属成形机床所处的位置即为重要。其成形加工中通常伴有金属粉尘、噪声污染、高温高湿与高劳动强度等，工作对工作人员身体健康的伤害程度较大，且简单枯燥，因此企业招工较为困难。而将工业机器人与金属成形机床相集成，既能有效提高汽车加工的精度、安全性与工作效率，又可以解决企业用工难问题，发展空间较大。由此，需对工业机器人与金属成形机床集成应用进行研究，为汽车制造业发展提供借鉴 [1]。

1 、工业机器人与金属成形机床集成的应用类型

1.1 工业机器人的激光切割

工业机器人定位精度高，因此，应用其进行激光切割已成为激光切割与工业机器人应用领域的主要热点。在工业机器人手臂中集成激光束引导装置，当工业机器人跟踪工件轮廓的同时，激光束也在工作，从而实现切削。此类型应用的主要特点包括 ：工业机器人运动灵活、柔性高 ；激光切割质量好、速度快且切缝窄，极大地满足了现代制造业的发展需要。

1.2 热模锻集成

热模锻生产线通常由切边与冲压两台模锻压机组成。在此生产线上，工业机器人集成应用通常会配置两台机器人，一台用于将中频处理后的高温物料，移送至冲压成型模锻压机 ；另一台负责从冲压成型模锻压机取料后，移送至另一台模锻压机进行切边。为了避免模具被粘附与高温冲压工件上，每次冲压后需用石墨对模具进行润滑。而此过程处于高温高湿环境中，既可由专门机构操作，又可由工业机器人完成。如由后者进行，可以大幅提升系统安全性于加工效率。但需做好机器人的维护工作，提升其抗热、抗辐射的能力。

1.3 数控折弯机集成

工业机器人折弯集成应用可分为两种主要方式，一是工业机器人与金属成形机床中的各类设备形成板材柔性加工线，包括真空吸盘抓手、定位台、板料传输线、工业机器人行走轴与激光设备或数控转台冲床等 ；二是工业机器人以折弯机为中心，配置真空吸盘，磁力分张上料架、定位台、下料台、翻转架形成折弯单元。制造商利用自身在工业机器人控制系统和机床数控系统上的技术优势，实现可实现二者的无缝连接。进而开发出折弯软件包，对折弯过程中工业机器人托料实现闭环控制 [2,3]。在不同折弯速度下，工业机器人实现了自动匹配的完全跟踪，使折弯示教实践叫从前缩短十倍。

2、 工业机器人与金属成形机床集成应用的主要形式

工业机器人在金属成形机床中的应用领域较为广泛，包括码操、搬运、焊接与装配等，但一般被作为辅机使用。目前，工业机器人与金属成形机床集成应用的主要形式如下。

第一，二者集成柔性生产线。此种形式中，工业机器人承担的工作任务是转换工件工序，并与多台金属成形机床组成柔性生产线。其较某种单机上下料更为复杂，价值也更高。在当前工业转型升级时代背景下，市场需求的旺盛程度不断增加。因此，现场条件与工艺路线等因素对金属成形机床的布局起着决定性因素。常见类型包括对面布置型、有直线型、U 型和 L 型等。其中，由三台金属成形机床构成的 U型布局，主要由一台工业机器人在场地中间进行工件转换，布局特别紧凑。

第二，单机上下料。此种形式中，工业机器人在金属成形机床中的应用最为成熟与典型。其对需要吊装的笨重工件，以及加工时间短且生产批量大的中小零件加工来说，明显优势是比人工上下料更为安全、速度快且准确。工业机器人与金属成形机床的结构关系可分为两种形式，即与金属成形机床构成一体和工业机器人安装于机床外部。其中，后者又可分为衔架式、移动式和固定式等 [4]。

第三，独立完成加工工序。此种形式中，为工业机器人装上专用手爪，其便可完成机床清洗、抛光、切割与打磨等工艺。甚至可以直接夹持切削工具，对工件进行切削加工、铆接、攻丝与打孔等。此外，可将其用于高温环境下，进行人工难以直接完成的工作，包括更换热态模具、上下热毛坯、浇注、机械锻造与铸造与取铁液等。在此情形下，工业机器人本身便可视为一台金属成形机床。并且，具备触觉与视觉的工业机器人，可以被用于复杂工序中，如零件分选、上下料与组装等，且无需携带专用工位器具。

第四，共同完成加工工艺。此种形式中，工业机器人在冲剪、折弯机上夹持工件，从而实现加工操作。此工作不仅是简单的上下料，而是替代全部的传统人工作业。此形式的主要优势是较人工操作更为快速、准确，可以大幅提升提高生产效率与产品质量，甚至有利于彻底解决冲压类机床工作中的工伤隐患。

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Motion Control 2090-UXNPAMP-8S09 CABLE, 230V,NON-FLEX,MOTOR POWER,MP,8 GAUGE,9M

CBL-30-BT-10 Brake Cable, MTR-3S & MTR-3T Series Servo Motors with Brake, 10 Ft.

IC640HWP310 Series 90 Workstation Intf. (XT/AT) w/LM 90-30/20 Serial

IC800SLCPVL100 Power Cable, 3500W and 5000W SL Servo Motor, 10 Meters

OC647IFXPESPC-50 iFIX for Embedded XP SPC Blocks Option V5.0

20AD8P0A0AYNANC0 PowerFlex 70 AC Drive 8 A at 5 Hp 20A

20DD034A0EYNANANE PowerFlex 700S AC Drive 20D

20P41AD027RA0NNN PowerFlex 460V AC 15 HP DC Drive

2711C-T4T PanelView Component 4-Inch Terminal

NT631C-ST141(B)-EV1 彩色STN LCD 分辨率：640×480点,8色 11.3英寸.

1492-MCBA2H50 50 A Ul489 Miniature Circuit Breaker

1494V-DJ644-A-B-D-E-F NEMA Flange Mtd Rod Switch Disconnect Sw

软启动器 3RW44576BC34

运行版软件 6AV2102-4AA04-0AE5 SIMATIC WinCC Advanced V14 Upgrade WinCC flexible 2008 Advanced -> WinCC Advanced V14 Combo

1585D-M8UGDM-20 Gigabit Ethernet Media

1756-L73SXT Logix 5573SXT Automation Controller 8/4M

1799-D16U16VL 32 Point Embedded I/P/Output Comb Module

194E-FA20E-PD10-TN 194E Load switch

2090-CFBM7DD-CEAA09 MP-Series 9m Servo Feedback Cable

2090-SCVP25-0 Kinetix 25-25m Fiber Optic Cable

BC646MPPU01 Logic Developer PLC Professional Upgrade with Proficy GlobalCare Complete

GC647AQC001 GC PA Quality Client

HMI-CCT-405 Backlight for the 12.1 inch Color TFT (QPLCxxE0000)

IC641VPS300 VersaPro Standard Edition - Windows Programming Software for Series 90 -30 and VersaMax PLCs

IC647IFPLDV00075K iFIX Plus SCADA 75 I/O Development (M1 Kit Part)

IC660EBS103RR 115Vac/125Vdc Low Leak Isol I/O, w/o Failed Sw Diag, Elec Asm

IC697ACC726 Top PWA Cover, CPU-Style, (Quantity 6)

IC756WRJ049J-27 Runtime License Windows 25-49 Users Japanese v2.7

FlexLogix System 1794-OF4I ISOLATED ANALOG OUTPUT MODULE, 16 BIT, 4 POINT

PLC-5/1771 System D6200-6.4.6RU PLC5 PROG. SW CONFIG.& MAINTENANCE MNL (RUSSIAN)

Process Control 1757-UPGNG PLX SERVER BATCH REPORT UPGRADE

Operator Interface 2711P-B12C4B1 PV PLUS 1250, KEY/TOUCH, ENET, AC PS, STD MEM

Support 6001-F2ES SUPT RENEWAL CONTRACT FOR 6001F2E

Support 2711-ND2DES SUPT RENEWAL CONTRACT FOR 2711ND2DE

Support F1785-L60CSERD FIRMWARE UPGRADE FOR 1785-L60C PLC5 PROCESSOR MODU

RSI Software Products 9301-2SE230JPU1R RSVIEW32 WORKS 300-1500 UPGRADE OUT-SUPT (JP)

RSI Software Products 9701-VWSS025LENE RSVIEW SE SERVER 25 W/RSLINX ENTERPRISE

RSI Software Products 9399-RSRGR RSRULES GETTING STARTED GUIDE

Motion Control 1394C-SJT22-C MODULE,SYSTEM,22KW,IMCS,NO RIO,NO AXIS,LI

BC646MPP005 Logic Developer - PLC Standard Bundled 1 Year SAFE - 5 Pack

IC300OCS072 OCS with 2x20 LCD Display and with 16-key keypad. Built in I/O no expansion. 16 DC Inputs (12/24vdc), 12 DC Outputs (5/12/24vdc, 0.5A neg. logic with ESCP). With CAN network interface

IC752WFC575 CONTROLSTATION DS2050 15" 566MHz/128MB RAM WNT

MTR-3T23-G-R-B-M-SRR Servo Motor Metric 24V Brake, Seal