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工業(yè)機器人作為綜合性的高新技術產(chǎn)品，實現(xiàn)了數(shù)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(shù)字制造時代背景下，數(shù)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(chǎn)提供更為多元的的智能解決方案。基于此，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(jù)國際機器人聯(lián)盟 (IFR) 統(tǒng)計數(shù)據(jù)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(chǎn)業(yè)發(fā)展規(guī)劃中均提出，到 2020 年，實現(xiàn)我國自主品牌工業(yè)機器人年產(chǎn)量 10 萬臺。其中，六軸及以上工業(yè)機器人年產(chǎn)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(xiàn)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(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模鍛壓機組成。在此生產(chǎn)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(shù)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(shù)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(shù)控系統(tǒng)上的技術優(yōu)勢，實現(xiàn)可實現(xiàn)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(xiàn)閉環(huán)控制 [2,3]。在不同折彎速度下，工業(yè)機器人實現(xiàn)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(chǎn)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(chǎn)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(xiàn)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(chǎn)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(xiàn)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(chǎn)效率與產(chǎn)品質(zhì)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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2090-CSBM1DF-10AF20 Kinetix Cable Single DSL 2090-Series

20AC011A3AYYANC1 PowerFlex 70 AC Drive 20A

GA647TDV075 Proficy GlobalCare Assist for CIMPLICITY HMI Server 75 I/O Development and Runtime System

GP647IFPRDV00075 GCP iFIX Profsnl SCADA 75 I/O Dev

IC600BF946RR Loop Management Module (Proloop System)

IC647HSTCS10000KM Historian Enterprise Corporate Server 10,000,000 Points (M4 Key)

IC647TRT075 CIMPLICITY HMI Server 75 I/O Runtime System

IC693PWR321CA Conbal Coated Power Supply 120/240VAC, standard.

IC756MDV001K-98 DV Development - Alpha OpenVMS Addt'l User, Korean, Version 9.8

MicroLogix 1000/1761 System 1761-MMB MICROMENTOR BASICS BOOK FOR PROGRAMMABLE CTRLRS

PLC-5/1771 System 1771-NIS HIGH RESOLUTION ISOLATED ANALOG MODULE

Distributed I/O 1792D-CBFM MAXUM MEDIA BASE FOR KWIKLINK FLAT MEDIA

Communications 9351-SLRS INTERCHANGE FOR SOLARIS

Operator Interface D6190-6.5.28 CONTROLVIEW SCADA OPTION USER MANUAL

Support 9358-B30R SUPT REINSTATEMENT CONTRACT FOR 9358B30ENE

Support 9392-CDRSJPU UPGRADE TO ENGLISH/JAPANESE BUNDLE

RSI Software Products 9310-WE5200E RSLOGIX EMULATE 5

RSI Software Products 9301-2SE3500PTU4 RSVIEW32 RUNTIME 150-100K UPGRADE IN-SUPT (PT)

RSI Software Products 9356-STD2200 RSSQL STANDARD VERSION WITH 300 TAG LIMIT

Motion Control TL-A2540P-BJ34AA MOTOR, SERVO, 2.9NM, 5000RPM, 17BIT SERIAL FEEDBAC

44C741863-001 Cable, Alpha SVU Amplifier Battery Kit, 2 Meters,

IC200CHS012 I/O INTERPOSING BOX STYLE

IC694MDL654 INPUT MODULE 5/12 VDC (TTL) 32 POINT POS/NEG LOGIC

MSI-UNIV-WEB-50 Universal Web Client(RTIP / Dashboard / Web / Excel Addin) 50 Pak

VSPC32-SF5 VisualSPC ShopFloor includes Attribute Data Collection, Measurement Sy stems Analysis and A-681 interface cable. 5 license pack.

20BD040A3AYNANC0 PowerFlex 700 AC Drive 40 A at 30 Hp 20B

20G11JF1K4JN0NNNNN PowerFlex 755 AC Packaged Drive

22D-D017N104 PowerFlex 40P- 7.5 kW (10 HP) AC Drive

140NOM21100C Quantum MB+ 網(wǎng)絡適配器, 1MB, 1MB+, 單電纜, CC

290E-FAZ-G1 Direct Online Starter

MY3N 24VDC，110VAC，220VAC，3開3閉，觸點 5A LED燈

1492-SPM2C080 MCB Supplementary Protector 8 A

軟啟動器 3RW30271BB04

電機啟動器 3VU16403MG00

150-F201NBDD SMC Flex Smart Motor Controller

1732D-IBDPM12MND ArmorBlock 16 Point Input Block

1771-OR 1771 6 Point Digital Output Module

193-ED1EP E1 Plus 5.4-27 A IEC Overload Relay

199-FSMA2 Industrial Relay R-C Surge Suppressor

2090-CPWM7DF-08AA05 MP-Series 5m Standard Power Cable

2094-XL75S-C2 Kinetix 6000 Line Interface Module

EDS-205 Industrial 5-port Unmanaged 10/100 Switch (-10 to 60 deg c op temp)

GFK-1179 Installation Requirements for Conbance to Standards

IC220ACC002 MODULE LABELS WIDE, QTY 10

IC647BSU010 Batch Server Pak Upgrade (5 to 10 Units)

IC647PRTHE050C Proficy Portal Historian Edition Client Pack 50 Users (M1 Key)

IC693CPU363RR CPU363 Module (240K Bytes configurable user memory)

IC756ADV000J-98 DV Development - AIX Op Sys, Japanese, Version 9.8

MSI-EFF-5 Efficiency Management Clients 5 Pack

SLC/1746 System 1746-RT25C REPLACEMENT TERMINAL BLOCK (ORANGE)

Distributed I/O 1738-IB2M12 24VDC 2 SINKING INPUTS WITH M12 CONNECTORS

Application-specific products 9307-RSPRTD RSPOWER RT FOR AB PM1 PM2 POWER MONITORING DEVICES

Operator Interface 2711-NF7 FUNCTION KEY STRIP PV300 KEY

Support 9302-PCOS SUPT RENEWAL CONTRACT FOR 9302PCO

Support 9510-PPKENS SUPT RENEWAL CONTRACT FOR 9510PPKEN

DeviceNet Products 1787-TCABL T-STYLE CABLE FOR 1770-KFD 6 FT (1.82 METERS)

RSI Software Products 9301-2SE3350ZHU3 RSVIEW32 RUNTIME 1500-5K UPGRADE IN-SUPT (ZH)

RSI Software Products 9326-AD10WDENE WIRING DIAGRAM GENERATOR ADD-ON 10 USER

Motion Control MPG-A004-091M24 MOTOR,SERVO,GEAR RATIO 91,15NM,66RPM,MULTI,BRK

Silver Series 1756-M2 LOGIX5550 1MBYTE EXPANSION MEMORY

HE693IBS313 Interbus-S slave module for Series 90-30 autoconfiguring CPU313 rack.

IC655MDL524RR Input Simulator Module, 16 or 32 Points Switch Selectable

QPI31200S2P QUICKPANEL COLOR 10.5" STN

ST-4622 STXi analog output module 2 Channels, 0~5Vdc, 12-bit

20BC170A3ANNACC0 PowerFlex 700 AC Drive 20B

20F1AGC367JN0NNNNN PowerFlex 753 AC Packaged Drive

22A-V6P0N104 PowerFlex 4- 1.1 kW (1.5 HP) AC Drive

140DAI74000 Quantum 開關量 AC 輸入, 16點, 48 VAC, 隔離

284D-FVD2P3D-10-CR-EMI DeviceNet Variable Frequency Drive

E3JK-T11 5m,分離式,明通，NPN晶體管輸出100mA，電源:10-30VDC

1492-SJ5-10 IEC Side Jumper, 10 PL 5mm

人機界面 6ES7810-5CC08-0YA5 "STEP7 V5.3 專業(yè)版 2004?SP1"