As an irreplaceable important equipment and means in advanced manufacturing, industrial robots have become an important indicator of a country's manufacturing level and technology level. According to relevant statistics, industrial robots are mainly used in the automotive industry and auto parts industry, accounting for 61% of the entire robot market, 8% of the metal products industry, 7% of the rubber and plastics industry and the electrical and electronics industry, respectively. 2%, other industries account for 15%.
However, there is no uniform standard in the classification of industrial robots, but welding robots, handling robots, painting robots, assembly robots, palletizing robots, and cutting robots are the top priorities.
1, welding robot
The welding robot is an industrial robot engaged in welding. According to the definition of the International Standards Organization (ISO) Industrial Robot Terminology Standard Welding Robot, the Industrial Robot is a versatile, reprogrammable Manipulator with three or more programmable axes for Industrial automation field. In order to adapt to different purposes, the mechanical interface of the last axis of the robot, usually a connecting flange, can be fitted with different tools or end effectors. The welding robot is to attach a welding tong or a welding (cutting) gun to the end shaft flange of an industrial robot, so that it can be welded, cut or thermally sprayed.
Welding robots have been widely used in the automotive industry, such as automotive chassis, seat frame, guide rails, mufflers and torque converters, especially in the production of automotive chassis welding. Toyota has decided to use spot welding as a standard to equip all spot welding robots in Japan and overseas. This technique can improve the quality of the weld and even attempt to replace some arc welding operations with it. The exercise time in a short distance is also greatly shortened. The company recently introduced a low-profile spot welding robot that uses it to weld lower parts of the car body. This short spot welding robot can also be assembled with higher robots to work together on the upper part of the body, thus shortening the length of the entire welding line. Domestically produced Santana, Passat, Buick, Sail, Polo and other rear axles, sub-frames, rocker arms, suspensions, shock absorbers and other car chassis parts are mostly force-safe parts based on MIG welding technology, the main components Adopting stamping and welding, the plate thickness is 1.5~4mm on average. The welding is mainly in the form of lap joints and angle joints. The welding quality requirements are quite high, and the quality of the steel directly affects the safety performance of the car. After the application of the robot welding, the appearance and internal quality of the welded parts are greatly improved, the quality stability is ensured, the labor intensity is reduced, and the working environment is improved.
2, painting robot
The spray robot, also known as the spraypainting robot, is an industrial robot that can automatically paint or spray other paints. It was invented in 1969 by Norwegian Trallfa (later incorporated into ABB Group). The painting robot is mainly composed of a robot body, a computer and a corresponding control system. The hydraulically driven painting robot also includes a hydraulic oil source such as an oil pump, a fuel tank and a motor. More than 5 or 6 degrees of freedom joint structure, the arm has a large movement space, and can do complex trajectory movement, the wrist generally has 2 to 3 degrees of freedom, flexible movement. The more advanced painting robot wrist uses a flexible wrist that can be bent and rotated in all directions. Its action is similar to that of a human wrist. It can easily penetrate into the inside of the workpiece through a small hole and spray the inner surface. The painting robot is generally driven by hydraulic pressure, and has the characteristics of fast action speed and good explosion-proof performance. It can be taught by hand teaching or point display. Painting robots are widely used in the production of automotive, instrumentation, electrical appliances, enamel and other processes.
The main advantages of the painting robot (1) are flexible. The scope of work is large. (2) Improve the quality of the spray and the rate of material use. (3) Easy to operate and maintain. Can be programmed offline, greatly reducing on-site debugging time. (4) High equipment utilization. The utilization rate of the painting robot can reach 90%-95%.
In order to pursue greater flexibility and higher efficiency in the spraying process, the automotive industry began to introduce robots instead of spraying machines in the 1990s, and began to use robots for automatic spraying of the inner surface. Compared with traditional mechanical spraying, robotic spraying has two outstanding advantages: it can reduce the number of spray guns by about 30% to 40%; and increase the speed of the spray gun movement.
In order to adapt to high-speed spraying, a high-speed rotary spray gun is used for the inner surface spray and the second layer of metal paint. The rapid development of the modern automobile industry has led to rapid changes in car models and constant adjustment of car body design. Only robots can adapt to this frequently changing production requirement. The role of the robot is to control the gun so that it maintains the correct angle and constant distance (typically 200 mm) from the painted surface during the spraying process. In order to achieve this task, engineers use specialized software to process the 3D model of the spray object to determine the path of the spray gun and the corresponding spray parameters. This data is then transmitted to the robot controller to control the movement of the robot throughout the spraying process. In general, such processing is only required in more complex and very precise spray processes. Today, with the increasing awareness of environmental protection, people say that the coating factory with good environmental protection effect is a “green factory†and the old-fashioned coating factory is a “brown factoryâ€. Whether it is a new green factory or a brown factory, it is necessary to establish a robotic automatic spraying production line. In the new factory, the rational use of funds is the most important principle, so reducing the investment in the spraying production line is a very important part. For factories that need to be retrofitted, how to properly introduce robots into existing coating lines, and the resulting costs are key issues. .
The design of the new generation of painting robots implements the principle of modular construction. The robot can be equipped with different connecting devices so that it can work either in a fixed manner or on a rail. The track can be attached to the side wall of the spray booth or it can be fixed close to the ceiling. If the spray gun of the spray robot is changed to the operation fixture, it becomes the robot that operates the door open because the drive systems of the two types of robots are the same. The robot's working arm can be moved in two or three axes. The two-axis robot works with a high-speed rotating gun to work in a rotationally symmetrical motion, which reduces one drive shaft, reduces weight and simplifies design. There are three main modes of robot painting:
The first is the dynamic/static mode, in which the spray is first transferred to the spray booth and remains stationary during the spray process.
The other is the flow mode, in which the spray passes through the spray booth at a constant rate. The robot can move in the dynamic/static mode, and the robot is stationary during the flow mode.
The third mode is the tracking mode, in which the spray passes through the spray booth at a constant speed, and the robot not only tracks the spray but also changes direction and angle depending on the spray surface. During the outer surface spraying process, the robot is placed on the movable rail and can freely approach the surface of the spray body, thereby reducing the operating space and reducing operating costs. In the retrofit of the old factory, if the old machine was replaced by a robot in this way, the original spray booth could be kept unchanged. This will reduce the cost of retrofitting and shorten the construction period. In the inner surface coating chamber, the tracks of different robots can be mounted in parallel up and down. The operating robot for opening the hood and the trunk lid is placed on a higher track so that it can "traverse" the painting robot placed on the lower rail to work. This solution can shorten the spray booth by 1 to 2 m, which can reduce construction investment and reduce operating costs. The robot's power supply, controller and safety system are installed in the control box outside the spray booth. Thanks to the modular design of the control box, it is easy to optimize the configuration for the actual coating process of the customer. In the advanced coating system produced by Dürr, multi-motion flexible control technology is adopted to integrate the control of the robot and the control of the spraying process, without the need to control the spraying process.
3, handling robot
The handling robot is an industrial robot that can perform automated handling operations. The earliest handling robots appeared in the United States in 1960, and the Versatran and Unimate robots were first used for handling operations. Handling is the process of holding a workpiece with one device, moving from one machining position to another. The handling robot can be equipped with different end effectors to complete the workpiece handling work in various shapes and states, which greatly reduces the heavy manual labor of human beings. At present, there are more than 100,000 handling robots in the world, which are widely used in the automatic handling of machine tools loading and unloading, automatic punching machine production lines, automatic assembly lines, palletizing and handling, and containers. Some developed countries have developed the maximum amount of manual handling, and the excess must be completed by the handling robot.
The handling robot is a high-tech in the field of modern automatic control. It involves mechanics, mechanics, electrical hydraulic pressure technology, automatic control technology, sensor technology, single-chip technology and computer technology. It has become a modern mechanical manufacturing system. An important part of it. Its advantage is that it can complete various expected tasks through programming, and has the respective advantages of human and machine in its structure and performance, especially reflecting artificial intelligence and adaptability.
4, assembly robot
The assembly robot is the core equipment of the flexible automated assembly system and consists of a robotic manipulator, a controller, an end effector and a sensing system. Among them, the structure types of the operating machine are horizontal joint type, rectangular coordinate type, multi-joint type and cylindrical coordinate type; the controller generally adopts multi-CPU or multi-level computer system to realize motion control and motion programming; the end effector is adapted to different The assembly object is designed into various claws and wrists; the sensing system acquires information about the interaction between the assembly robot and the environment and the assembly object.
The PUMA developed by Unimation Corporation of the United States in 1977 is a computer-controlled multi-joint assembly robot. There are generally 5 or 6 degrees of freedom, namely the rotation of the waist, shoulders, and elbow, as well as the bending, rotation and torsion of the wrist. Its control system consists of a microcomputer, a servo system, an input and output system, and an external device. Using VALII as the programming language, for example the statement "APPROPART, 50" means that the hand moves to 50 mm above the PART. The location of the PART can be typed or taught. VAL has the function of continuous trajectory motion and matrix transformation.
Assembly robots are mainly used in the manufacture of various electrical appliances (including household appliances such as televisions, tape recorders, washing machines, refrigerators, vacuum cleaners), small motors, automobiles and their components, computers, toys, mechanical and electrical products and their assembly.
5, palletizing robot
With the continuous development of China's economy and the rapid advancement of science and technology, robots have a wide range of applications in the industries of palletizing, gluing, spot welding, arc welding, painting, handling, and measurement.
There are many reasons, including the type of packaging, the factory environment, and customer needs, turning palletizing into a tough bone in the packaging factory. To overcome these difficulties, all aspects of palletizing equipment are evolving and improving, from robots to software that manipulates them. The demand for flexibility in the market is growing, and this trend has affected many aspects of packaging, and the latter part of the production line is no exception. Retail customers, especially those with influential supermarkets like Wal-Mart, often need to customize some random pallets, but they have to customize each pallet, and the pallets are only occasionally duplicated. And the efficient production of such random pallets is more difficult.
Palletizing robot features
1. Simple structure and few parts. Therefore, the failure rate of components is low, the performance is reliable, the maintenance is simple, and the required inventory parts are small. 2. Less floor space. Conducive to the layout of the production line in the customer's factory, and can leave a larger warehouse area. The palletizing robot can be placed in a narrow space for effective use. 3. Applicability is strong. When the size, volume, shape and shape of the customer's product change, it is only necessary to modify it on the touch screen without affecting the normal production of the customer. The mechanical palletizer change is quite cumbersome and even impossible. 4. Low energy consumption. Usually the power of a mechanical palletizer is around 26 kW, while the power of a palletizing robot is about 5 kW. Greatly reduce the operating costs of customers. 5, all control can be operated on the control cabinet screen, the operation is very simple. 6, just locate the starting point and the placement point, the teaching method is simple and easy to understand.
6, cutting robot
The cutting robot has the same cutting ability as the traditional CNC cutting machine, and realizes complete numerical control through graphic processing display and man-machine dialogue, which greatly changes the operation process of manual or semi-digital control in the past, which makes the operation more precise and the cutting quality is much higher. Traditional technology; at the same time, the machine itself is light in weight, as long as two people can lift up and move in the factory, no need for a fixed installation site, no need for a fixed operating area, automatic nesting, saving plates, and the price is far after being put into mass production. Lower than traditional products, and the cycle of results is short.
As the cost of labor continues to rise, industrial robots, as a new type of labor force, are quietly changing the manufacturing paradigm of manufacturing. Robotics and automation technology will “dominate†the world in the future, and this reality is accelerating. The current people-oriented production model will be gradually replaced by a robot-led model, which is increasingly attracting the attention of industrial companies with its high labor rate and low cost.
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