Industrial robot is an important automation equipment in modern manufacturing industry, which integrates multi-disciplinary advanced technologies such as machinery, electronics, control, computer, sensor and artificial intelligence. It involves many cutting-edge disciplines such as mechanical engineering, electrical engineering, microelectronics engineering, computer engineering, control engineering, information sensing engineering, acoustic engineering, bionics and artificial intelligence engineering. Industrial robot is a branch of robotics, which represents the highest achievement of mechatronics. With the continuous development of science and technology, industrial robots have become automatic tools for flexible manufacturing systems (FMS), automatic chemical plants (FA), and computer integrated manufacturing systems (CIMS). The wide use of industrial robots can not only improve the quality and quantity of products, but also have great significance in ensuring personal safety, improving the labor environment, reducing labor intensity, improving labor productivity, saving raw material consumption and reducing production costs, and promoting the rise of China's manufacturing industry.
The development of industrial robots in the world:
In 1962, AMF Company of the United States manufactured the world's first practical teaching and reproducing industrial machine passer-by. So far, the research, development and application of industrial robots in the world has gone through more than 50 years. Industrial robot products in Japan, the United States, France and Germany have become increasingly popular and perfect. With the rapid development of modern technology. Industrial robot technology has been widely used in various production cities. The industrial robot born in the manufacturing industry is a new generation of production tools, which has emerged after the power machine and computer, and comprehensively extends human physical strength and intelligence. The application of industrial robots is an important symbol of a country's industrial automation level. In foreign countries, industrial robot products are becoming more and more mature, and have become a standard equipment and widely used in the industry, thus forming a number of influential and famous industrial robot companies. For example, multinational group companies such as ABB Robotics, FANUC, Yaskawa, KUKA Robo-ter, Adept Technology, American Robot, Emerson Industrial Automation, S-T Robot-ics, COMAU, AutoTech Robotics, Jcd International Robotics, and Robogroup Tek have become pillar industries in their countries and regions. The development process of industrial robots can be divided into the following three stages:
The first generation of robot is the teaching and playback robot widely used in the industry at present. It stores information through teaching, reads these information during work, sends instructions to the executing agency, and the executing agency reproduces the teaching operation according to the instructions. It is widely used in welding, loading and unloading, painting and transportation.
The second generation robot is a robot with sense. The robot has vision, touch and other functions, and can complete detection, assembly, environment detection and other operations.
The third generation of robot is intelligent robot. It not only has the sense function, but also can make decisions and plan actions according to the command of people and the environment.
At present, more than 90% of robots operating in industry do not have intelligence. In FMS, the first and second generation robots are currently used.
Development of industrial robots in major countries in the world:
The United States is the birthplace of industrial robots, with a solid foundation and advanced technology. Today, the United States has a number of industrial robot suppliers with international influence, such as Adept Technology, American Robot, Emerson Industrial Automation, etc.
Germany has the third largest number of industrial robots in the world, second only to Japan and the United States, and its research and application of intelligent robots is in a leading position in the world. At present, on the basis of popularizing the first generation of industrial robots, the second generation of industrial robots has become the mainstream installation model through promotion and application, while the third generation of intelligent robots has occupied a certain proportion and become the development direction.
The world's robot suppliers are divided into Japanese and European. ABB in Sweden is one of the largest robot manufacturing companies in the world. In 1974, the world's first fully electronic industrial robot IRB6 was developed, which is mainly used for the handling of workpieces and materials. The first welding robot was produced in 1975. After the merger of Trallfa Paint Robot Company in 1980, its robot products tend to be complete. Industrial robots manufactured by ABB are widely used in welding, assembly and casting, sealing and gluing, material processing, packaging, painting, water cutting and other fields.
KUKA Roboter GmbH in Germany is one of the top industrial robot manufacturers in the world. In 1973, KUKA's first industrial robot was developed. The annual output will reach about 10000 units. The robots produced are widely used in instruments, automobiles, aerospace, food, pharmaceuticals, medicine, casting, plastics and other industries, mainly used in material processing, machine tool equipment, packaging, stacking, welding, surface finishing and other fields.
COMAU has been developing and producing industrial robots for more than 30 years since 1978. Its robot products include Smart series multifunctional robots and MASK series gantry welding robots. It is widely used in automobile manufacturing, casting, furniture, food, chemical industry, aerospace, printing and other fields.
Japan is the main faction of industrial robot manufacturing, and its representatives include FANUC, Yaskawa, Kawasaki, OTC, Panasonic, Fujitsu and other internationally renowned companies.
FANUC is one of the largest robot manufacturers in the world. The predecessor of FANUC is committed to the development and production of numerical control equipment and servo motor system. In 1972, FANUC was established independently from the computer control department of Fujitsu Company in Japan. FANUC's main business is divided into two parts: industrial robots and factory automation. According to statistics, by the end of June 2008, the number of robots produced by the company had exceeded 200000. FANUC's latest industrial robot products include R-2000iA series of multi-functional intelligent robots. With unique vision and pressure sensor, it can pick up and complete the assembly of randomly stacked workpieces; Y44CCLDiA high-power LD YAG laser robot. The 4.4kwLD YAG laser oscillator developed and installed has improved efficiency and reliability.
Yaskawa developed the first fully automatic industrial robot in 1977, and its subsidiaries include Motoman USA, Sweden, Germany, and Synetics Solutions USA. Its core industrial robots include spot welding and arc welding robots, paint and processing robots, LCD glass plate transmission robots and semiconductor chip transmission robots. In recent years, the new LCD glass panel handling robot produced by Yaskawa has been popular in the market. In addition, Yaskawa is also one of the first manufacturers to apply industrial robots to the semiconductor field.
Kawasaki produced the first industrial robot in Japan, making an indelible contribution to the industrial robot industry. The spraying robots, welding and assembly robots and semiconductor industrial robots produced by Kawasaki are also very popular in the market.
Development of industrial robots in Japan:
At the same time, Japan in the 1970s was facing a serious labor shortage, which has become a major problem restricting its economic development. There is no doubt that the industrial robots born in the United States and put into production have brought good news to Japan. In 1967, Kawasaki Heavy Industries of Japan first introduced robots and technology from the United States, established production plants, and trial-produced the first Japanese unimate robot in 1968. After a brief cradle stage, Japan's industrial robots soon entered the practical stage, and gradually expanded from the automobile industry to other manufacturing and non-manufacturing industries. In 1980, known as the "first year of robot popularization" in Japan, Japan began to promote the use of robots in various fields, which greatly alleviated the social contradiction of serious shortage of labor in the market. In addition, the Japanese government has adopted various encouraging policies, and these robots have been welcomed by many enterprises. From 1980 to 1990, Japan's industrial robots were in its heyday. Later, the international market once turned to Europe and North America, but Japan recovered its former glory after a brief downturn.
At the end of 1993, there were 610000 industrial robots installed in the world, including 60% in Japan, 8% in the United States, 17% in Europe, and 12% in Russia and Eastern Europe. What makes Japan's industrial robot industry develop so fast? Here are some reasons:
(1) The root cause is Japan's basic national conditions, small population and serious shortage of labor. Japan's annual population growth rate is about 1.1%, while the growth rate of its labor force has always remained at 0.7% because the Japanese want to receive higher education. In order to meet the 3% growth requirement of the national economy, we must improve production efficiency.
(2) The first oil crisis that broke out in October 1973 raised the labor cost. The Japanese government had to encourage private enterprises to invest in the field of automation to improve production efficiency, so as to curb the cost inflation caused by the oil crisis.
(3) Industrial robots can take the place of workers to engage in work that may endanger their health, avoid a large number of industrial accidents and occupational diseases, and are welcomed by people.
(4) Japan has adopted policies to promote the popularization of industrial robots and promote research and development since the 1980s. Founded in October 1972, the Japan Industrial Robots Association is the first industrial robot organization in the world. Its purpose is to accelerate the development of industrial robot manufacturing industry and promote industrial automation and safe production. In 1992, the Japan Industrial Robotics Association celebrated its 20th birthday. In the past 20 years, it has been supported and helped by the government and colleges and universities, and has cooperated with industrial robot manufacturers and users. It is all this that makes the Japan Industrial Robotics Association effectively promote the production of industrial robots and make itself in the forefront of improving productivity and employee welfare in all fields of industry.
Policy support and rapid development
Japan was in a period of high economic development in the late 1960s, with an annual growth rate of 11%. After the Second World War, Japan, where the labor force is becoming tense, is facing serious shortage of labor force because of its rapid economic development. At this time, the industrial robot developed by the United States undoubtedly brought the greatest gospel to Japan's industrial development
The heavy industry company imported robots and their technology from the United States, established a production workshop, and trial-produced the first Kawasaki "Unimante" robot in 1968.
Industrial robots, which have greatly alleviated Japan's labor shortage, have been welcomed by Japanese enterprises as "saviors". In addition, the Japanese government's positive economic support policy has further encouraged the development and promotion of robots, which has stimulated the enthusiasm of enterprises to engage in the robot industry. In particular, the government has a series of economic preferential policies for small and medium-sized enterprises. For example, the government bank provides preferential low-interest funds to encourage the establishment of long-term leasing companies for robots. The company invests in the purchase of robots and rents them to users for a long time. Users only need to pay a lower rent each month, which greatly reduces the financial burden for enterprises to purchase robots; The government takes computer-controlled teaching-playback robots as special discount products, and enterprises enjoy the usual 40% discount for new equipment. You can also enjoy a 13% price subsidy. In addition, the state also funded the application of robot expertise and technical guidance for small enterprises.
This series of supporting policies has led to the rapid development of the Japanese robot industry, after a short period of more than ten years. By the mid-1980s, it had leapt into the "kingdom of robots". The output and number of installed robots have leapt to the top in the world. According to Mimoto Manji, executive director of the Japan Industrial Robotics Industry Association, "the development of Japanese robots has gone through the cradle period of the 1960s. The practical period of the 1970s. By the 1980s, it has entered the popularization and improvement period." and officially designated 1980 as the first year of the popularization of industrial robots. ". It began to widely promote the use of robots in various fields.
Japan's top five industrial robot manufacturers
1. Matsushita Electric Industrial Co (6752) ranks first, with a market share of 25.1%. Although Matsushita ranked first, its market share fell by 3.5% compared with 2003. The reason is that in 2003, the strong growth of electronic devices, such as flat-panel televisions, DVD players/video recorders and other digital applications, boosted Matsushita's 5% market share. By 2004, the demand of electronic device installers was relatively weak.
People have reached the level of industrial application. At present, the country pays more attention to the development of robot industry, and more and more enterprises and researchers have invested in the development and research of robots.
After more than 50 years of development, industrial robots have been applied in more and more fields. In the manufacturing industry, especially in the automobile industry, industrial robots have been widely used. For example, robots have gradually replaced manual operations in blank manufacturing (stamping, die-casting, forging, etc.), machining, welding, heat treatment, surface coating, loading and unloading, assembly, inspection and warehouse stacking. With the development of industrial robots in a deeper and broader direction and the improvement of the level of robot intelligence, the application model of robots is still expanding. It has been extended from the automobile manufacturing industry to other manufacturing industries, and then to various non-manufacturing industries such as mining robots, construction robots, and maintenance and repair robots for hydro-electric systems. In addition, robots are increasingly used in the fields of national defense and military, medical and health care, and life services, such as unmanned reconnaissance aircraft (aircraft), police robots, medical robots, and domestic service robots. Robots are playing an important role in improving the quality of human life. The application practice of industrial robots in many production fields has proved that it plays a remarkable role in improving the level of production automation, labor productivity, product quality and economic benefits, and improving the working conditions of workers, and has aroused wide attention from people all over the world and at all levels of society. In the new century, the robot industry will be developed more rapidly and applied more widely.
From the products launched by the world robots in recent years, the industrial robot technology is developing in the direction of intelligence, modularization and systematization, and its development trend is mainly: modular and reconfigurable structure; Open, PC and network control technology; Digitalization and decentralization of servo drive technology; Practical application of multi-sensor fusion technology; The optimization of work environment design, the flexibility of work, and the networking and intelligence of the system. Robot technology is an important part of high technology. Its industrialization process has just started in China. Although it has made certain achievements, there are still many difficulties and deficiencies, so it needs more attention and support from various aspects. National policy support is an important prerequisite for accelerating high-tech industrialization. According to the fact that the relevant departments of our government should organize forces to carry out full investigation and research, and on this basis, formulate feasible preferential policies for the promotion and application of robots and the promotion of robot research and development. For example, the robot industry is supported in terms of tax, investment and loan. The Japanese government has adopted a series of measures to encourage enterprises to apply robots through formulating policies, and the experience of developing the market for Japanese robots in China is worthy of our reference. In addition, robot users can consider giving certain financial subsidies to encourage purchase. In order to avoid industrial accidents and occupational diseases caused by dangerous and harsh working environment, and to protect the physical and mental safety of workers, some special types of work, such as painting, casting, etc., are forced to use industrial robots to replace through labor law. This can greatly increase the demand for industrial robots. China's robot industrialization must be driven by the market. As a high technology, the development of robot is closely related to social production and economic conditions. For the research and development of robots, it is very important to select the priority application fields of robots based on the principle of high possibility of technological realization, and use this as a breakthrough to penetrate and spread to other fields. In order to successfully enter the market and realize industrialization, the application of machines in China still needs the joint efforts of all parties.
Development situation and problem solving measures of industrial robots in China
Development situation of China's industrial robot industry:
Industrial robots are manufactured in a variety of advanced ways. Digital equipment has become one of the important indicators to measure the level of a country's manufacturing industry. In recent years, industrial robots have achieved rapid development, and will gradually move from demonstration application to large-scale promotion, thus greatly reducing the dependence of manufacturing process on labor. China is the fastest growing industrial robot market in the world. According to statistics, the average annual growth rate of China's industrial robot market has reached about 30% since the 11th Five-Year Plan. At present, China's annual installation of industrial robots ranks third, with a cumulative installation of more than 50000 sets, ranking sixth in the world. With the rapid development of the market, in terms of product and technology research and development, China has made considerable progress in the design level of industrial robot technology after more than ten years of research and application. At present, in the field of spraying robot handling robot, we have basically mastered the design technology of robot operating mechanism, and have made some breakthroughs in key components and devices. In terms of industrial development, China not only has joint venture robot enterprises, but also has a batch of robot industries with independent intellectual property rights. Their products fill the gap of industrial robots and form certain market competitiveness. As China's manufacturing industry is in the period of industrial structure upgrading and transformation, the demand for industrial robots in key industries such as automobile industry has maintained a rapid growth trend.
Faced with such a good market development space, China's industrial robot industry still has a lot of problems to be solved.
The main problems in the development of China's industrial robot industry are summarized as follows:
First, the innovation ability is weak, the core technology and core key components are subject to human control, and the whole machine is faced with shelling. The manufacturing capacity of basic parts in China is poor. With the foundation of relevant parts in China, there is a big gap between China and foreign countries in terms of quality product series and mass supply. The precision monitor is particularly obvious, affecting the development of industrial robots. The secondary industry is small in scale, the market satisfaction rate is low, and the construction of relevant infrastructure service system is obviously lagging behind. Chinese industrial robot enterprises have not yet formed their own brands. Although a number of enterprises are engaged in robot development, they have not formed a large scale. The third industry is centralized, and the industrial planning needs to be further clarified. At present, the industrial robot has not established its own industry system, and the lack of industry management has led to the absence of key work in the industry, such as the construction of industrial planning, industrial policy research and standard system. Relevant manufacturing enterprises, scientific research institutes and universities cannot give full play to the advantages and characteristics of concentrating their efforts on major events.
Main measures to promote the development of industrial robots in China:
We fully realize that China is moving from a manufacturing power to a manufacturing power, and the development of industrial robots can play an important role in the process of upgrading the equipment industry. At present, the development of industrial robots in China is also at a critical turning point. We need all sectors of society to work together to promote the development of China's robot industry to a new level and enter a rapid development stage. In May this year, the Ministry of Industry and Information Technology issued the 12th Five-Year Plan for the development of intelligent equipment. Industrial robots have given priority to development. The 12th Five-Year Plan for intelligent manufacturing equipment points out that the industrial robot body, the core components of motor controller, and the industrialization of industrial robots and their core components will be achieved. We have consulted with the Ministry of Finance for many times, and have also allocated special funds to support intelligent manufacturing equipment. In 2012, the intelligent manufacturing equipment project also supported a number of industrial robot research and development projects. In 2013 and even before 2015, the equipment manufacturing support channel still needs the development of industrial robots as the support field.
In addition, in promoting the development of the robot industry, we are ready to do a good job in the following aspects:
1、 Create a good policy environment for the development of industrial robots in China. As the competent department of the equipment manufacturing industry, it has achieved the coordination of various policies of China's industrial robot trade, and comprehensively and systematically promoted the technological innovation of China's industrial robots.
2、 Actively promote the establishment of industrial robot industry organizations and promote the formation of joint forces in the industry. Put forward the industrial plan in line with the characteristics of China's market and technology development, establish the operation detection and information release and analysis evaluation system, and establish and improve the industrial technical standard system. Continue to promote the industrialization of industrial robots. China's industrial robot industry has reached a certain scale, but it is far from reaching the threshold of 10 billion yuan. We will give full play to the fundamental role of the market in allocating resources, seize the concentrated breakthroughs of several key products, concentrate the main technical forces and funds, focus on promoting the industrialization development of two or three types of industrial robots, achieve scale application and overall technological breakthroughs, form the local competitiveness of industrial robots with international brands, and lay a solid foundation for the development of industrial robots. Give priority to encourage industrial alliances formed by user enterprises and manufacturing enterprises to participate in project bidding and jointly develop industrial robots. We will encourage financial institutions to carry out various forms of first-rate insurance business, actively introduce risk investment mechanisms, and fully implement policies.
3、 Based on the long term, lay a solid foundation. Industrial robots focus on the development of key technologies, strengthen the research of basic technologies, and strive to promote the upgrading of product quality, reliability and service life. Strengthen the promotion, application and industrialization of advanced technology, and create an environment conducive to the high-end development of the technology manufacturing industry. Change the long-term idea of driving the development of parts by the whole machine to give priority to the development of basic technology and parts, and improve the overall level and international competitiveness of industrial robot basic technology and parts industry.
4、 We should further strengthen international exchanges and cooperation, and promote international exchanges at multiple levels, channels and forms. Encourage overseas enterprises and scientific research institutions to further strengthen R&D cooperation with domestic enterprises and scientific research institutions, support enterprises to actively participate in technical standards and improve export credit insurance policies, and promote the export of industrial robot manufacturing technology equipment and engineering services. We hope that in the context of globalization, we can give more play to the comparative advantages of China's equipment manufacturing industry and work with all friends present to promote and witness the development of China's industrial robot industry.
Development trend of industrial robots in China:
(1) Research on industrialization technology of teaching and reproducing industrial robot
These researches mainly include: standardization, generalization, modularization and serialization design of joint type, side spray type, top spray type and gantry type spraying robot products; Development of flexible profiling spraying robot; Standardized, universal, modular and serial design of welding robot products; Development of laser vision seam tracking device for arc welding robot; Off-line teaching programming of welding robot and dynamic simulation of workstation system; Standardization, generalization, modularization and serialization of assembly robot products for electronic industry
Design; Research and development of special manufacturing, assembly, testing equipment and tools required for mass production of robots. (2) Development and Research of Intelligent Industrial Robot
These studies mainly include: research on the constitution and control strategy of remote control plus local autonomy system; Research on navigation and positioning technology of intelligent mobile robot; Virtual reality system for remote control robot; Human-computer interaction environment modeling system; Multi-robot remote control technology based on computer screen. (3) Research and development of robotic machinery
These research and development mainly include: parallel mechanism machine tool (VMT) and robotic machining center (RMC) development research; Robotized unattended and adaptive multi-machine remote control operation of large bulk conveying equipment. (4) Robot-based Reassembly System
These systems mainly include: open modular assembly robot; Design technology for robot assembly; Design technology of robot flexible assembly system; Design technology of reconfigurable robot flexible assembly system; Assembly force perception and visual technology; Intelligent assembly strategy and control technology.
(5) Multi-sensor information fusion and configuration technology
This technology mainly includes: the application of robot sensor configuration and fusion technology in cement production process control and sewage treatment automatic control system; Design and application of electromechanical intelligent sensor.