應用機械手臂製造於金屬板加工

以往的建築設計數位化之後，由二維繪圖延伸至三維形體的探討；然而在電腦模型存在於虛擬的螢幕裡，並缺少了建造時的建構邏輯思考。在電腦軟體與數位製造工具日新月異的進步之下，建築設計跳脫無重力下的虛擬螢幕，數位建築與營造之間的距離日益縮小，由一開始的電腦輔助設計銜接到電腦輔助製造，並思考數位建築變為真實建築的可能性，改變了以往的繪圖邏輯，整合了施工流程、細部設計與構造的流程。今日能與電腦溝通的工具日益增加，相較於以往介面友善許多，大大增加了真實製造的可行性。而機械手臂自1970年代投入重工業裡使用，其三維的運動方式能能縮短加工流程中的時間與人力，有助於實踐建築設計中複雜形體製作與組裝的可能性。本研究以金屬板材作為實驗材料，研究如何應用機械手臂進行金屬加工。本研究主要選用兩種金屬加工技術：單點加壓成型(SPIF，Single Point Incremental Forming)與摺疊(Folding)作為研究對象。研究初期以機械手臂離線編程軟體Scorpion搭配UR10進行單點加壓成型，由於UR的安全保護模式讓UR不適合金屬加工。後期改以離線編程軟體Robots與硬體KUKA KR30進行金屬加工。第一階段在Grasshopper圖像介面下做參數化編程，透過軟體了解機械手臂的操作與整體編程邏輯，以單點加壓成型加工作為研究主軸。加工路徑偏向二維平面，並沒有複雜的三維空間操作模式與訊號控制，運用自製的末端執行器搭配圓形沖頭安裝於機械手臂上進行加工，透過機械手臂在鋁板材上一層一層往下壓，利用金屬延展性所造成薄的板形變，製成可以受力的元件。在第二階段則是以摺疊加工為主軸，將金屬板材固定於輔具上，使用訊號控制安裝於機械手臂上的氣動夾爪，對板材進行彎折加工製成具有形抗能力的單元，以鑲嵌或鉚釘接合成為小型的拱，足以乘受自重而站於平面上。最後以實際尺寸建構小型展示亭，其外型為三面不以同單元加工方式所相接的三角錐；在實際空間中的構築需要考慮結構強度、材料細部接合、預算等問題，透過機械手臂加工的精準性以減少整個設計造流程中的誤差與成本。本研究對於金屬的延展特性進行數位製造與技術的探討，而應用機械手臂的優勢在於適合多元的加工流程與彈性，將不同的設計、製造與加工加以程序化，並搭配不同的自製末端執行器對於各種材料的加工進行相對應的實驗。以機械手臂作為工具有別以往金屬加工廠的加工方式，並思考如何建立屬於新型態金屬加工技術的流程，將其運用在建築的真實建構上。

關鍵字

金屬加工；機械手臂製造；參數化設計；數位製造

並列摘要

The development of technology has brought us to an age of digitalization, virtualization, and automation, and the computer-aided design environment has been shifted from two-dimensional (2D) graphical drawing to three-dimensional (3D) modelling design. However, computer modelling is virtual and lack of the information for the structural system in real construction. Along with the advancement of computer technology and digital fabrication, and it becomes possible of making the virtual digital architecture design into the physical world. The distance between digital architecture design and digital fabrication are shortened thanks to the development of computer-aided design and manufacturing. Digital design software changes the logic of design thinking, as well as integrates the fabrication process, detail design and construction. In addition, the interfaces of computer software are much more user-friendly nowadays, this also benefits digital design and fabrication a lot. Robotic arm has been applied to heavy industry since the 1970s, that reduces the manpower of works. Robotic arm also helps the fabrication and construction of sophisticated structures designed by digital modelling. In this study, metal sheets are used as experimental materials to study how to apply robotic arms for metal processing, and two metal processing technologies are selected: single point incremental forming (SPIF) and folding. At the beginning of this research, the robotic off-line programming software Scorpion is used with UR10 for SPIF, however, the safety mode of UR10 limits itself from the metal processing. Subsequently, the KUKA KR30 and the off-line programming software, Robots are used to do the metal processing. In the first stage, the parametric modeling is performed under the Grasshopper. The operation of the robot arm and the programming logic are conducted by the software, and the SPIF process is the objective of this stage. The machining path emphasizes on the two-dimensional plane, and there is no complicated three-dimensional operation mode and signal control at this stage. The self-made end effector is mounted on the robot arm with a circular punch for processing, and the robotic arm presses the aluminum plate down layer by layer. A thin metal plate deformation caused by the ductility of the metal helps to form a force-receiving behavior. In the second stage, the focus is on the metal processing folding technique, the metal plate is fixed on the jig, and the pneumatic grippers mounted on the robotic arm is controlled by signals to bend the plate to form a folding unit. The units are joined with rivets into a small arch, which is strong enough to stand on the ground by self-weight. Finally, a pyramid shaped pavilion is built up with the units which are processed with different metal processing techniques. It is essential to consider the strength of structure, joint techniques, budgets, etc., in actual constructions, and the planning can be more accurate and economical with the advantage of robotic arm fabrication. This study applies the digital fabrication and technology to explore the ductile properties of metal, and the advantage of robotic arm application is suitable for multiple processing processes, thus different design programming, manufacturing and processing are able to conducted by self-made end effectors. Corresponding experiments were performed on the processing of various materials. With the robotic arm as a tool, it is different from the traditional metal processing methods, this research establishes a process for the new state of metal processing and the implementation for the real construction of the building.