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激光制造業(yè)亟需組建優(yōu)秀的激光加工團(tuán)隊，大力普及激光加工技術(shù)，設(shè)立激光加工教學(xué)、科研和生產(chǎn)基地，加大相關(guān)技術(shù)同步研究，將機(jī)器人技術(shù)、仿真技術(shù)應(yīng)用等大規(guī)模地應(yīng)用到城市軌道車輛制造中，發(fā)展我國自主特色的激光加工設(shè)備以及加工工藝。激光加工技術(shù)在城市軌道車輛制造中的應(yīng)用，包括焊接、切割、表面改性、打標(biāo)、快速成型、打孔及微細(xì)加工等。文章以城市軌道車輛為研究對象，闡述了先進(jìn)激光焊接、激光切割在城市軌道車輛制造和輪軌表面處理等的原理和特點(diǎn)，分析了目前激光加工技術(shù)在城市軌道車輛制造中的特點(diǎn)和應(yīng)用前景，為縮短與國外先進(jìn)技術(shù)的差距，加快軌道交通技術(shù)儲備提供參考。

城市軌道交通已成為現(xiàn)代城市公共交通的主動脈，具有運(yùn)量大、能耗低、效率高、污染小、準(zhǔn)點(diǎn)率高等優(yōu)勢。中國如今已成為全球城市軌道交通建設(shè)投入的主力軍，甚至連許多二線城市都具備了軌道交通建設(shè)的條件與需求。
隨著中國政府“十三五”規(guī)劃的提出，國家發(fā)改委已批復(fù)了多地軌道交通的規(guī)劃，到2020年投資預(yù)計將超萬億。目前城市軌道車輛制造行業(yè)中，激光加工制造技術(shù)備受矚目，其很大程度上提升了城市軌道車輛制造水平；輕量化與高速化的趨勢，也持續(xù)為其提出新方向、新課題。

由于中國的城市軌道交通起步較晚，因此為了縮短與國外先進(jìn)技術(shù)的差距，應(yīng)引進(jìn)、研究和消化當(dāng)前最新技術(shù)及設(shè)計思路，加快軌道交通技術(shù)儲備，探究激光加工技術(shù)在城市軌道車輛制造中的應(yīng)用。車輛激光焊接車輛轉(zhuǎn)向架以及車體是城市軌道車輛上的關(guān)鍵構(gòu)成，材質(zhì)也經(jīng)歷了普通合金鋼、不銹鋼、鋁合金型材幾個階段。目前在城市軌道車輛制造中，逐步引入了激光焊接等新的加工工藝。

激光拼焊

激光拼焊是城市軌道車輛中最被看好的技術(shù)之一，屬于無接觸焊接，可將不同鋼種、厚度、表面處理的鋼板焊接成一個整體，區(qū)別于電阻滾壓縫焊，通過自由組合，使得構(gòu)件變輕，零件變少，不僅提高可靠性，為寬體車制造奠定基礎(chǔ)，同時也改善了焊接質(zhì)量，提高了鋼材收得率，并降低了生產(chǎn)成本。

激光組焊

激光組焊在城市軌道車輛車身制造中舉足輕重，通過雙件組焊、多件組焊，將已切割成形的各類車身構(gòu)件，焊接成白車身分總成，進(jìn)而總裝成整車車身。激光組焊因其焊接強(qiáng)度高，可明顯改善車身強(qiáng)度、剛度及密閉性。焊接同時結(jié)合面小、變形小、焊接速度快、可焊材料范圍廣，適合于柔性化生產(chǎn)，投資效益好。但激光組焊技術(shù)也有明顯的缺點(diǎn)，如對夾具、被焊件、監(jiān)測精度等要求嚴(yán)格，焊接后檢測評價和返修困難，一次性投入大等。

激光-電弧復(fù)合焊

1) 不銹鋼車體制造。城市軌道車輛車體通常選用不銹鋼車體，由于電弧焊接后熱影響及變形等較嚴(yán)重，因此為改善外觀，過去常常進(jìn)行涂裝作業(yè)，而現(xiàn)在則選用激光或電阻焊進(jìn)行作業(yè)。

通過長期加工技術(shù)應(yīng)用的實踐、積累及分析，不銹鋼接頭焊接技術(shù)規(guī)范、疲勞曲線、硬度、抗拉強(qiáng)度、屈服強(qiáng)度、等技術(shù)指標(biāo)相繼被取得或檢驗，車體激光焊接樣件的制評亦完成。


2) 車輛轉(zhuǎn)向架制造。城市軌道車輛轉(zhuǎn)向架通常選用日本進(jìn)口或國產(chǎn)的中厚合金鋼板材，同時多選用熔化極氣體保護(hù)焊。用于長直縫焊接的機(jī)械人手臂，已被各廠商所引進(jìn)，來改善焊接穩(wěn)定性；而開具有不同規(guī)格的坡口，通常留較小鈍邊，以確保熔透。激光-電弧復(fù)合焊優(yōu)化焊接效率，顯示了激光和電弧的特點(diǎn)；同時減少了設(shè)備和人員投入，降低了焊接成本，并且可選較大鈍邊。


車輛激光切割

激光切割技術(shù)特性城市軌道車輛制造廠商已大量使用激光切割技術(shù)，其加工的產(chǎn)品有很多，如車體、內(nèi)裝板材、轉(zhuǎn)向架，常選用二維平面切割。激光可以加工出高精度、高切割斷面質(zhì)量的零件外形、輪廓和孔。

固體(或CO2)激光切割機(jī)通常適用于碳合金鋼、不銹鋼，同時也適用于鋁合金板，可達(dá)到理想斷面加工質(zhì)量和切割速度。以某企業(yè)為例，軌道車輛車體為不銹鋼，選用6 k W激光和剪板機(jī)對6 mm以下板材下料。車輛轉(zhuǎn)向架選用激光切割機(jī)對14 mm以下板材進(jìn)行下料，其材料為Q345C低合金結(jié)構(gòu)鋼。

下料環(huán)節(jié)激光切割

城市地鐵機(jī)車制造首先要準(zhǔn)備相關(guān)材料，這個階段激光切割技術(shù)尤為重要。激光切割與火焰切割相比，切割速度快、工件變形小、加工精度高、適用性強(qiáng)、節(jié)料省錢、經(jīng)濟(jì)適用[16]，因此激光切割技術(shù)已被廣泛用于軌道車輛制造中。以某企業(yè)為例，其高速動車組車體選用激光和剪板機(jī)對6 mm以下板材下料，材料為鋁合金板材及型材。車輛轉(zhuǎn)向架選用6 k W激光切割機(jī)對12 mm以下板材下料[17]。

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280-PWRM22C-M4 ArmorStart Three-Phase Power Media

285-BRCF25-M10 ArmorConnect Brake and Motor Cable

S8VS-24024 NEW 100-240VAC,容量：240W輸出 10A 導(dǎo)軌安裝型

1492-XIM4024-8R Connection Products

中央處理單元 6ES7417-4HL04-0AB0 CPU417-4H,20MB RAM，用于存儲器卡的槽，電源 24VDC，兩個槽用于同步模板,一個MPI/PROFIBUS-DP 主站接口；包括槽號標(biāo)簽,30ns

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1492-PD3C112 255 A Power Distribution Block

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1760-USB-GFX PicoGFX USB Programmer Cable

188-K3B100 Miniature Circuit Breaker 10 A

194L-E12-C34 Terminal Cover 3 Pole 12 - 16 A

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GC647NXV001 Proficy GlobalCare Complete for Tracker Order Execution Management Web Viewer

IC200MDD842 Mixed 24VDC POS LOG b group 16 point / output 24VDC 0.5 amp with ESCPoutput 16 point.

IC646NMR000 Modbus RTU Communications

IC647M32C M32:Moore MYCRO 320 Independent Computer Interface

IC670MFP100 Micro Field Processor

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IC800SLMCONKITVL connector kit for 3.5 kW to 5 kW S-series servo motors without brake

ControlLogix/1756 System 1751-SL4SP SYNCHLINK FIBER 4-PORT SPLITTER BLOCK

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Support 9326-AD10APR SUPT REINSTATEMENT CONTRACT FOR 9326AD10APENE

Support 9371-EDBA3S SUPT RENEWAL CONTRACT FOR 9371EDBA3

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RSI Software Products 9301-2SE240FRU1R RSVIEW32 WORKS 1500-32K UPGRADE OUT-SUPT (FR)

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Motion Control 2090-UXNFDN-R30 CABLE,ULTRA,NON-FLEX, MOTOR FEEDBACK,N,R/A,30M

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IC610MDL156RR 24Vdc Sink Output, D Connector, with LEDs (16 points)

IC800SLCBVL100 Power/Brake Cable, 3500W and 5000W SL Servo Motors with Brake, 10 Meters

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280-PWRM24A-M2 ArmorConnect 3-PH Power Media drop cable

3G3MV-A4075 NEW 14KVA 18A 7.5KW 3相AC380-460V/50HZ/60HZ

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1494U-PC2 1494U Long Protective Cover

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1585D-M4UBJM-15 1585D Ethernet Media Patchcord

1756-L63S GuardLogix 8 MB Standard Mem Controller

1797-TPR FlexEx Accessories

194E-E80-1753-6G 80 A 194E Load switch

2090-CFBM6DF-CBAA02 TL-Series 2m Feedback Cable

2090-SCEP8-0 Kinetix 8-8m Fiber Optic Cable

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GC647AEC005 GC Efficiency Client 5 Pak

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IC641SWP710 C Developer's Toolkit for Series 90 PCMs

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Support 2707-DP1S SUPT RENEWAL CONTRACT FOR 2707DP1

Support F1785-L40LSERA FIRMWARE UPGRADE FOR 1785-L40L PLC5 PROCESSOR MODU

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6SE6440-2UD38-8FB1 90KW

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1585-C8TB-S300 Cable Spool Ethernet Media

1746-RL51 SLC Octal Label Kit

1790-T8BV8VX CompactBlock LDX 16 Expansion Block

194E-A25-1753 25 A 194E Load switch

20-PP11002 WIRE SET 2

2090-CSBM1DF-18AF04 Kinetix Cable Single DSL 2090-Series

20AC043A3AYNAEC0 PowerFlex 70 AC Drive 43 A at 22 kW 20A

GC646IFCLNTCRO005 GCC iFIX iClient Read Only 10 PK Keyless Runtime Version

HE660GGM100 Discontinued Part. Check with GE IP on migration path.

IC600LR632RR 16K/16K Combined Memory

IC647HSTES500M Historian Enterprise Server 500 Points (M4 Key)

IC655ALG566RR Analog Output (2 Channels)

IC694CHS392 Base Expansion 10 Slots

IC756SDV001E-98 DV Development - Solaris Op Sys Addt'l User, English, Version 9.8

MicroLogix 1500/1769 System 1764-24AWA ML 1500 BASE 120V AC IN / RELAY OUT / AC POWER

PLC-5/1771 System 1771-AF FIBER OPTIC CONVERTER MODULE

Distributed I/O 1794-IJ2K CONFORMAL COAT, 2-CHANNEL HI RES FREQUENCY MODULE

Communications 9399-WABLUG WINTELLIGENT LINX LITE USER'S GUIDE

Support 6233-5VTLS SUPT RENEWAL CONTRACT FOR 62335VTL

Support 9358-BPMG03S SUPT RENEWAL CONTRACT FOR 9358BPMGR03ENE

Support F1771-KF FIRMWARE UPGRADE FOR 1771-KF COMMUNICATION MODULE

RSI Software Products 9324-RLD0U6ITE RSLOGIX 5000 SERVICE ED TO FULL UPG, ITA

RSI Software Products 9301-2SE350PTU5R RSVIEW32 RUNTIME 5K-100K UPGRADE OUT-SUPT (PT)

RSI Software Products 9358-MTRCK03ENE RSBIZWARE MATERIALTRACK (1 - 10 BATCH SERVER)

Motion Control 8720SM-018S2FBS1 18.5 KW/47.1 AMP, 460VAC, AC MOTOR WITH SRS60 ENC.

829-8-1 Thumbwheel Assembly. 8 Digit, 1 True. Dust Seal

IC200MDL740 OUTPUT 24VDC POS LOGIC 0.5A PER PT (1 GROUP OF 16) 16PT

IC697VAL216 Analog Input, 16 channel, jumper selectable for 0 to 5VDC, 0 to 10VDC, +/-2.5VDC, +/-5VDC, +/-10VDC. 16bit Resolution

MTR-1324-N-D-E-SRR Stepping Motor Nema34 3A Splashproof

ZA06B-0034-B175#7008 B6/2000 servo motor with holding brake and 32k serial encoder

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Quantum Cablefast Connection Cablefast 預(yù)接線系統(tǒng)

294E-FD1P5Z-G2 Variable Frequency Drive

WLCA12 觸點(diǎn):1開/1閉,10A 250VAC機(jī)械壽命:1500萬次?撞壓式高度可調(diào)

1492-SPM3B250 MCB Supplementary Protector 25 A

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TS 模塊 6ES7 972-0MS00-0XA0 TS Module RS232

150-F780NBEB SMC Flex Smart Motor Controller

1734-IE4S Point IO Safety Analog Input Module

1783-BMS4S2SGA Stratix 5700 6 port managed switch

193-EOS-SCS-BP E300 Control Station

20-750-EMC1-F4 PowerFlex 750 Frame 4 EMC Kit

2090-CPWM7DF-12AA15 MP-Series 15m Power Cable

2098-DSD-020X-DN Ultra 3000 Servo Drive

G-C441/OBG PC to GagePort Cable and Power Supply (9-pin for Owens Brockway OEM)

GFK-2198 PCB3695-3795 Quad/Dual Channel Incremental Encoder Interface

IC220TBK061 I/O TERMINAL STRIP W/SHIELD, 6 POSITION SPRING STYLE, QTY 5

IC647EURC EUR:Eurotherm 800 Series

IC647SCL001 Scheduler Server Client ( Plan+ View)

IC693MDL641RR 24 Vdc Output, Negative Logic (16 Points)

IC756DVE010E-97 EO GECK (Graphical Editor Construction Kit) - Inb x87, English, Vers ion 9.7

MSI-QUAL-43 Quality Mang Clients-43

PLC-5/1771 System 1771-A3B1 I/O CHASSIS ASSEMBLY, 12 SLOT, 19

Distributed I/O 1790D-T0B16 DNET LDX, 24VDC, 16 SOURCE OUT BASE, TERMINAL BLK

Communications 1770-CD6 DATA HWY TWINAXIAL CABLE, 600 FT/183 M

Operator Interface 2711E-UTCT14 PANELVIEW 1200 TOUCH TO 1400E TOUCH MIGRATION KIT

Support 9305-RSVADFCESR SUPT REINSTATEMENT CONTRACT FOR 9305RSVADFCES

Support 9324-RLDSTXES SUPT RENEWAL CONTRACT FOR 9324RLDSTXE

EtherNet/IP Products 1785-ENET PLC-5 ETHERNET/IP EXPANSION MODULE FOR PLC-5

RSI Software Products 9301-2SE3400KOU1 RSVIEW32 RUNTIME 1500-32K UPGRADE IN-SUPT (KO)

RSI Software Products 9515-RSAAMPRDENE RSMACC AUTO ASSET MGMT, PREDICTIVE MAINT

Motion Control 1326AB-B420H-S2L MOTOR,SERVO,460V,5.1NM,6000RPM,SINGL,IP67

3414 Greyline OS, 2 Line, (20) 9MM Chars, VFD, Quick Connect, NEMA 4

HMI-AGO-204 ANTI-GLARE OVERLAY 6"

IC693ACC341 Redundant Power Supply Base with 0.5 meter cable to connect to Power Supply Adapter module. Supports any Series 90-30 power supply.

QPKSTDN0000 6" Color STN, TCP Label, No Ethernet, CF, 24Vdc,UL,cUL,CE,UL1604

TGT-DI0L-32-0 Target series digital I/O module with 16 bs/outputs

20BC5P0A0AYNANC1 PowerFlex 700 AC Drive 5 A at 2.2 kW 20B

20F1ANE192AN0NNNNN PowerFlex 753 AC Packaged Drive

22B-D2P3F104 PowerFlex 40 0.75 kW (1 Hp) AC Drive

Quantum Analog Input Module 模擬量輸入模板

284E-FVD4P0Z-10-RR-3-DB-SB-EMI EtherNet Variable Frequency Drive

E2E-X1C1 1mm,電感式,三線,常開5-100mA NPN電源:10-30VDC圓M5

1492-SPM1C020 MCB Supplementary Protector 2 A

通用型變頻器 6SE6 420-2UC23-0CA1 "3.0 KW，185 x 245 x 195"

電機(jī)啟動器 3VU13400MP00

1497D-A17-M22-0-N 1En Purpose Transber

1608N-012A240V2S 12 A Mini DySC Sag Corrector

1769-OF8V CompactLogix 8 Pt A/O Voltage Module

190S-BND2-CB63C 4.0-6.3 A Compact Comb Starter W/Ckt-Bkr

194R-NE630-1753 Disconnect Non-Fused IEC 3 Poles 630A

2090-CPBM7DF-16AF02 MP-Series 2 m Length Pwr and Brake Cable

2090-XXTPMP-10S12 MP-Series 12 m Length Power Cable

CFDA-3WPB-0070-AZ This cable has been replaced by cable CFDA-7WPB-0070-AZ

GF-3910R Connecting FlashCable to Ohaus Model C/ E/ GT/ MB/ TP/ TS series.

IC200UDR010-24 Qty of 24, 28 point PLC, (16) 24VDC In, (11) Relay Out, (1) 24VDC Out, 24VDC Power Supply

IC646TRT915 1500 I/O Point Runtime System

IC647PATH105 Proficy PAT - Historian. The capability is to store spectra data from the driver into the Proficy Historian. This for a single dri

IC693APU302RR Axis Positioning Module (APM), 2 Axis, requires (1) or (2) CBL311

IC752PBI100 PC/104 Profibus Card

IMC-105E-1-D 5 amp IMC enhanced stepping motor controller

SLC/1746 System 1746-P5 POWER SUPPLY - RACK MOUNT

Industrial Computers 6189V-MMA15 MNTG ADAPTER FOR CONVERTING 6185-C OR J TO 1500M

Application-specific products 1404-M505B-CNT-02 1404-M5 CONTROLNET PM3000 CLASS 0.2 24V P.S.

Operator Interface 2711-K10C15L1 PV1000 COLOR KEY, CNET & RS232 PRINT

Support 9301-2SE3200FRR SUPT REINSTATEMENT CONTRACT FOR 93012SE3200FR

Support 9380-RSBS SUPT RENEWAL CONTRACT FOR 9380RSB

DeviceNet Products 1792D-16BVT0CD MAXUM 16 IN WITH POINT LEVEL DIAGNOSTICS

RSI Software Products 9301-2SE3203ZHE RSVIEW32 RUNTIME 300 WITH RSLINX (CHINESE)

RSI Software Products 9358-BPMGR03ENE RSBATCH PRODUCTION MANAGER (SUPT 1-10 BATCH SVR)

Motion Control MPL-B4530F-RK22AA MOTOR,SERVO,8.36 NM,2800RPM,RSLVR,460V

Motion Control 2090-SCVP1-0 SERCOS FBR CABL,CONN,STANDARD PVC JKT,PLASTIC 1.0M

GHMI-KPN-302 QUICKPANEL KEYPAD FOR 10.5" GE LABEL

IC646MPP010 Logic Developer - PLC Professional - 10 Pack