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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(duì)，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(guó)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(duì)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(guó)外先進(jìn)技術(shù)的差距，加快軌道交通技術(shù)儲(chǔ)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(dòng)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(shì)。中國(guó)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(guó)政府“十三五”規(guī)劃的提出，國(guó)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(jì)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(shì)，也持續(xù)為其提出新方向、新課題。

由于中國(guó)的城市軌道交通起步較晚，因此為了縮短與國(guó)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(jì)思路，加快軌道交通技術(shù)儲(chǔ)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(gè)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(gè)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(shí)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(shí)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(duì)夾具、被焊件、監(jiān)測(cè)精度等要求嚴(yán)格，焊接后檢測(cè)評(píng)價(jià)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(zhǎng)期加工技術(shù)應(yīng)用的實(shí)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(yàn)，車體激光焊接樣件的制評(píng)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(guó)產(chǎn)的中厚合金鋼板材，同時(shí)多選用熔化極氣體保護(hù)焊。用于長(zhǎng)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(shí)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(shí)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(duì)6 mm以下板材下料。車輛轉(zhuǎn)向架選用激光切割機(jī)對(duì)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(gè)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(dòng)車組車體選用激光和剪板機(jī)對(duì)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(duì)12 mm以下板材下料[17]。

 

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20BD180A3ANNANC0 PowerFlex 700 AC Drive 20B

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25-EMC1-FA PowerFlex 520 Frame A EMC Plate

140XTS00206 Quantum CABLEFAST電纜, 帶 QUANTUM I/O 端子, 1.8M

294E-FD4P2P-G2 Variable Frequency Drive

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1492-SPM3C030-N MCB Supplementary Protector 3 A

軟啟動(dòng)器 3RW40362TB04

數(shù)字量輸出模 6ES7 222-1XF32-0XB0 SM 1222DQ 8 x RLY（雙態(tài)）

150-FPP317C SMC Flex Repair Part

1734-OB8 POINT I/O 8 Point Digital Output Module

1783-HMS8SG4CGR Stratix 5400 12 Port Managed Switch

193-ESM-I-30A-E3T E300/E200 30 Amp Sensing Module

20-750-FLNG1-F4 PowerFlex 750 NEMA 1 Flange Adaptor Kit

2090-CPWM7DF-14AA60 MP-Series 60m SpeedTec Standard Cable

2098-DSD-HV030X-DN Ultra 3000 Servo Drive

GA646PCMS10 GlobalCare Assist for Change Management Electronic Signature Module 10 Pack

GP-0602NT-F1 GagePort LVDT NT (Full Bridge F1 Blocks)

IC5002CAC0000 12in Inbligence PanelClient H/W Only

IC647HSTAE10000KM Alarm and Events Option for Historian - Standard Server 10,000,000 Points (M4 Key)

IC647SI7M SI7:Siemens SIMATIC S7

IC693MDL655LT 24 Vdc Input, Neg/Pos Logic, 1 ms, (32 pts) (LT)

IC756HDV000K-98 DV Development - HP/UX Op Sys, Korean, Version 9.8

MSI-SDK SDK Connections

PLC-5/1771 System 1771-IC INPUT MODULE, 48V DC, 8 INPUT

Distributed I/O 1790P-T4T0 PROFIBUS,4 INPUT THERMOCOUPLE BASE, TERMINAL BLOCK

Communications 1784-CP2 CABLE ASSY, 10 FT/3.20 M, 1784-KTP, -KT, -KT2, -KL

Operator Interface 2727-T7P30D1FEU MOBILEVIEW TABLET T750 - EUROPEAN

Support 9305-RSVADFVCJPS SUPT RENEWAL CONTRACT FOR 9305RSVADFVCJP

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EtherNet/IP Products 2711-B5A20 PV550 MONO KEY&TOUCH, ENET & RS232 PRINT

RSI Software Products 9301-2SE3400ZHU2 RSVIEW32 RUNTIME 300-32K UPGRADE IN-SUPT (ZH)

RSI Software Products 9515-RSNHS025ENE RSMACC NETWORK HEALTH FOR 25 NETWORKS

Motion Control 1326AB-B520E-S2K5L MOTOR,SERVO,460V,13.0NM,3000RPM,SINGL,BRK,IP67

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HMI-CAB-C58-2 CABLE AEG MODICON SLOT PR

IC693CBL314 Cable, I/O Expansion, 15 Meters, Shielded

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20BC8P7A0NYNACC1 PowerFlex 700 AC Drive 8.7 A 4 kW 20B

20F1ANF050JN0NNNNN PowerFlex 753 AC Packaged Drive

22B-E1P7F104 PowerFlex 40 0.75 kW (1 Hp) AC Drive

140ACO13000C Quantum 模擬量輸出, 8通道, 高密度, CC

284E-FVD7P6Z-25-CR-OC EtherNet Variable Frequency Drive

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1492-SPM1C150-N MCB Supplementary Protector 15 A

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150-C16NCD SMC-3 16A Smart Motor Controller

1608P-100A400V4S 100 A Pro DySC Sag Corrector

1769-SDN CompactLogix DeviceNet Scanner Module

193-CB1 Configuration Terminal Accessory

194R-R4 Operating Shaft

2090-CPBM7E7-08AF04 4 m Length SpeedTec Extension Cable

2090-XXTPMP-16S15 MP-Series 15 m Length Power Cable

CP3I-0WEB-0140-AZ Shielded motor power cable for B8HVis/B12Hvis/A8HVis/A12HVis motors (straight connector). 14 meters

GF-905692 Connecting FlashCable to Mitutoyo Angled Connection (RIGHT).

IC200UER008 VersaMax Micro Expansion 8 Output Expansion (8) Relay Outputs, 24VDC Power Supply (includes IC200CBL501)

IC647ACV103 9 to 25 Pin Convertor Connector (use XT cables on PS/2 class computers )

IC647PCL000 Proficy Process Systems Standard Edition 5000+ I/O with CIMPLICITY

IC693CBL304 Cable, Port Expansion, Used With PCM300

IC754ACC08MNT Mounting Clips (6) & PWR Connector 8in

IMC-313X-X-DRR IMC-D Series Servo Motor Controller, 3 Amp

SLC/1746 System 9399-CCAUG CONTROLGUARDIAN ARCHIVER5 USERS GUIDE

Open Automation Systems 1789-STRT1 SOFTLOGIX 5800 STARTER KIT ENGLISH

Application-specific products 1404-M805A-000-02 MASTER MODULE-PQ-120/240V P/S-CLASS 0.2

Operator Interface 2711-K10G15 PV1000 GRAYSCALE KEY, CNET & RS232 PRINT

Support 9301-2SE3300ITS SUPT RENEWAL CONTRACT FOR 93012SE3300IT

Support 9381-P15KENR SUPT REINSTATEMENT CONTRACT FOR 9381P15KEN

DeviceNet Products 1792D-CB23 MAXUM CABLE BASE WITH 17 PIN M23 CONNECTORS

RSI Software Products 9301-2SE3300FRU2 RSVIEW32 RUNTIME 150-1500 UPGRADE IN-SUPT (FR)

RSI Software Products 9358-EP30U1R UPGRADE: OUT-SUPT: RSBIZWARE EPROCEDURE 03 TO 30

Motion Control MPL-B4540F-MJ24AA MOTOR,SERVO,10.2 NM,3000RPM,MULTI,460V,BRK,13KG

Motion Control 9101-0325 CONNECTOR KIT, MOTOR POWER, H-2X/3X, STRAIGHT

GQPI31200S2P QUICKPANEL COLOR 10.5" STN GE LABEL

IC646MRB000 Logic PC Runtime 8,000 I/O

MTR-1N41-G-E-A-E-0 Stepping Motor Nema42, Parallel Wdg

RM-PS-024-01F Universal AC/DC Power Supply (24 VDC, 1 amp)