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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(wàn)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(wú)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(guò)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(guò)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(guò)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(guò)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(lái)改善焊接穩(wěn)定性；而開(kāi)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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RSI Software Products 9305-RSVADFCFRE RSVIEW32 ACTIVE DISPLAY FLOATING CLIENT (FRENCH)

RSI Software Products 9358-SPCSUE SPC SUITE

Motion Control 2094-BC01-M01 MODULE, INTEGRATED, 400/460V, 6KW CONV. 9A INV.

A06B-0153-B075#7008 A30/3000 Servo Motor, 64K Serial Encoder

IC200UDR002-24 Qty of 24, 14 point PLC, (8) 24VDC In, (6) Relay Out, 24 VDC Power Supply

IC752CBT010RR Datapanel 320T ME (Mono Expansion): 320x240 1/4 VGA Monochrome LCD with 80386SX/40 PC processor. Analog touch screen with text, bitmaps, bar graphs, real time clock. With 2M memory and PC/104 capability.

MTR-1N32-I-E-D-S-0 MTR series NEMA 34 stepping motor with series winding connection and encoder

ZA06B-0116-B175#0008 BM1/4000 servo motor with brake and 32k serial encoder

20BD481A0ANNNND0 PowerFlex 700 AC Drive 20B

20G11TF370AN0NNNNN PowerFlex 755 AC Packaged Drive

25-PM1-D017 PowerFlex 520 7.5kW (10Hp) Power Module

372SPU47701V26 Quantum Concept 2.6 應(yīng)用程序下載軟件

FRN 2.2E1S-7C 4.1 KVA 11 A 2.2KW 單相AC220V/50Hz/60Hz

A20B-2902-0070 A20B-2902-0070/02B

1492-SPM3D010-N MCB Supplementary Protector 1 A

軟啟動(dòng)器 3RW40282TB04

SIMATIC 存儲(chǔ)卡 6ES7 954-8LC02-0AA0 4 MB

150-SD1NUD SMC-50 SOLID STATE MOTOR CONTROLLER 361A

1738-8CFGM23 ArmorPoint 8 Point Combination Module

1783-US6T2F Stratix 2000 6+2 port unmanaged switch

193-EXP-DIO-42-120 E300 120V AC Digital Expansion Module

20-750-NEMA1-F1 PF753 & PF755 FR 1 EMC CORES W PLATE

2090-CPWM7DF-16AF03 MP-Series 3m Length Power Cable

20AB-DB1-D PowerFlex 70 Resistor Kit

GA647IFESGRNUNLMT GCA iFIX Optn: ESig & ERec Unl I/O Run

GP646IFCLNTCRO010 GCP iFIX iClient Read Only 25 PK Keyless Runtime Version

IC600BF802RR 24-48Vac/dc Input Module (8 points)

IC647HSTCC1KM Calculation Collector for Historian - Standard Server 1000 Points (M4 Key)

IC647TBLCPVC001 Virtual Campus for Proficy Troubleshooter and Cause+ - 1 User

IC693MDL753CA Conbal Coated Output module, 12/24VDC POS logic, 32 points. Interfaceis Fujitsu connector.

IC756LDV000K-912 DV Development - Inb/Linux RedHat Op Sys, Korean, Version 9.12

Pico Controllers 1760-SIM INPUT SIMULATOR FOR 12 I/O DC PICO CONTROLLER

PLC-5/1771 System 1771-OD16K CONFORMALLY COATED, 120V AC ISOLATED OUTPUT MODULE

Distributed I/O 1791-0A32 BLOCK I/O, 120V AC, 32 POINT MODULE (32 OUTPUT)

Communications 1786-RPA CONTROLNET MODULAR REPEATER ADAPTER

Operator Interface 2706-PRIOK REMOTE I/O COMMUNICATION MODULE FOR 2706-P7X & P9X

Support 9701-VWSCWAS SUPT RENEWAL CONTRACT FOR 9701VWSCWAENE

Support 9324-RL0100ESR SUPT REINSTATEMENT CONTRACT FOR 9324RL0100ES

EtherNet/IP Products 2711P-K15C4B1 PV PLUS 1500, KEYPAD, ENET, AC PS, STD MEM

RSI Software Products 9301-2SE340PTU1R RSVIEW32 RUNTIME 1500-32K UPGRADE OUT-SUPT (PT)

RSI Software Products 9356-PRO2350U6R UPGRADE: OUT-SUPT: RSSQL PROF.300 TO PROF.5000 TAG

Motion Control F-4050-Q-H04AA MOTOR/ENCODER/BRAKE

4360-N 4360 WITH NEMA 4

IC200ACC303 I/O SHORTING BAR QTY 2

IC693DNM200 DeviceNet Master

TGT-DI0L-64-0 Target Ditial I/O 32 Inputs,32 Inputs/Outputs

VDOC-SF VisualDocs ShopFloor seat

20BD014A3AYNAND1 PowerFlex 700 AC Drive 14 A at 10 Hp 20B

20G11BF590JN0NNNNN PowerFlex 755 AC Packaged Drive

22C-B120A103 PowerFlex 400- 30 kW (40 HP) AC Drive

140XCA71706 Quantum 背板擴(kuò)展電纜, 2M

285-BRC25-M1 Source Brake Cordset Cable

H7ET-N1 7位液晶顯示累積計(jì)時(shí)器,觸點(diǎn)輸入、外部/手動(dòng)復(fù)位、量程999h59m-3999d23.9h可切換

1492-SPM1D100 MCB Supplementary Protector 10 A

通用型變頻器 6SE6 440-2UD24-0BA1 4.0 KW,149 x 202 x 172

電機(jī)啟動(dòng)器 3VU13403NK00

150-C43NBR SMC-3 43A Smart Motor Controller

1609-RSC 1609 Remote Start Cable UPS Accessory

1771-IA 1771 8 Point Digital Input Module

193-EC2EE E3 Plus 18-90 A Overload Relay

198-MS23 ModCenter IEC Push-Button

2090-CPBM7E7-16AF12 MP-Series 12 m Length Cable

2094-AL75S Kinetix Line Interface Module

CQPM3D200B2P QUICKPANEL MINI BLUE, TCP, 24VDC, UL/CE

GFK-0467 Series 90-30/20/Micro PLC CPU Instruction Set Reference Manual

IC200UEX636 6 channel Analog expansion. (4) Analog bs & (2) Analog outputs. 120/240 VAC Power Supply (includes IC200CBL501)

IC647APXC APX:Moore APACS

IC647PFL200 Proficy Process Systems Standard Edition 2000 I/O with iFIX

IC693CHS398CA Conbal Coated 5 slot expansion base

IC754TAN001 VersaMax I/O Interface for QP Control

MA15/D/1/SI AC15AMP PWR SRG PROTECT (120AC)

SLC/1746 System D1747-UM011DENP SLC500 MODULAR HARDWARE STYLE

Distributed I/O 1734D-IB8XOB8ES 24 VDC 8 SINK IN 8 SOURCE OUT, DNET COMMS, SPRING

Application-specific products 1803-EEM01E4 EEM,8 ANALOG, 4 TO 20 MA, NEMA 4 ENCLOSURE