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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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1756-PBR2 ControlLogix Power Supply Bundle

188-K1D020-N Miniature Circuit Breaker 2 A

194E-Y16-1753-4N 16 A 194E Load switch

2090-CFBM7E7-CDAF01 MP-Series 1m Feedback Cable

2090-UXNFBMP-S25 MP-Series 25 m Length Feedback Cable

BC646TPD150 ProServer 150 I/O Develop/Runtime Systems with Proficy GlobalCare

GC647IFESGSR00300 GCC iFIX Optn: ESig & ERec 300 I/O Srv

IC200BEM104 VersaMax AS-Interface Network Master to interface a VersaMax PLC or I/O NIU to AS-Interface network. The AS-i module supports 31 slave devices.

IC646MOP001 Logic Developer PC with View for 8000 I/0 Development only

IC647IFPRSR00075C iFIX Profsnl SCADA 75 I/O Server (M1Component Part)

IC660TBD025 Terminal Assembly for IC660BBD025

IC697CMM721RR Series 90-70 Carrierband Lan Interface (MAP 30)

IC800MCUB12210XD 100 oz-in NEMA 23 stepping Motorcube with Devicenet interface

ControlLogix/1756 System 1756-IG16 0-5 VDC TTL INPUT (LOW TRUE) 16 PTS (20 PIN)

Industrial Computers 6182H-7TRH6D VVCE 700, TOUCH, STD MEM, RIO/DH, DC

Process Control 9358-PBNTK03ENE RSBATCH NT FOR PROCESSLOGIX BACK-UP KEY 03 UNITS

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ControlNet Products 1786-TPYR CONTROLNET Y-TAP/RIGHT ANGLE

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Motion Control MPL-A310P-HK22AA MOTOR,SERVO,1.58NM,5000RPM,ENCDR,230V,3.0KG

Motion Control 2090-DANFCT-S09 CABLE, NF, MTR FBACK FOR CABLE-MTD CONN, T, 09M

BC647MPP005 Logic Developer PLC Professional - 5 pack with Proficy GlobalCare Complete and 5 hardware keys

IC5002TBN0000 12" Inbligence Industrial PC, Perbance Series, WinNT

IC800CBL068 B2/3000 and B6/2000 Motor Power Cable, 14 Meters

OC647HSTSCADA500 Proficy Historian for SCADA 500 pts

20AD014A3AYYANC1 PowerFlex 70 AC Drive 14 A at 10 Hp 20A

20DC140A0EYNANANK PowerFlex 700S AC Drive 20D

20G1ANE063AN0NNNNN PowerFlex 755 AC Packaged Drive

25C-D030N114 PowerFlex 527 15kW (20Hp) AC Drive

280-PWRM22A-M025 ArmorStart Three-Phase Power Media

FX1S-20MT 主機(jī)12入/8出 晶體管輸出

1492-M5X12H1-20 Connection Products

1494H-CA3N Heavy Duty Non-Fus Safety Discon Switch

軟啟動(dòng)器 3RW44452BC34

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1585D-M4TBDM-2 Micro D-Code, QD Style Ethernet Media

1756-CPR2U ControlLogix Redundant Supply Cable Up

1794-OB16D Flex 16 Point Digital Output Module

194E-CA40-P11 194E Load switch

2085-IF8 Micro800 8 Point Analog Input Module

2090-DANBT-18S09 TL-Series 9 m Length Brake Cable

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HE693THM666 Discontinued Part. Check with GE IP on migration path.

IC630MDL311RR 24Vac/dc Source Input Module (16 points)

IC647HSTSS40KM Historian Standard Server 40000 Points (M4 Key)

IC660BLA025 Cover w/Label for IC660BBA025

IC695ALG626 Analog Input HART module, 16 channels single ended, 8 channels differential,channels are configurable for voltage,current and current/ HART. Supports Current: 0 to 20mA, 4 to 20mA, +/- 20mA; Voltage: +/- 10V, 0 to 10V, +/- 5V, 0 to 5V, 1 to 5V. The

IC756WDV009E-27 DataViews Development System Visual Basic English v2.7

CompactLogix System 1769-OF8C 8 CHANNEL ANALOG CURRENT OUTPUT MODULE

PLC-5/1771 System 9399-L5PG 9399-L5PG PLC-5 A.K. SERIES PROGRAMMING GUIDE

Distributed I/O 1799-ZCIOV ZONE CONTROL I/O CARD W/SINKING OUTPUTS AND ZIP

Operator Interface 2711P-T6C8A PV PLUS 600 COLOR, TOUCH, DH+, AC PS

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Support F1779-KP2R FIRMWARE UPGRADE FOR 1779-KP2R COMMUNICATION MODUL

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RSI Software Products 9701-VWMR075ENU2 RSVIEW ME STATION RUNTIME 30 TO 75 DISPLAY UPGRADE

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Motion Control 2098-DSD-HV030 HIGH VOLTAGE DRIVE, 7A/14A, ULTRA3000

ABI31200C2P/SER QUICKPANEL 10.5" TFT W/SE

IC200UUB001 VersaMax Micro 64, USB Slave communications option board. The option board also supports program storage memory module. Compatible with VersaMax Micro 64 only.

IC752DPA060RR Datapanel 1060 with resistive touch. 10.4" VGA (640x480) active matrix TFT color display. No bezel - mounts from inside panel. Supports all WinCfg functionality.

MTR-3S32-G-R-0-E-SRR Servo Motor Nema34 Flg with Seal

ZA06B-0273-B500 Alpha 40/4000HVis servo motor with straight shaft with key and brake

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20G14ND302AA0NNNNN PowerFlex 755 AC Packaged Drive

25-PMFC-FC PowerFlex 520 Fr C Power Mod Front Cover