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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(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，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(jì)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(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)，如對夾具、被焊件、監(jiān)測精度等要求嚴(yán)格，焊接后檢測評價(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(shí)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(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(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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GuardPLC Systems D1753-UM001AENP GUARDPLC CONTROLLER SYSTEMS USER MANUAL

Process Control 1757-UPGSIFZF UPGRADE BAILEY INFI90 QUICKBUILDER INTERFACE

Operator Interface 2711P-B15C15D2 PV PLUS 1500, KEY/TOUCH, CNET, DC PS, EXT MEM

Support 9230-IOLINXSDKR SUPT REINSTATEMENT CONTRACT FOR 9230IOLINXSDK

Support 6300-DES 6300-DE SOFTWARE SUPPORT RENEWAL

Support F1785-V80BSERC FIRMWARE UPGRADE FOR 1785-V80B PLC5 PROCESSOR MODU

RSI Software Products 9301-2SE2350PTU2 RSVIEW32 WORKS 300-5K UPGRADE IN-SUPT (PT)

RSI Software Products 9701-VWSTPU1 RSVIEW STUDIO FOR ME TO RSVIEW STUDIO WITH PE

RSI Software Products 9399-WABOUGPT RSLINX OEM USER GUIDE (PORTUGUESE)

Motion Control 8720MC-HF-B 460VAC HARMONIC FILTER

BC646MRC300 Logic PC & View Runtime 300 I/O

IC300RCS071 16 DC Inputs (12/24vdc), 12 Positive Logic DC Outputs (5/12/24vdc, 0.5A with ESCP)

IC754VBI06MTD 6" Monochrome Quickpanel View Intermediate, Touch, 24VDC, Blank label

MTR-3T54-H-R-B-M-0RR Servo Motor Metric 24V Brake

20AC8P7A3AYYANC0 PowerFlex 70 AC Drive 8.7 A at 4 kW 20A

20DC030A0EYNANANE PowerFlex 700S AC Drive 20D

20G1ANC140JN0NNNNN PowerFlex 755 AC Packaged Drive

25B-E022N104 PowerFlex 525 15kW (20Hp) AC Drive

2715-T7CA PanelView 5500 6.5 in. Graphic Terminal

FR-A740-37K 54KVA 71A 37KW

1492-LDG3P IEC Term Blck 5.1x95x41mm Spr Clp

1494F-N20 Master Door Interlock Kit

軟啟動器 3RW44356BC35

ET 200SP 6ES7131-6BF00-0AA0 DI 8x24VDC 基本型， 基座單元類型 A0

1585D-E4TBDE-2 Micro D-Code, QD Style Ethernet Media

1753-HHT GuardPLC Handheld Terminal

1794-IB16D Flex 16 Point Digital Input Module

194E-AA20EX-6 194E Load switch

2080-LC20-20QBBR Micro820 20 I/O ENet/IP Controller (RTB)

2090-CSWM1DF-14AA25 Kinetix Cable Single DSL 2090-Series

20AC3P5A0AYNANC1 PowerFlex 70 AC Drive 20A

GC646MPPS50 Proficy GlobalCare Complete for Logic Developer - PLC Professional - 50 Seat Site License

HE693OIU907 Full-sized Genius VF OIU powered by 80-240VAC

IC610CHS100RR Rack, Non-Expandable, 115/230Vac Power Supply HiCap (5 Slots)

IC647HSTSC300M Server to Server Collector for Historian - Standard Server 300 Points (M4 Key)

IC660BBA104 Block 115Vac/125Vdc Analog Current Source 4 Inputs / 2 Outputs

IC694MDL754CA Conbal Coated. 12/24VDC Output (0.75 amps/point)Module 32 point. Requires terminal block IC694TBBx32 box style or IC694TBSx32 spring clamp. Terminal block is sold seperaby. Output response Time is 0.5ms.

IC756WDJ009K-22 DV Development Sys VB and Java, Korean, Version 2.2

MicroLogix 1500/1769 System 9399-RLD300GR RSLOGIX 5000 GETTING RESULTS GUIDE

PLC-5/1771 System 1771-P2 POWER SUPPLY, 6.5A, 120/220V AC

Distributed I/O 1794-CE1 EXTENDER CABLE FOR TERMINAL BASES, 1FT/.3M

Operator Interface 2711P-B6C8A PV PLUS 600 COLOR, KEY/TOUCH, DH+, AC PS

Support 9323-PA2ES SUPT RENEWAL CONTRACT FOR 9323PA2E

Support 9358-MTRCK02R SUPT REINSTATEMENT CONTRACT FOR 9358MTRCK02ENE

Support F1772-LXSERC FIRMWARE UPGRADE FOR 1772-LX PLC2 PROCESSOR MODULE

RSI Software Products 9324-RLD600ESE RSLOGIX 5000 FULL EDITION, SPANISH

RSI Software Products 9305-RSVADFCDEE RSVIEW32 ACTIVE DISPLAY FLOATING CLIENT (GERMAN)

RSI Software Products 9358-SCHVWENE RSBIZWARE SCHEDULER VIEW

Motion Control 2094-AM01 MODULE, AXIS, 200/230V, 9A INV.

A06B-0147-B075#7076 A22/2000 Servo Motor, IP67 Sealing, 64K Serial Encoder

IC200UDR001 14 point (8) 24VDC In, (6) Relay Out, AC Power Supply

IC752CBT000RR Datapanel 320T MB (Mono Base): 320x240 1/4 VGA Monochrome LCD with 80386SX/40 PC processor. Analog touch screen with text, bitmaps, bar graphs, real time clock.

MTR-1N31-I-N-D-S-0 MTR series NEMA 34 stepping motor with series winding connection

ZA06B-0115-B503 B0.5/5000is servo motor with 24 VDC brake and 64k serial encoder

20BD3P4A3AYNAND0 PowerFlex 700 AC Drive 3.4 A at 2 Hp 20B

20G11TF265JN0NNNNN PowerFlex 755 AC Packaged Drive

25-PM1-B8P0 PowerFlex 520 1.5kW (2Hp) Power Module

372SPU47411V26 Quantum Concept 軟件,XL 版本,3 用戶,V2.6

FRN 0.4E1S-7C 1.1 KVA 3.0A 0.4KW 單相AC220V/50Hz/60Hz

A20B-2902-0343 A20B-2902-0343/03B

1492-SPM3D005 MCB Supplementary Protector 0.5 A

軟啟動器 3RW40282BB15

輸入仿真器 6ES7 274-1XH30-0XA0 14 位置仿真器

150-SCMR SMC-50 CONTROL MODULE 24 VDC

1738-8CFGDLXM12 ArmorPoint 8 Point Combination Module

1783-US4T1H Stratix 2000 4+1 unmanaged port switch

193-EXP-AIO-31 E300 Analog Expansion Module

20-750-MNT3-F10 PF755 FR10,IP00,FLOOR MOUNTING KIT

2090-CPWM7DF-16AA90 MP-Series 90m Servo Power Cable

20AB-DB1-A PowerFlex 70 Resistor Kit

GA647IFESGRN00150 GCA iFIX Optn: ESig & ERec 150 I/O Run

GP-3102NT GagePort Combo NT 2-port b

IC5105KAX0001 Panel C IPC 15in Unbundled WXP

IC647HSTCC150KM Calculation Collector for Historian - Standard Server 150000 Points (M4 Key)

IC647SYM001 Scheduler Yeast Manufacturing