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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(chē)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(chē)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(chē)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(chē)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(chē)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(xiàn)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(chē)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(chē)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(chē)輛制造中的應(yīng)用。車(chē)輛激光焊接車(chē)輛轉(zhuǎn)向架以及車(chē)體是城市軌道車(chē)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(chē)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(chē)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(chē)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(chē)輛車(chē)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(lèi)車(chē)身構(gòu)件，焊接成白車(chē)身分總成，進(jìn)而總裝成整車(chē)車(chē)身。激光組焊因其焊接強(qiáng)度高，可明顯改善車(chē)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(chē)體制造。城市軌道車(chē)輛車(chē)體通常選用不銹鋼車(chē)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(xiàn)、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(chē)體激光焊接樣件的制評(píng)亦完成。


2) 車(chē)輛轉(zhuǎn)向架制造。城市軌道車(chē)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(chē)輛激光切割

激光切割技術(shù)特性城市軌道車(chē)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(chē)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(chē)輛車(chē)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(chē)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(chē)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(qián)、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(chē)輛制造中。以某企業(yè)為例，其高速動(dòng)車(chē)組車(chē)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(chē)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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Support F1785-L80ESERE FIRMWARE UPGRADE FOR 1785-L80E PLC5 PROCESSOR MODU

RSI Software Products 9301-2SE2350FRU2 RSVIEW32 WORKS 300-5K UPGRADE IN-SUPT (FR)

RSI Software Products 9701-VWSS250FRU2 RSVIEW SE 100 TO 250 DISPLAY UPGRADE (FRENCH)

RSI Software Products 9399-WAB32LUGFR RSLINX LITE USER GUIDE (FRENCH)

Motion Control 8720MC -D078-AA- 78 AMP C CHASSIS DRIVE, ENCLOSURE., LESS OPTIONS

BC646MRA000 View Runtime 8,000 I/O

IC300OCS980 OCS250 Demo with Case

IC752WTE001 Display Station 2000 Series - 10.4" active matrix VGA (640x480) resistive touchscreen, Pentium 233MHz, 64MB RAM, 6.4 GB HD, Ethernet, 300pt count CIMPLICITY HMI, field detachable front/rear housing and Win '95

MTR-3T44-J-R-0-M-0 MTR series metric servo motor with resolver

20AC8P7A0AYNNDC0 PowerFlex 70 AC Drive 8.7 A at 4 kW 20A

20DC011A3EYYAEANE PowerFlex 700S AC Drive 20D

20G1ALD545AN0NNNNN PowerFlex 755 AC Packaged Drive

25B-D024N114 PowerFlex 525 11kW (15Hp) AC Drive

2711T-T10R1N1 MobileView Tethered Operator Terminal

FR-E540-3.7K 6.8 KVA 9A 3.7KW 3相AC380V/50Hz/60Hz

1492-L6T IEC Term Blck 8.1x90x38mm Spr Clp

1494F-D30 Disconnect Switch

軟啟動(dòng)器 3RW44342BC46

電源 6EP1 333-4BA00 PM1507：額定輸入電壓 120 V / 230 V AC 自適應(yīng)，輸出 24 V / 8 A

1585D-D4TBJM-0M3 Micro D-Code, QD Style Ethernet Media

1747-M13 SLC 64KB Memory Module

1794-ADN Flex DeviceNet Adapter

194E-AA16-PE 194E Load switch

2071-TBIO Kinetix 3 Limited I/O Breakout Board

2090-CSWM1DF-14AA07 Kinetix Cable Single DSL 2090-Series

20AC2P1A0AYNNNC1 PowerFlex 70 AC Drive 20A

GC646MNT700 Proficy GlobalCare Complete for Logicmaster 90-70

HE693IBMOIU-57 Personal Computer Programming Utility for all Release 3.0 OIUs

IC609EXP101RR UL Listed Series One Junior Expansion 115Vac I/O

IC647HSTSC10000KM Server to Server Collector for Historian - Standard Server 10,000,000 Points (M4 Key)

IC660BBA023 Block 24/48VdcThermocouple Input 6 Channels

IC694MDL660 RX3i 24VDC Input Module 32 point. Module is supported by serial bus andis not limited to the universal base or expansion base. The module requires a terminal block (IC694TBB032 box style or IC694TBS032 spring clamp style terminal block). Terminal

IC756WDC009K-20 DV Dev Sys (Pro) VB, C++, Kor v2.0

MicroLogix 1500/1769 System 1769-CRR3 3.28 FT (1 M) RIGHT-TO-RIGHT BUS EXPANSION CABLE

PLC-5/1771 System 1785-KE DATA HWY PLUS RS-232C INTERFACE MODULE

Distributed I/O 1797-IBN16 EX NAMUR DIGITAL INPUT MODULE, 16 PT.

Operator Interface

Support 9321-PLC5R SUPT REINSTATEMENT CONTRACT FOR 9321PLC5

Support 9358-HSTS2100R SUPT REINSTATEMENT CONTRACT FOR 9358HSTS2100

Support F1772-LVSERA FIRMWARE UPGRADE FOR 1772-LV PLC2 PROCESSOR MODULE

RSI Software Products 9324-RLD300ITE RSLOGIX 5000 STANDARD, ITA

RSI Software Products 9304-WVPR300DU1R UPGRADE: OUT-SUPT: WINVW TO WINVW PRO RUNTIME 3000

RSI Software Products 9358-PLTM2600U2R UPGRADE: OUT-SUPT: PLANTMETRICS 10 TO 200 WORKCELL

Motion Control 8720SM-093-S6TAS1 93 KW/176 AMP, 750 VDC, AC MOTOR WITH SRS60 ENC.

A06B-0113-B175#7008 B0.5/3000 Servo Motor, Holding Brake, 32K Serial Encoder

IC200UAA007-24 Qty of 24, 28 point PLC, (16) 120VAC In, (12) 120VAC Out, 120V/240AC Power Supply. Battery (IC200ACC403) is required for data retention

IC752BCL101 Datapanel 150/160/240E to SNP (25 pin to 15 pin)

MTR-1350-N-A-E-S MTR series NEMA 34 splashproof stepping motor with parallel winding connection

ZA06B-0085-B203 B22/2000is servo motor with 128k serial encoder

20BD2P1A0AYNANC0 PowerFlex 700 AC Drive 2.1 A at 1 Hp 20B

20G11TC540AN0NNNNN PowerFlex 755 AC Packaged Drive

25-JBAD PowerFlex 520 Frame D NEMA/UL Type 1 Kit

140XCP90000C Quantum RAM電池備用模塊, 用于ESI061和EHC105, CC

FRN30F1S-4C 44 KVA 59 A 30KW 3相AC380V/50Hz/60Hz

Z-15GQ2-B 觸點(diǎn):1開(kāi)/1閉,15A 250VAC機(jī)械壽命:1000萬(wàn)次 按鈕型

1492-SPM3C160 Mcb Supplementary Protector 16 A

軟啟動(dòng)器 3RW40471TB05

熱電阻模擬量輸入模塊 6ES7 231-5PF32-0XB0 SM 1231 AI 8 x 16 位熱電阻

150-SB4NBD SMC-50 SOLID STATE MOTOR CONTROLLER 180A

1734-RTBS POINT I/O Accessory

1783-MX04T04E Stratix 8000 4+4 Port PoE Exp. Module

193-ESM-IG-60A-E3T E300/E200 60 Amp Sensing Module

20-750-I1B-C770D740 PowerFlex 750 Replacement Inverter

2090-CPWM7DF-14AF75 MP-Series 75 m Length Power Cable

2098-DSD-HV220-SE Ultra 3000 22kW with SERCOS Servo Drive

GA647IFCLNTS010 GCA iFIX iClientTS 10 Additional Users

GP-0602NT-H1SB GagePort LVDT NT (Half Bridge H1 Blocks) - Sales BOM.

IC5005TAX0110 PanelPC 15 inch Standard Unit with Windows XP and Stainless Steel Bezel

IC647HSTAE3KM Alarm and Events Option for Historian - Standard Server 2500 Points (M4 Key)

IC647SRVPPCREW PA Solutions Pack Crew Scheduler

IC693MDL740 12/24 Vdc Output, 0.5 Amp, Positive Logic (16 Points)

IC756HDV010E-99 DV Draw Development on HP/UX Op Sys, English, Version 9.9

Pico Controllers 1760-L12DWD 12 I/O PICO CONTROLLER W/RTC, 12V DC

PLC-5/1771 System 1771-IQ16K CONFORMALLY COATED,ISOLATED INPUT MODULE,24V DC

Distributed I/O 1791D-0V16PX 24 VDC COMPACTBLOCK I/O EXPANSION, 16 OUT SINK

Communications 1784-PCMS 1784PCMK/B OR 1784PCMKS/A RIO CBL (3 PIN PHOENIX)

Operator Interface 2706-P92C INVIEW MESSAGE DISPLAYS

Support 9701-VWMR015AR SUPT REINSTATEMENT CONTRACT FOR 9701VWMR015AENE

Support 9515-RSNHS005S SUPT RENEWAL CONTRACT FOR 9515RSNHS005ENE

EtherNet/IP Products 2711-T10G20L1 PV1000 GRAYSCALE TOUCH, ENET & RS232 PRINT