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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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Application-specific products 1404-DM DISPLAY MODULE FOR POWERMONITOR

Operator Interface 2711-K6C8L1 PV600 COLOR KEY, DH+ & RS232 PRINT

Support 9301-2SE2500ZHR SUPT REINSTATEMENT CONTRACT FOR 93012SE2500ZH

Support 9380-RSBAR10000S SUPT RENEWAL CONTRACT FOR 9380RSBAR10000

DeviceNet Products 1734-VHSC5 5 VDC VERY HIGH SPEED COUNTER WITH SOURCE OUTPUTS

RSI Software Products 9301-2SE3200FRE RSVIEW32 RUNTIME 300 (FRENCH)

RSI Software Products 9358-BPC60U3 UPGRADE: IN-SUPT: RSBIZWARE PC PHASES 30 TO 60

Motion Control MPL-B430P-SJ22AA MOTOR,SERVO,6.55 NM,5000RPM,SINGL,460V,6.4KG

Motion Control 2090-SCNP1-0 SERCOS FBR CABL,CONN,HARSH DUTY,JKT,PLASTIC,1.0M

GFK-1246 TCP/IP Ethernet Communications (Type 2) for the Series 90-70 PLC User's Manual

IC646MDD159 Logic Developer PC (HRT)1500 Tag Runtime & Development System

MSP-TCK-IN1 Obsolete - Type K (0 to 1300C) in / Pulse out

QPI-GEG-201 Communication Module for 7 inch/ 9 inch/ 10 inch & 12 inch: GE Fanuc Genius/ UL/ cUL/ UL1604

20BC022A3NYNAEC0 PowerFlex 700 AC Drive 22 A at 11 kW 20B

20F11GD034AA0NNNNN PowerFlex 753 AC Packaged Drive

21G14PF795AN2NNNNN-ND-P20-P30 PowerFlex Air Cooled 755 Packaged Drive

2711P-RDT12CK PanelView Plus Display Module

280E-F12Z-10B-CR-3 ArmorStart Direct Online Starter

C200HX-CPU44-E CPU單元? 內(nèi)存31.2K最大I/O點(diǎn)數(shù)：880點(diǎn)?帶RS-232C時(shí)鐘

1492-PD3141 175 A Power Distribution Block

電源模塊 6ES7405-0DA02-0AA0 PS405 輸入電壓 24V DC 4A

變送器 3RS17051KD00

TIA 博途數(shù)字化選件 6ES7823-0BA00-1CA0 SIMATIC OPC UA S7-1500 medium ( CPU-1515 / CPU-1516 (F) )

1585J-M8PBJM-8X 1585J Ethernet Media Cables

1760-NDC Pico Protective Cover

188-K2D320 Miniature Circuit Breaker 32 A

194L-E12-4501 12A 194L Load Switch

2090-CPBM4DF-14AF02 MP-Series 2 m Length Pwr and Brake Cable

2090-XXLF-X330B Kinetix 6200/6500 Line Filter

BC647OEM0210 OEM Edge Program Additional Key - CIMPLICITY (Approval Required)

GC647IPWRTSUSBSEM iPower Option - TS Base Globalcare Complete part

IC200ETM001CA EXPANSION TRANSMITTER CONFORMAL COATED

IC646NHR000 Redundancy

IC647ITMM ITM:Intermec Barcode Readers

IC670MDL730 24VDC 2A Output, Pos. Logic, 8 Point, Electronic Short Circuit Protect ion

IC697MDL640 125 Vdc Input (16 Points)

IC800SLCPV100 Power cable for SDM100 or SLM100 or SDM250 or SLM250 or SGM450 S-series servo motor. 10 meters

ControlLogix/1756 System 1756-PA75R 85-265VAC REDUNDANT POWER SUPPLY

Industrial Computers 6182H-12TEH6D VVCE 1250, TOUCH, EXT MEM, RIO/DH, DC

Process Control 1757-PFBUPG003 PROFIBUS LIC UPG 3 IOMS

Operator Interface 2711P-RW3 PV PLUS INTERNAL CF W/ OS & ME, 256 MB

Support 9357-ENETL3R SUPT REINSTATEMENT CONTRACT FOR 9357ENETL3

Support 9363-PORTALS SUPT RENEWAL CONTRACT FOR 9363PORTAL

ControlNet Products 1734-SSI SSI ABSOLUTE ENCODER INTERFACE

RSI Software Products 9301-2SE240DEU1R RSVIEW32 WORKS 1500-32K UPGRADE OUT-SUPT (DE)

RSI Software Products 9358-B10UB1R UPGRADE:OUT-SUPT:RSBIZWARE BATCH 10 UNTS TO BUNDLE

Motion Control MPL-A430H-SJ22AA MOTOR,SERVO,6.55 NM,3500RPM,SINGL,230V,6.4KG

Motion Control 2090-UXNFBY-S09 CABLE,ULGRF50ON-FLEX,MOTOR FEEDBACK,Y,9M

CBL-14-ED-30 Encoder Cable, MTR-1235, 13xx, 14xx & 1N Series Splashproof Stepping Motors to IMC-D or S2K, 30 ft.

IC610MDL127RR 230Vac Input (8 points)

IC800SLA3502 3500W, 230VAC SL Series Amplifier

OC647IFGLBLDPNSRVENM iFIX WebSpace Dependent Server Enabler

20AD3P4A0AYNNDC0 PowerFlex 70 AC Drive 3.4 A at 2 Hp 20A

20DD011A3EYNACANE PowerFlex 700S AC Drive 20D

20P21AE405RA0NNN PowerFlex 405 A DC Drive

2711-NMCD PanelView Accessory

280-PWRM22H-M6 ArmorConnect 3-PH Power Media drop cable

3G3JV-A2015 4.3KVA 8.0A 1.5KW 三相AC200-240V/50HZ/60HZ

1492-MCAA235 35 A Ul489 Miniature Circuit Breaker

1494U-LM31 1494U 100A Multi-port Lugs

軟啟動(dòng)器 3RW44556BC34

Safety Advanced V14 6ES7833-1FB14-0YA5 STEP 7 Safety Basic V14 SP1

1585D-M4UBDM-60 1585D Ethernet Media Patchcord

1756-IV16 ControlLogix 16 Pt 12/24V DC D/I Module

1797-PS1N FlexEx Power Supply

194E-E63-1753-6A 63 A 194E Load switch

2090-CFBM6DD-CCAA07 TL-Series 7m Feedback Cable

2090-SCEP1-0 Kinetix 1-1m Fiber Optic Cable

BC646MDG001 GE FANUC SRTP OPC Server with Proficy GlobalCare Complete

GC647ADC005 GC Dashboard Client 5 Pak

HMI-CAB-C52 CABLE IBM AT 9 PIN COMM P

IC641SWP062 Series 90 PCM Development S/W, CIMPLICITY 90-ADS/CIMPLICITY 70

IC647IFCLNTSRO005K iFIX iClientTS Read Only 5 PK (M1 Kit Part)

IC660EBA106RR Current Source Analog, 115Vac/125Vdc Power, Elec Asm only

IC695PSD040CA RX3i 24VDC power supply, 40 Watt Conbal Coated.

IC756WRE099E-26 DV Runtime Win 50-99 Per User Eng v2.6

FlexLogix System 1794-OB16 24V DC SOURCE OUTPUT MODULE, 16 POINT

PLC-5/1771 System D1785-6.5.19 1785ENET PLC5 ETHERNET INTERFACE MODULE USR MANUAL

Process Control 1757-PLXSIFV ASEA CONTROLLER QUICKBUILDER INTERFACE

Operator Interface 2711P-K10C15D2 PV PLUS 1000, KEYPAD, CNET, DC PS, EXT MEM