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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(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。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(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(duì)夾具、被焊件、監(jiān)測精度等要求嚴(yán)格，焊接后檢測評(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(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(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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BC647TPD915 CIMPLICITY HMI ProServer 1500 I/O Development and Runtime System with Proficy GlobalCare

GC647PRTKIT002 GlobalCare Complete - Proficy Portal Enterprise Edition Starter Kit 2 User Ver 3.0

IC200MDL742 Output 24VDC POS LOGIC 0.5 amp per point(2 group of 16) with ESCP 32 points

IC646PEW110 OpenProcess Engineering Workstation (700 I/O)

IC647MRC000 Logic PC and View Runtime 8000 I/O with USB Hardware key

IC677PBI001 Profibus VersaMax IP Modular local bus master with (8) 24VDC bs.

IC697RCM711RR Redundancy Communications Module (Hot Standby Redundancy)

IC800SSI228D2 28 amp 230 VAC Devicenet S2K servo controller for S-series motors

SLC/1746 System 1747-L532 SLC 5/03 CONTROLLER, 16K MEMORY

Industrial Computers 6181P-12NP2KH VERSAVIEW INTEGRATED DISPLAY COMPUTER 12-INCH TFT

Application-specific products 9358-PBA30ENE RSBIZWARE BATCH FOR PROCESSLOGIX ARCHIVER 30 UNITS

Operator Interface 2711-B5A9L1 PV550 MONO KEY&TOUCH, RS232 (DH485) & RS232 PRINT

Support 9303-3CS0EFFUR UPGRADE: OUT-SUPT: DRVTOOLS SUITE TO DT32 SUITE

Support 9391-SDWK3R 9391-SDWK3 SOFTWARE SUPPORT CONTRACT REINSTATEMENT

ControlNet Products 2711-B6C15 PV600 COLOR KEY&TOUCH, CNET & RS232 PRINT

RSI Software Products 9301-2SE2500KOU4 RSVIEW32 WORKS 150-100K UPGRADE IN-SUPT (KO)

RSI Software Products 9358-BEBNT60ENE RSBATCH / EPROCEDURE FOR NT BUNDLE 60 UNITS

Motion Control MPL-A4540C-HK24AA MOTOR,SERVO,10.2NM,1500RPM,ENCDR,230V,BRK,13KG

Motion Control 2090-XXNFMP-S20 CABLE,NON-FLEX,MOTOR FEEDBACK,MP/1326AB,20M

CBL-RKLK-10 Rack Linker Cable, Target ARS Series Controller

IC641PCC012 Toolkit, Symbol Server C

IC800SSD104RS1 4.3A, 115/230V, S2K Servo Drive for MTR Series Motors

PR-PAT-AXIOM-INR Proficy PAT - Axiom Multiplexer Interface: Provides The Capability To Control An Axiom Analytical Fmx Series Fiber-Optic Multiplexer

20B-VECT-C0AE 20B-VECT-C0AE,PF700VC,AE,24V

20DD5P0A0EYNANANE PowerFlex 700S AC Drive 5 A at 3 Hp 20D

20YD1K3A0ANNANA0 PowerFlex 700 AFE Active Front End

2711P-B7C22D9P PanelView Plus 7 Graphic Terminal

280-PWRM35C-M10 ArmorStart Three-Phase Power Media

CPM1A-AD041 NEW 4路模擬量輸入，分辨率1/6000

1492-MR6X8C Connection Products

1495-N24 Auxiliary Contact Adapter Kit

行程開關(guān) 3SE53120SB12

運(yùn)行版軟件 6AV2105-0HA04-0AA0 SIMATIC WinCC Runtime 專業(yè)版 4096 PowerTags V14

1585J-M4TBJM-30 RJ45 Ethernet Media

1756-OF6CI ControlLogix 6 Pt Isolated Module

188-K1C030 Miniature Circuit Breaker 3 A

194E-GA16 194E Load switch

2090-CFBM7DF-CEAA02 MP-Series 2m Servo Feedback Cable

2090-UXBK-D1503 Ultra Series 3m Cable Breakout Board Kit

BC646OEM0410 OEM Edge Additional Key - Historian

GC647DMS003 GC DataMart 3 PA Connections

IC200ALG262CA ALG IN 15B CURR DIF 8CH CONF COAT

IC646IFCLNTCRO010M iFIX iClient Read Only 10 PK Keyless (M4 Part)

IC647IFPLSRUNLMTM iFIX Plus SCADA Unlimited Server (M4 Part)

IC660MLR101 Label for IC660BBR101 (Qty 100)

IC697BEM733RR Series 90-70 Genius Remote I/O Scanner

IC800BBK021 Battery backup kit for Beta and Beta i series amplifiers

ControlLogix/1756 System 1756-L55M16 LOGIX5555 PROCESSOR WITH 7.5MBYTE MEMORY

Industrial Computers 6182H-7BEH6B VVCE 700, KEY/TOUCH, EXT MEM, RIO/DH, AC

Process Control 9358-BHIST03ENE RSBIZWARE BATCHHISTORIAN - 1-3 BATCH SERVERS

Operator Interface 2711P-B15C6D2 PV PLUS 1500, KEY/TOUCH, RIO/DH, DC PS, EXT MEM

Support 9240-WIN16RTR SUPT REINSTATEMENT CONTRACT FOR 9240WIN16RT

Support 6723-PCOS SUPPORT RENEWAL CONTRACT FOR 6723-PCO

Support F5130-KA FIRMWARE UPGRADE FOR 5130-KA PLC5250 PROCESSOR MOD

RSI Software Products 9301-2SE2350ZHE RSVIEW32 WORKS 5K (CHINESE)

RSI Software Products 9351-HPUSRT INTERCHANGE FOR HP-UX RUNTIME

RSI Software Products 9399-WGSUG RSSERVER FOR GE FANUC SERIES 90 USER'S GUIDE

Motion Control 8720MC-RPS190BM MASTER 460V 190AMP RPS

BC646MRE000 Logic PC & View Runtime (HRT) 8,000 I/O

IC300RTD000 2 channel RTD Inputs (Pt-100, Pt-200, Pt-500, Pt-1000), 18 bit

IC754VKI06STD Starter Kit - 6" Color-STN QuickPanel View Intermediate, Touch, 24VDC

MTR-3T57-G-R-B-M-0RR Servo Motor Metric 24V Brake

20AD-DB1-B PowerFlex 70 Resistor Kit

20DC037A0EYNANANE PowerFlex 700S AC Drive 20D

20G1ANC260AA0NNNNN PowerFlex 755 AC Packaged Drive

25B-V2P5N104 PowerFlex 525 0.4kW (0.5Hp) AC Drive

280-M22F-M1 ArmorConnect M22 Female Receptacle

FR-F740-11K 17.5KVA 23A 11KW 3相AC380V/50Hz/60Hz

1492-LG3T IEC Term Blck 5.1x64.5x31.3mm Spr Clp

1494F-V4 Combination Starter Door Hardware

軟啟動(dòng)器 3RW44362BC46

ET 200SP 6ES7132-6BF00-0BA0 DO 8x24VDC/0,5A 標(biāo)準(zhǔn)型，基座單元類型 A0

1585D-E4UBDE-20 1585D Ethernet Media Patchcord

1753-L32BBBP-8A GuardPLC 1800 Safety Controller

1794-IE4XOE2XT Flex XT 4 Input 2 Output Analog Module