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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(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(dòng)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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2094-BC07-M05-S Kinetix 6000 Integrated Axis Module

DEMOCD00009 iWeb Server DEMO CD

GFK-0731 ECLiPS English Control Language Programming System for Series 90-70 PLC User's Guide

IC210BDD024 24V DC Power Source, (12) 24VDC in/(8) out (Transistor) , (4) analog bs, Expandable, without LCD/Keypad

IC647ARC100 PA Reporting Client 100 Pak

IC647PPSEWF Proficy Process Systems Engineering Workstation with iFIX

IC693CMM321RR Ethernet Interface Module

IC754VBI12MTD View Intermediate 12 Inch Mono Touch DC Blank

MSI-CONNECTOR Historian Connector

SLC/1746 System 1746-R11 REPLACEMENT COVERS & LABELS FOR CTLG # 1746-P2/P3

Distributed I/O 1734-OB8E 24V DC8 CHANNEL SOURCE OUTPUT MODULE

Application-specific products 1803-EEM20E12 EEM,32 PULSES, 24V DC, NEMA 12 ENCLOSURE

Operator Interface 2711-T10G9L1 PV1000 GRAYSCALE TOUCH, RS232(DH485) & RS232 PRINT

Support 9302-APOS SUPT RENEWAL CONTRACT FOR 9302APO

Support 9381-PP2500KENR SUPPORT REINSTATEMENT CONTRACT FOR 9381PP2500KEN

DeviceNet Products 1791D-4B0 DNET 24VDC CBLOCK I/O, 4 IN SINK (NOT EXPANDABLE)

RSI Software Products 9301-2SE3350ESU1 RSVIEW32 RUNTIME 150-5K UPGRADE IN-SUPT (ES)

RSI Software Products 9358-PBPCNT30ENE RSBATCH NT FOR PROCESLGIX PC BASED PHASES 30 UNITS

Motion Control MPL-B860D-MJ24AA MOTOR,SERVO,63.0NM,2000RPM,MULTI,460V,BRKE

Silver Series 1398-DDM-005X-DN DRIVE,7.5A PEAK, ULTRA 100 W/DNET INDEX

HE300RSL130 P1 interface for AF300E$ drives

IC646TDV915 1,500 I/O Point Development System

QBH2D100S2P QUICKPANEL 6" STN HAND HELD BUNDLE

ST-2792 STXi output module Relay Output 2 points, 230V AC/ 2A, Manual

20BC105A0AYNACD0 PowerFlex 700 AC Drive 20B

20F14NC205JN0NNNNN PowerFlex 753 AC Packaged Drive

22A-B1P5H204 PowerFlex 4 0.2 kW (0.25 Hp) AC Drive

140CPS11420C Quantum 電源, 115/230 VAC, 可累加, 8A, CC

284D-FHD1P4Z-10-CR-SB DeviceNet Variable Frequency Drive

CJ1H-CPU66H CPU單元I/O點(diǎn)數(shù)2560，120K程序容量，最多三個(gè)擴(kuò)展機(jī)架。

1492-RIFM20F-2 Connection Products

總線插頭 6GK1500-0FC00 RS485 總線插頭， 12MBd180? ，連接 OP 及 OLM

變送器 3RS21 40-2GD60

1497A-A1-M18-0-N 50Va 208/230/480-120/24V 50/60 Hz Cpt

1606-XLP100E Power Supply XLP 100 W Power Supply

1764-MM2 MicroLogix 1500 Memory Module

188-K4B130 Miniature Circuit Breaker 13 A

194L-HE6A-375 194L Control And Load Switch Actuator

2090-CPBM7DF-08AF25 25 m Length SpeedTec Flexible Cable

2090-XXNPMF-16S25 Kinetix Drives 25m Standard Cable

CA-860-2 LMI Adapter to GP-3102NT GagePort.

GC647SDL001 GCScheduler Doublet license for PC user

IC200PKG101 I/O starter kits, Genius NIU

IC646TBAPC002 Back-up Server for Advanced Process Control

IC647NCL000 CIMPLICITY HMI Action Calendar Option

IC690CBL710 CIMPLICITY 70 RGB Video Cable

IC697VSC096 Single Board Computer, with 32Mbyte SDRAM & 96 Mbyte Flash. NO OPERAT ING SYSTEM PRE LOADED

IC800VMA012 100 W VersaMotion servo amplifier

SLC/1746 System 1746-C16 CHASSIS INTERCONNECT CABLE, 4FT (1.22M)

Industrial Computers 6181P-17TPXPH VERSAVIEW INTEGRATED DISPLAY COMPUTER 17-INCH TFT

Application-specific products 9358-PBPC03ENE RSBIZWARE BATCH FOR PLX PC BASED PHASE 03 UNITS

Operator Interface 2711-K5A2L3 PV550 MONOCHROME KEY, DH485

Support 9301-2SE2100JPR SUPT REINSTATEMENT CONTRACT FOR 93012SE2100JP

Support 9500-CPAKPLENS SUPT RENEWAL CONTRACT FOR 9500CPAKPLEN

ControlNet Products 2711P-K15C15D2 PV PLUS 1500, KEYPAD, CNET, DC PS, EXT MEM

RSI Software Products 9301-2SE2503DEE RSVIEW32 WORKS 100K WITH RSLINX (GERMAN)

RSI Software Products 9358-BEPNT30U2R UPGRADE: OUT-SUPT: EPROCEDURE FOR NT 10 TO 30

Motion Control MPL-A520K-SJ22AA MOTOR,SERVO,10.7 NM,4000RPM,SINGL,230V,11.3KG

Motion Control 2090-XXNPMP-14S15 CABLE,NON-FLEX,MOTOR POWER,MP/1326AB,14 GAUGE,15M

GABK3D200C2P/DN QUICKPANEL 6" TFT W/DVN GE LABEL

IC641SWM306 LM 90-30/20/Micro Serial Software, 3.5"/5.25" disks + paper docs.

IC800SSI216RP2 16A, 230V, Profibus S2K Servo Controller for MTR Series Motors

PSPC-ADMIN50 Prof Shop Floor SPC Admin 50 User

20BB130A0ANNANC0 PowerFlex 700 AC Drive 20B

20DF820A0ENNBNANE PowerFlex 700S AC Drive 820 A 800 kW 20D

2198-D032-ERS3 Kinetix 5700 Dual Axis Inverter

2711P-K4M5A8 PanelView Plus 6 4 Gray Key AC RS232