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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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1585D-M8UGJM-4 Gigabit Ethernet Media

1756-M02AE ControlLogix 2 Axis Analog Servo Module

1799ER-IQ10XOQ10 Embedded I/O 20 Point Combo

194E-FA32EX-P11-6 194E Load switch

2090-CFBM7DD-CEAF05 Kinetix 5m Flexible Cable

2090-U3BB-D44 Ultra 3000 Breakout Board

BC646MQPU01 Machine Edition View for Quick Panel 1 user Upgrade from QuickDesigner with Proficy GlobalCare Complete

GC647ARC025 GC Reporting Client 25 Pak

I5T/1 Proficy Process Systems Tuning Tools from ControlSoft for Single Loop

IC646APS30002 Csense Predictive Soft Sensor 2 KPI's

IC647IFPLDVUNLMTM iFIX Plus SCADA Unlimited Development (M4 Part)

IC660ERD020 Genius 24/48Vdc Source Electronics Module for Redundancy T Output Co nfiguration

IC697ACC804 I/O Cable (96 conductor) for IC697Vxxxxx modules. Ten feet long

IC756XDV010CS-925 DV-Draw Development on Solarisx86 Op Sys, Simplified Chinese v9.25

FlexLogix System 1794-TB3K CONFORMALLY COATED, TERMINAL BASE 3-WIRE

GuardPLC Systems

Process Control 1757-UPGSIFF UPGRADE HW TDC3000 DATA HIWAY QUICKBUILDER I/F

Operator Interface 2711P-K12C4B2 PV PLUS 1250, KEYPAD, RIO/DH, AC PS, EXT MEM

Support 6008-SQS1R SUPT REINSTATEMENT CONTRACT FOR 6008SQS1

Support 2711-ND3UR UPGRADE: OUT-SUPT: PB 1200/1200E TO PB ND3

Support F1785-L80C15SERE FIRMWARE UPGRADE FOR 1785-L80C15 PLC5 PROCESSOR MO

RSI Software Products 9301-2SE2350ESE RSVIEW32 WORKS 5K (SPANISH)

RSI Software Products 9701-VWSS250AJPE RSVIEW SE SERVER 250 DISPLAY (JAPANESE)

RSI Software Products 9399-WAB32CSDKPG RSLINX C SDK PROGRAMMER'S GUIDE

Motion Control 8720MC -B042-AA- 42 AMP B CHASSIS DRIVE, ENCLOSURE, LESS OPTIONS

BC646MPSS99 Logic Developer - PLC Standard Unlimited Seat Site License

IC300OCS300 OCS300 5.7" STN WITHOUT ETHERNET

IC752WTC552 Display Station 2000 Series - 15" active matrix XGA (1024x768) resistive touchscreen, AMD K6-2 350 Mhz, 128 MB RAM, 6 GB HD, expansion slots, Ethernet, with unlimited point count CIMPLICITY HMI R&D and Win NT

MTR-3T43-J-R-0-M-0 MTR series metric servo motor with resolver

ZA81L-0001-0168 AC line filter rated 5.4 kW for Beta HVi series servo amplifiers

20DB104A0EYNANANE PowerFlex 700S AC Drive 20D

20G1ALC750JN0NNNNN PowerFlex 755 AC Packaged Drive

25B-D010N114 PowerFlex 525 4kW (5Hp) AC Drive

2711T-5MCABLE MobileView Accessory, 5M Cable

6SE6420-2UD27-5CA1 7.5KW

1492-L4Q IEC Term Blck 6.1x105x35.7mm Spr Clp

1494C-DJX622-A4-B-D 200 A Flange Mtd Cable Switch

軟啟動(dòng)器 3RW44273BC46

備品備件 6ES7 590-8AA00-0AA0 備件：S7-1500 PS/PM 供電模板連接頭，內(nèi)含 10 片

1585BX-M8UBBM-5 1585 Ethernet Media Patchcord

1747-L541 SLC 5/04 16K Controller

1791DS-IB8XOBV4 Guard I/O 16 Point Digital Comb Module

194E-A80-3753 80 A 194E Load switch

2071-AP0 Kinetix 3 220 VAC 50 Watts Servo Drive

2090-CSWM1DF-14AA01 Kinetix Cable Single DSL 2090-Series

20AC1P3A3AYNNNC0 PowerFlex 70 AC Drive 20A

GC646MDC300 Proficy GlobalCare Complete for Logic Developer - PC & View Development/Runtime 300 I/O

HE693DLL308 PCIF-30 Windows DLL, multi-license (8)

IC600WD005 Expansion Rack I/O Cable, 5 feet (1.5m)

IC647HSTESEO75KM eSignature Option for Historian - Enterprise Server 75000 Points (M4 Key)

IC655PWR501RR Power Supply, 12 Amp, 115/230Vac

IC694MDL646CA Conbal Coated Input module 24 VDC 16 point POS/NEG logic. 1msecond filtering.

IC756WDC009E-26 DV Dev Sys VB, Java, C++, Eng v2.6

MicroLogix 1500/1769 System 1764-RPLTB1 REMOVABLE TERMINAL BLOCK KIT (17 PT)

PLC-5/1771 System 1784-CP5 CABLE ASSY, 10FT/3.20M, 1784-KTK1 (15-PIN D-SHELL)

Distributed I/O 1797-TCAP CONTROLNET EX TAP (DUMMY) TERMINATOR (5 PIECES)

Communications D5000-6.6.1 PI DATA TALBE LIBRARY INSTALLATION & CONFIGURATION

Support 9321-L5160R SUPT REINSTATEMENT CONTRACT FOR 9321L5160

Support 9358-EP60S SUPT RENEWAL CONTRACT FOR 9358BEPNT60ENE

Support F1771-VHSCSERB FIRMWARE UPGRADE FOR 1771VHSC I/O MODULE

RSI Software Products 9324-RLD2U7PTE RSLOGIX 5000 MINI TO PRO UPGRADE, PORTUGUESE

RSI Software Products 9304-WVPD300DU2R UPGRADE: OUT-SUPT: WINVW 256 TO WINVW PRO DEV 3000

RSI Software Products 9358-PLTM2500U4R UPGRADE: OUT-SUPT: PLANTMETRICS 50 TO 100 WORKCELL

Motion Control 8720SM-063S5QAS4 63 KW/117.5 AMP, 750 VDC, MOTOR W/SNS60,+MPL

A06B-0033-B175#7008 B3/3000 Servo Motor, Holding Brake, 32K Serial Encoder

IC200TBX223 Tool box, 23 point, (IC200UAL006) 24VDC In/Relay Out, requires 120VAC Power, VersaMax SE (IC200SET001) with all software, cables (IC640VPS002)and manuals.

IC698PSA350 RX7i PLC Power Supply, 85 to 264 VAC at 47 to 63 Hz Input, 350 Watt output

MTR-1350-E-D-E-0RR Stepping Motor Nema34 Encoder

ZA06B-0078-B503#0100 B12/3000is Servo Motor with Straight Shaft, Key, Brake and IP67 Sealing

20BD248A3AYNANC0 PowerFlex 700 AC Drive 20B

20G11RD3P4AA0NNNNN PowerFlex 755 AC Packaged Drive

25-FAN1-FE PowerFlex 520 Frame E Fan Kit

140XCP40200 Quantum 10槽本版安裝架, 20MM

FRN7.5F1S-4C 12KVA 16.5 A 7.5 KW 3相AC380V/50Hz/60Hz

Z-15GD-B 觸點(diǎn):1開/1閉,10A 250VAC機(jī)械壽命:1000萬(wàn)次?彈簧式短按鈕型

1492-SPM3C100 MCB Supplementary Protector 10 A

軟啟動(dòng)器 3RW40472TB05

模擬量輸入模塊 6ES7 231-5ND32-0XB0 SM 1231 AI 4 x 16 位

150-SB2NBD SMC-50 SOLID STATE MOTOR CONTROLLER 110A