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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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RSI Software Products 9358-BA30U2 UPGRADE: IN-SUPT: RSBIZWARE ARCHIVER 10 TO 30

Motion Control MPL-A4520K-SJ22AA MOTOR,SERVO,6.10 NM,4000RPM,SINGL,230V,6.8KG

Motion Control 2090-UXNPAMP-8S03 CABLE,230V,NON-FLEX,MOTOR POWER,MP,8 GAUGE,3M

CBL-209 SIEMENS S7-200 Cable

IC640HWP308 LM 90-30/20 Std. Comm. NEC 9800 w/Converter & Cables

IC800SLCPVL050 Power Cable, 3500W and 5000W SL Servo Motor, 5 Meters

OC647IFXPESPC iFIX for Embedded XP SPC Blocks Option

20AD8P0A0AYNAEC0 PowerFlex 70 AC Drive 8 A at 5 Hp 20A

20DD027A3EYYANCNL PowerFlex 700S AC Drive 20D

20P41AD019RA0NNN PowerFlex 460V AC 10 HP DC Drive

2711C-T4T PanelView Component 4-Inch Terminal

280-PWRM24E-M2 ArmorConnect 3-PH Power Media drop cable

NT631C-ST141(B)-EV1 彩色STN LCD 分辨率：640×480點(diǎn),8色 11.3英寸.

1492-MCBA2H50 50 A Ul489 Miniature Circuit Breaker

1494V-DJ644-A-B-D-E-F NEMA Flange Mtd Rod Switch Disconnect Sw

軟啟動(dòng)器 3RW44576BC34

運(yùn)行版軟件 6AV2102-4AA04-0AE5 SIMATIC WinCC Advanced V14 Upgrade WinCC flexible 2008 Advanced -> WinCC Advanced V14 Combo

1585D-M8UGDM-20 Gigabit Ethernet Media

1756-L73SXT Logix 5573SXT Automation Controller 8/4M

1799-D16U16VL 32 Point Embedded I/P/Output Comb Module

194E-FA20E-PD10-TN 194E Load switch

2090-CFBM7DD-CEAA09 MP-Series 9m Servo Feedback Cable

2090-SCVP20-0 Kinetix 20-20m Fiber Optic Cable

BC646MPPS99 Logic Developer PLC Professional Unlimited Seat Site License with Proficy GlobalCare Complete

GC647APS001 GC PA Production Server

HMI-CCT-403 Backlight for 6 Inch Color-STN (QPKSxDN0000)

IC641VPS002 Windows Programming Software for VersaMax Nano/Micro PLCs

IC647IFPLDV00075C iFIX Plus SCADA 75 I/O Development (M1Component Part)

IC660EBS103 Electronic Assembly for IC660BBS103

IC697ACC724 Rack Cooling Fan, 230 Volt

IC756WRE499K-99 DataViews Runtime for Windows 100+, Per User, Korean, Version 9.9

FlexLogix System 1794-OE4K CONFORMAL COATED, ANALOG OUPUT MODULE, 4 POINT

PLC-5/1771 System D6200-6.4.6JP PLC5 PROGRAMMING SW CONFIG./MAINT. (JAPANESE)

Process Control 1757-UPGNB UPGRADE POINT CNTRL SCHEDULER

Operator Interface 2711P-B12C15D2 PV PLUS 1250, KEY/TOUCH CNET, DC PS, EXT MEM

Support 6001-F2ER SUPT REINSTATEMENT CONTRACT FOR 6001F2E

Support 2711-ND2DER SUPT REINSTATEMENT CONTRACT FOR 2711ND2DE

Support F1785-L60C15SERD FIRMWARE UPGRADE FOR 1785-L60C15 PLC5 PROCESSOR MO

RSI Software Products 9301-2SE230ITU2R RSVIEW32 WORKS 150-1500 UPGRADE OUT-SUPT (IT)

RSI Software Products 9701-VWSS025AJPE RSVIEW SE SERVER 25 DISPLAY (JAPANESE)

RSI Software Products 9399-RSPCPHPG RSBATCH PC-BASED PHASES PROGRAMMER'S GUIDE

Motion Control 1394C-SJT22-A MODULE,SYSTEM,22KW,SERVO,W/ANALOG INTFC,N

BC646MPP001 Logic Developer - PLC Professional w/1 Yr of SAFE

IC300OCS071 OCS with 2x20 LCD Display and with 16-key Keypad. 16 DC Inputs (12/24vdc), 12 DC Outputs (5/12/24vdc, 0.5A pos. logic with ESCP). With CAN network interface

IC752WFC572 DISPLAYSTATION DS2050 15" 566 MHz/128 MB RAM WNT

MTR-3T23-G-R-B-M-S MTR series metric servo motor with resolver and brake and shaft seal

ZA66L-6001-0023#L2R003 FSSB cable, 2 meter

20D-PP10031 MEASUREMENT WIRE KIT, FR10, PF700S

20G1AJC770JN0NNNNN PowerFlex 755 AC Packaged Drive

25B-A8P0N104 PowerFlex 525 1.5kW (2Hp) AC Drive

2711P-T9W22D9P-B PanelView Plus 7 Graphic Terminal

6SE6430-2UD41-1FB0 110KW

1492-L3QS-RE Side-By-Side 2Ckt Feed-Through Blk,2.5mm

1494C-CMX6 Cable Mechanism

軟啟動(dòng)器 3RW44263BC45

附件 6ES7 592-1BM00-0XA0 25 mm 模板前連接器，快連型，40 針

1585BT-M8UB-2 1585 Ethernet Media Cordset

1747-C10 SLC Replacement Cable

1790D-T32BV0 32 UNIVERSAL IN TB

194E-A40-1753 40 A 194E Load switch

20-PP20300 FUSE HOLDER FOR FAN INVERTER PF HIGH PWR

2090-CSBM1DF-18AF30 Kinetix Cable Single DSL 2090-Series

20AC060C3AYNANC0 PowerFlex 70 AC Drive 60 A at 30 kW 20A

GC646MDA150 Proficy GlobalCare Complete for View Development /Runtime 150 I/O

HE693ADC816 Discontinued Part. Check with GE IP on migration path.

IC600PM541RR CPU/DPU Power Supply, 24Vdc

IC647HSTESEO20000KM eSignature Option for Historian - Enterprise Server 20,000,000 Points (M4 Key)

IC655MDL512RR 12-24Vac/dc Input, Positive Logic (32 points)

IC694MDL310 Output module, 120 VAC 0.5 amps 12 points.

IC756SDV010J-99 DV Draw Development on Solaris Op Sys, Japanese, Version 9.9

MicroLogix 1500/1769 System 1769-OB8 1769 8 POINT HIGH POWER 24VDC OUTPUT MODULE

PLC-5/1771 System 1785-TR10BT AUI TO TW PAIR ENET TRANS

Distributed I/O 1794-TBNK CONFORMALLY COATED, NEMA TERMINAL BASE

Communications D1784-6.5.22 1784-KTX COMMUNICATION INTERFACE CARD USER MANUAL

Support 9313-L5225R SUPT REINSTATEMENT CONTRACT FOR 9313L5225

Support 9358-CTATHENS SUPT RENEWAL CONTRACT FOR 9358CTATHEN

Support F1771-QBSERC FIRMWARE UPGRADE FOR 1771-QB I/O MODULE

RSI Software Products 9324-RLD250FRE RSLOGIX 5000 LITE EDITION FRENCH

RSI Software Products 9301-VIEWU3R UPGRADE: OUT-SUPT: CTRVW TO RSVIEW32 WKS 32/RSLX