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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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CPU 模塊 6ES7 677-2AA31-0EB0 CPU 1515SP PC，2 GB RAM，8 GB CFAST，Windows 7 嵌入版 32 位

153H-C201XBD-52 SMC-3 ENCLOSED COMBINATION 201A

1738-SSIM23 ArmorPoint I/O SSI Encoder Module

1786-BNC ControlNet Media Coaxial BNC Connector

193-T1AA16 0.10-.16 A IEC Bibllic Overload Relay

20-COMM-M PowerFlex Modbus/TCP Adapter

2090-CSBM1DF-10AF03 Kinetix Cable Single DSL 2090-Series

20AC011A3AYNAEC0 PowerFlex 70 AC Drive 20A

GA647IFSTRN00300 GCA iFIX Std HMI 300 I/O Run

GP647IFPLRNUNLMT GCP iFIX Plus SCADA Unlmt Run

IC600BF940RR Local I/O Transmitter Module, Enhanced

IC647HSTCR500KM Collector Redundancy Option for Historian - Standard Server 500,000 Points (M4 Key)

IC647TPR910 CIMPLICITY HMI ProServer 10000 I/O Runtime

IC693PRG300RR Hand Held Programmer (HHP) With Cable & Manual

IC756MDV001E-98 DV Development - Alpha OpenVMS Addt'l User, English, Version 9.8

MicroLogix 1000/1761 System 1761-CBL-HM02 CABLE: MICROLOGIX 1000 TO HAND HELD PROGRAMMER

PLC-5/1771 System 1771-NBSC HIGH RESOLUTION ISOLATED ANALOG MODULE

Distributed I/O 1792D-CB12JP MAXUM MEIDA BASE W/12MM CONNECTORS

Communications 9351-DKTSRT INTERCHANGE SOFTWARE FOR MS-DOS RUNTIME

Operator Interface D6190-6.5.22DE CONTROLVIEW SYSTEM DOCUMENTER USER MANUAL(GERMAN)

Support 9356-STD2400R SUPT REINSTATEMENT CONTRACT FOR 9356STD2400

Support 9392-CDRSESU UPGRADE TO ENGLISH/SPANISH BUNDLE

RSI Software Products 9311-SG800 A.I. SERIES LADDER MONITORING STATION KEY

RSI Software Products 9301-2SE3500KOU4 RSVIEW32 RUNTIME 150-100K UPGRADE IN-SUPT (KO)

RSI Software Products 9356-SQLSAP250U2R UPGRADE: OUT-SUPT: RSSQL GATEWAY SAP PLUS TO PREM

Motion Control TL-A220P-BJ34AA MOTOR, SERVO, 0.83NM, 5000RPM, 17BIT SERIAL FEEDBA

44A737560 Series 90-30 State Logic CSE340A,B,C Upgrade to latest revision CSE340D

IC200CHS001 I/O CARRIER BARRIER STYLE

IC694MDL330 OUTPUT MODULE 120/240 VAC 2AMPS 8 POINTS

MSI-UNIV-WEB-2-43 Univ Web(RTIP/Dash/Web/Excel) 2 Pak-43

VSPC32-OPC25 OPC Client Option includes VisualSPC Importer (licensing is per client PC), Support for up to 25 Points/Tags.

20BD040A0AYNANA0 PowerFlex 700 AC Drive 40 A at 30 Hp 20B

20G11JC1K0JN0NNNNN PowerFlex 755 AC Packaged Drive

22D-D010H204 PowerFlex 40P 4 kW (5 Hp) AC Drive

Quantum Communication Module 網(wǎng)絡(luò)通訊模板

290D-FBZ-G1-3 Direct Online Starter

E53-AZM NEW 高級底板，使用通訊等功能時(shí)需要

1492-SPM2C020 MCB Supplementary Protector 2 A

軟啟動器 3RW30182BB04

電機(jī)啟動器 3VU16402MM00

150-F135NBR SMC Flex Smart Motor Controller

1732D-IB161212D ArmorBlock 16 Point Input Block

1771-OFE2 Analog Output Module

193-ED1CB E1 Plus 1-5 A IEC Overload Relay

199-DR2 IEC 35mm x 7.5mm x 2 m DIN Rail

2090-CPWM6DF-16AA25 TL-Series 25m Standard Power Cable

2094-PRS7 Kinetix 6000 Slim Power Rail

DT1005 Industrial Keyboard

GFK-1038 Series 90-70 FIP Bus Controller User's Manual

IC210NDD012 24V DC Power Source, (6) 24VDC in/(4) out (Transistor) , (2) analog bs. Not expandable,no LCD/Keypad, no cover.

IC647BR3C BR3:Bristol Babcock

IC647PRTHE005C Proficy Portal Historian Edition Client Pack 5 Users (M1 Key)

IC693CPU360LT CPU 360 Module (240K Bytes configurable user memory, 4K I/O, 8 Racks), no built-in Serial Ports .22msec/K (LT)

IC754VSL06MTD View Loaded 6 In Mono Touch DC

MSI-EFF-2 Efficiency Management Clients 2 Pack

SLC/1746 System 1746-RL60 REPLACEMENT OCTAL LABEL KIT FOR CTLG # 1746-IB32

Distributed I/O 1734-TBCJC SCREW TERMINAL BASE CJC SPRING TERMINAL BASE CJC

Application-specific products 9307-EMRPTENE RSENERGY METRIX REPORTPLUS

Operator Interface 2711-NF2A FUNCTION KEY STRIP PV900 MONO

Support 9302-MODR SUPT REINSTATEMENT CONTRACT FOR 9302MOD

Support 9510-PBEWENR SUPT REINSTATEMENT CONTRACT FOR 9510PBEWEN

DeviceNet Products 1784-PCIDS PCI BUS TO DEVICENET INTERFACE

RSI Software Products 9301-2SE3350U3 UPGRADE: IN-SUPT: RSVIEW32 RUNTIME 1500 TO 5000

RSI Software Products 9310-CPSENE RSTESTSTAND ENTERPRISE

Motion Control MPG-A004-031M22 MOTOR,SERVO,GEAR RATIO 31,14NM,194RPM,MULTI,230V

Silver Series 1756-L1 LOGIX5550 PROCESSOR, 64KBYTE USER MEMORY

HE693DQM220 4 point, 30A @ 125VDC Breaker Control Module

IC648MNT036 One Year Subbion Renewal for IC641SWM306

QPI2D101S2P QUICKPANEL 10.5" STN COLOR WITH CE MARK

ST-4422 STXi analog output module 2 Channels, 0~10Vdc, 12-bit

20BC170A0ANNAND0 PowerFlex 700 AC Drive 20B