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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(kāi)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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1492-SPM1D320-N MCB Supplementary Protector 32 A

通用型變頻器 6SE6 440-2UD41-6GB1 160 KW,326 x 1533 x 545

電機(jī)啟動(dòng)器 3VU13401TM00

150-C9NBD SMC-3 9A Smart Motor Controller

170-PW37 Bulletin 100-C Accessory

1771-IND 1771 Input Module

193-EC3LH E3 Plus 172-860 A Overload Relay

198-SHB Operating Handle Black

2090-CPWM4DF-14AF25 MP-Series 25 m Length Power Cable

2094-BC04-M03-S Kinetix 6000 Integrated Axis Module

DEMOCD00007 Batch Demo CD

GFK-0729 Series 90-70 DLAN/DLAN+ Interface Module User's Manual

IC210BAR020 AC (85 to 264VAC) Power Source, (12) AC in/8 out (Relay, 8 Amp), Expandable, with without LCD/Keypad

IC647ARC010 PA Reporting Client 10 Pak

IC647PPSAPC Proficy Process Systems App Server with Cimplicity

IC693CMM311RR Communications Module, CCM2

IC754VBI06STD View Intermediate 6 inch STN Touch DC Blank

MSI-BETA-43 Beta Software Ver 4.3

SLC/1746 System 1746-F8 FUSE FOR CTLG # 1746-OBP16/OVP16 OUTPUT MODULE

Distributed I/O 1734-OB2E 24V DC 2 CHANNEL SOURCE OUTPUT MODULE

Application-specific products 1803-EEM12E12 EEM,16 PULSES,24V DC,16 ANALOG,4 TO 20MA, NEMA12

Operator Interface 2711-T10G8 PV1000 GRAYSCALE TOUCH, DH+ & RS232 PRINT

Support 9301-RSVWSENR SUPT REINSTATEMENT CONTRACT FOR 9301RSVWSEN

Support 9381-PP1KENS SUPT RENEWAL CONTRACT FOR 9381PP1KEN

DeviceNet Products 1791D-0V16P DNET 24 VDC COMPACTBLOCK I/O, 16 OUT SINK, BASE

RSI Software Products 9301-2SE3350DEU2 RSVIEW32 RUNTIME 300-5K UPGRADE IN-SUPT (DE)

RSI Software Products 9358-PBPC60ENE RSBIZWARE BATCH FOR PLX PC BASED PHASE 60 UNITS

Motion Control MPL-B680F-SJ22AA MOTOR,SERVO,60.0NM,3000RPM,SINGL,460V

Silver Series 1398-DDM-005 DRIVE,7.5A PEAK, ULTRA 100

HE300GEN250 Genius interface board for new generation AV300/DV300 drives (internal mount).

IC646NWV010 WebView-10 Pack License

PC752PBM604 Scanner module to be a master of Profibus network for 6" unit only

ST-2742 STXi output module Isolated Relay Output 2 points, 230V AC/ 2A

20BC105A0ANNANC0 PowerFlex 700 AC Drive 20B

20F14NC170JN0NNNNN PowerFlex 753 AC Packaged Drive

22A-B017H204 PowerFlex 4- 3.7 kW (5 HP) AC Drive

140CPS11100 Quantum 電源, 115/230 VAC, 獨(dú)立, 3A

284-PWRM24A-M14 Power Cable, Patch,Shielded,M24, 14m

CJ1G-CPU44H CPU單元I/O點(diǎn)數(shù)1280，30K程序容量，最多三個(gè)擴(kuò)展機(jī)架。

1492-RFB4 IEC Term Blck 8 x 97 x 43.8mm Spr Clp

總線插頭 6ES7972-0BB41-0XA0 RS485 總線插頭， 12MBd 35? ，帶編程接口

變送器 3RS20 41-2GW50

1497-M-M4-0-N Control Circuit Transber

1606-XLE96B-2 480VAC Input 12VDC Out 8A Power Supply

1764-LSP MicroLogix 1500 Processor

188-K4B060 6 A Miniature Circuit Breaker

194L-HE6A-250 IEC Control And Load Sw Actuator Type A

2090-CPBM7DF-08AF12 12 m Length SpeedTec Flexible Cable

2090-XXNPMF-16S12 Kinetix Drives 12m Standard Cable

C-602-2 Adapter for Marposs probes to GP-0602NT.

GC647SCL001 GCScheduler Server Client ( Plan+ View)

IC200PBI001CA Remote I/O Profibus DP network interface unit conbal coated.

IC646PPT100 4-day OpenProcess Training per Student

IC647NCA915 CIMPLICITY Change Approval for 1500 Point Server

IC690CBL701 Cable, PCM to IBM-PC/XT Class Computers, 10 feet (3m)

IC697VPC464RR Plug & Play PC Coprocessor, 486DX2/66, 32 Mbytes

IC800STI105S1RR 5A, 115V, S2K Stepper Controller

SLC/1746 System 1746-A2 2-SLOT EXPANSION CHASSIS FOR FIXED HARDWARE STYLE

Industrial Computers 6181P-17NPXPH VERSAVIEW INTEGRATED DISPLAY COMPUTER 17-INCH

Application-specific products 9358-PBNTK30ENE RSBATCH NT FOR PROCESSLOGIX BACK-UP KEY 30 UNITS

Operator Interface 2711-K5A2L1 PV550 MONOCHROME KEY, DH485

Support 9301-2SE2100ITR SUPT REINSTATEMENT CONTRACT FOR 93012SE2100IT

Support 9500-CPAKMENS SUPT RENEWAL CONTRACT FOR 9500CPAKMEN

ControlNet Products 2711P-K15C15B2 PV PLUS 1500, KEYPAD, CNET, AC PS, EXT MEM

RSI Software Products 9301-2SE2500ZHU5 RSVIEW32 WORKS 5K-100K UPGRADE IN-SUPT (ZH)

RSI Software Products 9358-BEPNT30U1R UPGRADE: OUT-SUPT: EPROCEDURE FOR NT 03 TO 30

Motion Control MPL-A520K-MK22AA MOTOR,SERVO,10.7 NM,4000RPM,MULTI,230V,11.3KG

Motion Control 2090-XXNPMP-14S09 CABLE,NON-FLEX,MOTOR POWER,MP/1326AB,14 GAUGE,9M

GABK3D200C2P/AD QUICKPANEL 6" TFT W/AB DH+ GE LABEL

IC641SWC716 Logicmaster Series 9070 S/W, TCP/IP Ethernet Dev. Pkg. for Windows 95/NT in a Dos Box 3.5"/5.25" disks + CD-ROM docs.

IC800SSI216P2 16 Amp S2K Series Servo Amplifier/Controller with Profibus, 230 VAC

PSPC-ADMIN5 Prof Shop Floor SPC Admin 5 User

20BB104A0ANNANC0 PowerFlex 700 AC Drive 20B

20DF590N0ENNBNANE PowerFlex 700S AC Drive 590 A 560 kW 20D

2198-D012-ERS3 Kinetix 5700 Dual Axis Inverter

2711P-K4M20A8 PanelView Plus 6 4 Grayscale Keypad AC

280-PWRM35D-M4 ArmorStart Three-Phase Power Media

CPM2A-BAT01 鋰電池 3.6v

1492-MS6X12V1-10 Connection Products

數(shù)字量輸入/輸出模塊SM 6ES7 321-1BH50-0AA0 DI/16 24VDC，光電隔離，20pin 前連接器