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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(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(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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IC646IFCLNTCRO025M iFIX iClient Read Only 25 PK Keyless (M4 Part)

IC647IFPRDV00075M iFIX Profsnl SCADA 75 I/O Development (M4 Part)

IC660MPH509 Hand-Held Monitor Standalone Connector Kit (Qty 3)

IC697BEM761 Series 90-70 I/O Interface (Used with Series Six Plus PLC)

IC800BIHV020 BSVM1-20HVi Beta HVi 20 amp amplifier kit

ControlLogix/1756 System 1756-L55M24 LOGIX5555 PROCESSOR WITH 3.5MBYTE NV MEMORY

Industrial Computers 6182H-7BRH15D VVCE 700, KEY/TOUCH, STD MEM, CNET, DC

Process Control 9323-LOOP01ENE RSLOOP OPTIMIZER

Operator Interface 2711P-K15C15D1 PV PLUS 1500, KEYPAD, CNET, DC PS, STD MEM

Support 9240-WIN16SDKS SUPT RENEWAL CONTRACT FOR 9240WIN16SDK

Support 6723-PFPR SUPPORT REINSTATEMENT CONTRACT FOR 6723-PFP

Support F5150-RS2 FIRMWARE UPGRADE FOR 5150-RS2 PLC5250 PROCESSOR MO

RSI Software Products 9301-2SE2350ZHU3 RSVIEW32 WORKS 1500-5K UPGRADE IN-SUPT (ZH)

RSI Software Products 9351-OSFRT INTERCHANGE FOR DIGITAL UNIX RUNTIME

RSI Software Products 9399-WINIGDE INSTAL'ION GUIDE FOR WINDOWS-BASED PRODUCTS(GERMAN

Motion Control 8720MC-RPS027BM-HV1 MASTER RPS WITH VARISTOR AND HARMONIC FILTER

BC646MRE159 Logic PC & View Runtime (HRT) 1,500 I/O

IC300THM000 2 channel Thermocouple Inputs (J, K, T, E), 18 bit

IC754VKL06CTD Starter Kit, 6 TFT View Loaded, 24VDC" (IC754VSL06CTD, IC646VSCEMK, HMI-CAB-ETH and 510-1000-041)

MTR-3T57-H-R-B-M-0 MTR series metric servo motor with resolver and brake

20AD011A0AYNANC0 PowerFlex 70 AC Drive 11 A at 7.5 Hp 20A

20DC037A0NYNANANE PowerFlex 700S AC Drive 20D

20G1ANC260JN0NNNNN PowerFlex 755 AC Packaged Drive

25C-A011N104 PowerFlex 527 2.2kW (3Hp) AC Drive

280-M24M-M1 ArmorConnect M24 Male Receptacle

FR-F740-22K 32.8KVA 43A 22KW 3相AC380V/50Hz/60Hz

1492-LG4T IEC Term Blck 6.1x84.5x35.7mm Spr Clp

1494G-BF3N-420 NEMA 1494G Enclosed Disconnect

軟啟動(dòng)器 3RW44366BC35

ET 200SP 6ES7132-6BF60-0AA0 DO 8x24VDC/0,5A 漏型輸出，基本型， 基座單元類型 A0

1585D-E4UBDE-3 Ethernet Media M12 Patchcord

1753-OW8 GuardPLC Relay Output Module

1794-IE8H Flex 8 Point Analog Input Module

194E-AA63E 194E Load switch

2080-LC30-48AWB Micro830 48 I/O Controller

2090-CSWM1DF-18AA07 Kinetix 7m Smartb Single Cable

20AC3P5A3AYNNNC0 PowerFlex 70 AC Drive 20A

GC646MQP001 Proficy GlobalCare Complete for View for QuickPanel

HE693RTD665 Discontinued Part. Check with GE IP on migration path.

IC610MDL105RR Thumbwheel Interface Module

IC647HSTSS10000KM Historian Standard Server 10,000,000 Points (M4 Key)

IC660BBD022RR 24Vdc Source I/O Block, 16 Circuit, Ph B

IC694PWR331 Power Supply 24 Vdc High Capacity.

IC756WDN009J-23 DV Development Sys VB, Java, C++, C, Japanese, Version 2.3

CompactLogix System

PLC-5/1771 System 1771-P6S POWER SUPPLY,SLOT (ONE SLOT), 8A, 220V AC

Distributed I/O 1798-OE2 FLEXARMOR 2 CHANNEL ANALOG OUTPUT MODULE

Operator Interface 2711P-B6M8D PV PLUS 600 GRAYSCALE, KEY/TOUCH, DH+, DC PS

Support 9323-PI300DU UPGRADE: IN-SUPT: 6200-5250 BOTH TO AI-5250 BOTH

Support 9358-PB60S SUPT RENEWAL CONTRACT FOR 9358PB60ENE

Support F1772-SD2 FIRMWARE UPGRADE FOR 1772-SD2 PLC2 PROCESSOR MODUL

RSI Software Products 9324-RLD700NXDEE RSLOGIX 5000 PRO EDITION, GERMAN

RSI Software Products 9305-RSVADFVCITE RSVIEW32 ACTIVE DISPLAY FLOAT. VIEW CLNT (ITALIAN)

RSI Software Products 9301-PCI2000MBP APPLICOM PCI2000MBP MODBUS PLUS INTERFACE

Motion Control 2094-BSP2 MODULE, SERVO SHUNT, 400/460V 200W DISSIPATION.

A06B-6050-K119 Connector Kit, B0.5 Motor Power

IC200UEX010 14 point expansion. (8) 120VAC In, (6) 120VAC Out, 120/240VAC Power Supply. (includes IC200CBL501)

IC752CBT060 Mature, order QuickPanel instead. DataPanel 320T CE (Color Expansion): 320x240 1/4 VGA Passive Color with 80386SX/40 PC processor. Analog touch screen with text, bitmaps, bar graphs, real time clock. With 2M memory and PC/104 capability.

MTR-1N41-G-N-A-E-0RR Stepping Motor Nema42

ZA06B-0128-B675#7076 A6/3000 servo motor with IP67 sealing and brake and 64k serial encoder

20BD5P0A3AYNACD0 PowerFlex 700 AC Drive 5 A at 3 Hp 20B

20G14NC085JA0NNNNN PowerFlex 755 AC Packaged Drive

25-PM1-E019 PowerFlex 520 11kW (15Hp) Power Module

771BSS47401 Quantum CONCEPT XL 版注冊(cè)軟件

FRN5.5E1S-2J 9.5KVA 25A 5.5KW 3相AC220V/50Hz/60Hz

6GT2091-1CH20

1492-SPM3D050-N MCB Supplementary Protector 5 A

軟啟動(dòng)器 3RW40281BB14

SIMATIC HMI 系列面板 6AV2123-2JB03-0AX0 KTP900 Basic PN 9 寸觸摸 + 按鍵

150-SF1R SMC-50 Frame B 24V DC Replacement Fan

1738-AENTR ArmorPoint Dual Port Adaptor

1783-ZMS4T4E2TGN ArmorStratix 5700 10 port managed switch

193-KA50 0.35-.50 A IEC Bibllic Overload Relay

20-750-P5-E510F500 PF750,Fr8,DC Input w Precharge,600/690V

2090-CPWM7DF-16AF25 MP-Series 25m Length Power Cable

20AB028A0AYNANC0 PowerFlex 70 AC Drive 28 A at 10 Hp 20A

GA647IFPLDV00300 GCA iFIX Plus SCADA 300 I/O Dev