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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(chē)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(chē)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(chē)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(chē)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(chē)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(chē)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(chē)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(chē)輛制造中的應(yīng)用。車(chē)輛激光焊接車(chē)輛轉(zhuǎn)向架以及車(chē)體是城市軌道車(chē)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(chē)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(chē)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(chē)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(chē)輛車(chē)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(lèi)車(chē)身構(gòu)件，焊接成白車(chē)身分總成，進(jìn)而總裝成整車(chē)車(chē)身。激光組焊因其焊接強(qiáng)度高，可明顯改善車(chē)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(chē)體制造。城市軌道車(chē)輛車(chē)體通常選用不銹鋼車(chē)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(chē)體激光焊接樣件的制評(píng)亦完成。


2) 車(chē)輛轉(zhuǎn)向架制造。城市軌道車(chē)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(chē)輛激光切割

激光切割技術(shù)特性城市軌道車(chē)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(chē)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(chē)輛車(chē)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(chē)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(chē)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(qián)、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(chē)輛制造中。以某企業(yè)為例，其高速動(dòng)車(chē)組車(chē)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(chē)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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QPICGAE0000 10.4" Color TFT, GE Fanuc, Ethernet, CF Card, 110 VAC

ST-5252 STXi Serial Interface module RS-232 , 2 Channels,32 Bytes,

20BC205A0ANNANC0 PowerFlex 700 AC Drive 20B

20F1ANC140AN0NNNNN PowerFlex 753 AC Packaged Drive

22B-A5P0N114 PowerFlex 40- 0.75 kW (1 HP) AC Drive

140DDI36400C Quantum DC IN 24VDC 6X16 SINK, CONFORMAL COAT

284D-FVD4P0B-N-R Cntl Mod. Variable Frequency Drive

E3S-5E4 5m,對(duì)射型 , 晶體管輸出80mA, 電源:12-24VDC

1492-SJMD5-12 IEC Term Blck 12 pole Side Jumper

人機(jī)界面 6AV6545-0BC15-2AX0 TP170B 觸摸屏，彩色，6 英寸，320? 240

6ES78331FA130YA8

1497B-A14-M14-0-N Control Power Transber

1606-XLS480E-3C Power Supply XLS 480 W Power Supply

1769-IA8I CompactLogix 8 Pt 120VAC D/I Iso Module

189-AL11 MCB Accessory Auxiliary Contact

194R-HM1 194R 100-400 A Operating Handle

2090-CPBM7DF-12AA30 MP-Series 30m Power and Brake Cable

2090-XXNPMP-16S20 MP-Series 20 m Length Power Cable

CBL-30-BT-30 Brake cable for MTR-3S or MTR-3N series servo motors with brake. 30 feet

GF-0203R Connecting FlashCable to Fowler (Chinese with RS-232).

IC200TBX210 Tool box, 10 point, (IC200NDR001) 24VDC In/Relay Out, 24VDC Powered (r equires an external 24VDC Power Supply), VersaMax SE (IC200SET001) wit h all software, cables and manuals (IC640VPS002 and IC646MPM001).

IC646TBSPMPS600 Smart Process Monitoring Process+ server 600 loops

IC647NSG000 Siemens AS511 OPC Server

IC693ACC332 TBQC Base for IC693MDL940

IC752CAB201 AB SLC500 cable for DataPanel 150/160/240

IC800VMCP1050 Power cable for 1 kW VersaMotion servo motor- 5 meter

SLC/1746 System 1746-OW8 RELAY OUTPUT MODULE FOR PROGRAMMABLE CONTROLLER

Industrial Computers 6189V-ACPS AC POWER SUPPLY ATX STANDARD

Application-specific products 1400-PD52A POWERMONITOR DISPLAY MODULE

Operator Interface 2711-B6C3 PV600 COLOR KEY&TOUCH, DH485 & RS232 PRINT

Support 9301-2SE2400ESR SUPT REINSTATEMENT CONTRACT FOR 93012SE2400ES

Support 9307-EM8MGRS SUPT RENEWAL CONTRACT FOR 9307EM8MGRENE

DeviceNet Products 1734-IB2 24V DC 2 CHANNEL SINK INPUT MODULE

RSI Software Products 9301-2SE250ZHU2R RSVIEW32 WORKS 1500-100K UPGRADE OUT-SUPT (ZH)

RSI Software Products 9358-BNT60U3 UPGRADE: IN-SUPT: RSBATCH 30 TO 60

Motion Control MPL-B330P-RJ22AA MOTOR,SERVO,4.18 NM,5000RPM,RSLVR,460V,5.9KG

Motion Control 2090-U3BK-D4401 BREAKOUT BOARD KIT,CONTROL,CN1,ULTRA 3000,1M

GFK-0685 Series 90 PLC Flow Computer User's Manual

IC646CNU000 CIMPLICITY Client for Microsoft Windows User Package

MSCPX-312806NT Marathon Exp CPU,566 MHz CPU, 128M, 6G, Win NT, 2 PCI/ISA , 1 PCI, 1ISA

PSPC-DC50/E-220 Prof Shop Floor SPC DC 50 User eSig 220v

20BC015A3AYNACC0 PowerFlex 700 AC Drive 20B

20F11FC072JA0NNNNN PowerFlex 753 AC Packaged Drive

2198-KITCON-IOSC CONKIT,K5500,I/O,SCREW TRM

2711P-RBK15 PanelView Plus Accessory

280-PWRM35H-M6 ArmorStart Three-Phase Power Media

CQM1-IA221 輸入 8點(diǎn).200 –240V AC

1492-N36 TERM BLCK End Barrier High Density

回路閉環(huán)控制模塊 6ES7355-0VH10-0AE0 FM355C，4 回路閉環(huán)控制模塊，8DI/DO，4AI，2個(gè) 20pin 前連接器

行程開(kāi)關(guān) 3SE53223SE23

TIA 博途 WinCC 選件 6AV2107-2KG00-0BD0 SIMATIC WinCC WebNavigator for Runtime Professional Powerpack 5 -> 10 Clients

1585J-M8HBJM-50 RJ45 Ethernet Media

1760-IB12XOW6I Pico DC Expansion Input/Output Module

188-K2C005 Miniature Circuit Breaker 0.5 A

194L-A12-1754 12A 194L Load Switch

2090-CHBP8S8-12AA12 Kinetix 6000M IDM Hybrid Cable

2090-UXTBMP-18S12 MP-Series 12 m Length Brake Cable

BC647MPP101 Logic Developer PLC Professional with Programming Cable with Proficy GlobalCare Complete with USB Hardware key

GC647IFSTDV00075 GCC iFIX Std HMI 75 I/O Dev

IC200CHS111 I/O interposing relay style, relay 8 amps isolated, fused 16 points

IC646MSP101 Logic Developer State Professional with Programming Cable

IC647IFSTRN00075M iFIX Standard HMI 75 I/O Runtime (M4 Part)

IC670CHS004 Thermocouple Cold Junction Compensation Base is obsolete. Recommend IC670CHS001 I/O Base, Barrier Style. Refer to the manual GFK1290-D for the Thermocouple Input Module (IC670ALG630), on page 5, explains the alternatives for cold junction compensat

IC697CSE925RR State Logic CPU, 64MHz, 80486DX2

IC800SKCPV050 Power cable for SDM100 or SLM100 or SDM250 or SLM250 or SGM450 S-series servo motor connected to an S2K. 5 meters

ControlLogix/1756 System 1756-OH8I 90-146 VDC ISOLATED 2 AMP OUTPUT 8 PTS (36 PIN)

Industrial Computers 6182H-12BEH15D VVCE 1250, KEY/TOUCH, EXT MEM, CNET, DC

Process Control 1757-FIMUPG100 FIELDBUS LICENSE UPGRADE, 100 FIMS

Operator Interface 2711P-RGT15 PV PLUS/VVCE PROTECTIVE ANTIGLARE OVERLAYS QTY 3

Support 9355-WABOEMESR SUPT REINSTATEMENT CONTRACT FOR 9355WABOEMES

Support 9354-SS100S 9354-SS100 SOFTWARE SUPPORT CONTRACT RENEWAL

ControlNet Products 1788-CNFR CONTROLNET LOGIX DAUGHTER CARD

RSI Software Products 9301-2SE2400PTU1 RSVIEW32 WORKS 1500-32K UPGRADE IN-SUPT (PT)

RSI Software Products 9357-ANETL3 RSNETWORX BUNDLE FOR CNET, DNET & ENET

Motion Control MPL-A330P-MJ22AA MOTOR,SERVO,4.18 NM,5000RPM,MULTI,230V,5.0KG

Motion Control 2090-UXNBMP-18S03 CABLE,ULTRA,NON-FLEX,MOTOR BRAKE,MP 3 MTR.

CBL-12-MPS-30 Power Cable, MTR-1221-*-D & MTR-1231-*-D Stepping Motor with S2K, 30 Ft.

IC600PB552RR PDT Prom Board

IC800SKCBVL100 Power/Brake Cable, S2K to 4.5 - 5kW S-Series Servo Motors, 10 Meters

OC647IFESGRNUNLMTM iFIX Optn: ESig & ERec Unl I/O Runtime (M4 Part)

20AD052A3AYNAEC0 PowerFlex 70 AC Drive 52 A at 40 Hp 20A

20DC5P0A0EYNANBNE PowerFlex 700S AC Drive 20D

20P-RES-A0 PowerFlex DC Resolver Feedback Board

2711-CBL-HM05 PanelView 300 5 m Operating Cable

280-PWRM22E-M3 ArmorConnect 3-PH Power Media drop cable

FX2N-4DA 4通道模擬量輸出模塊

1492-M6X5V1-50 Connection Products

1494U-AC 1494U 30A-100A Crossbar Adapter

軟啟動(dòng)器 3RW44532BC44

SIMATIC STEP 7 V14 6ES7822-0AA04-0YA7 SIMATIC STEP 7 基本版 V14 試用授權(quán)