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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(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。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(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(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(dòng)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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PLC-5/1771 System 1771-P6S1 POWER SUPPLY,SLOT(ONE SLOT), 8A,220V AC

Distributed I/O 1798-ADN FLEXARMOR DEVICENET ADAPTER

Operator Interface 2711P-K6C1A PV PLUS 600 COLOR, KEYPAD, SRIO, AC PS

Support 9323-PI300DUR UPGRADE: OUT-SUPT: 6200-5250 BOTH TO AI-5250 BOTH

Support 9358-PBA03R SUPT REINSTATEMENT CONTRACT FOR 9358PBA03ENE

Support F1774-KA FIRMWARE UPGRADE FOR 1774-KA COMMUNICATION MODULE

RSI Software Products 9324-RLD700NXENE RSLOGIX 5000 PRO EDITION, ENGLISH

RSI Software Products 9305-RSVADFVCJPE RSVIEW32 ACTIVEDISPLAYFLOATINGVIEWCLIENT(JAPANESE)

RSI Software Products 9301-PCI2000PFB APPLICOM PCI2000PFB PROFIBUS DP SERIAL INTERFACE

Motion Control 2094-PR1 POWER RAIL, 230V OR 460V, 1 AXIS

A06B-6050-K120 Connector Kit, B0.5 Motor Encoder

IC200UEX010-24 Qty of 24, 14 point expansion. (8) 120VAC In, (6) 120VAC Out, 120/240VAC Power Supply (includes IC200CBL501)

IC752CBT060RR 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-N-A-E-SRR Stepping Motor Nema42 Splashproof

ZA06B-0141-B075#7008 AC12/2000 servo motor with 32k serial encoder

20BD5P0A3AYNANC0 PowerFlex 700 AC Drive 5 A at 3 Hp 20B

20G14NC104AA0NNNNN PowerFlex 755 AC Packaged Drive

25-PM1-E022 PowerFlex 520 15kW (20Hp) Power Module

771BSS47403 Quantum CONCEPT XL 版注冊軟件,3用戶

FRN7.5E1S-2J 12KVA 33A 7.5KW 3相AC220V/50Hz/60Hz

P69-MDDE256LAUF

1492-SPM3D060 MCB Supplementary Protector 6 A

軟啟動(dòng)器 3RW40382BB15

SIMATIC HMI 系列面板 6AV2123-2MA03-0AX0 KTP1200 Basic DP 12 寸觸摸 + 按鍵

150-SF2D SMC-50 Frame C 120/240V Replacement Fan

1738-APB ArmorPoint ProfiBus Network 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

GP647IFCLNTS005 GCP iFIX iClientTS 5 Additional Users

IC600BF814RR Type K Thermocouple Input Module (8 points)

IC647HSTCC40KM Calculation Collector for Historian - Standard Server 40000 Points (M4 Key)

IC647TDV000 CIMPLICITY HMI Server NO LIMIT Development & Runtime System

IC693MDL930LT Relay Output, Isolated, 4 Amp (8 Points) (LT)

IC756LDV001E64-925 DataViews Development on Inb Linux/Red Hat 64 bit, Addt'l User, English v9.25

Pico Controllers 1760-CONN-RJ45 INTRA-CBL CONNECT 10/PACK

PLC-5/1771 System 1771-OMD 220V AC OUTPUT MODULE, 16 OUTPUTS

Distributed I/O 1791-24AR BLOCK I/O, 120V AC, 32 POINT MODULE

Communications 1786-TNCLP4 CONTROLNET TNC COAXIAL CONN - PLUG TO PLUG

Operator Interface 9701-VWSTMDEE RSVIEW STUDIO FOR MACHINE EDITION (GERMAN)

Support 9701-VWSS250AS SUPT RENEWAL CONTRACT FOR 9701VWSS250AENE

Support 9324-RL0300DER SUPT REINSTATEMENT CONTRACT FOR 9324RL0300DE

EtherNet/IP Products 1747-L551 SLC 5/05 CONTROLLER

RSI Software Products 9301-2SE3500 RSVIEW32 RUNTIME 100K

RSI Software Products 9356-PRO2450U3 UPGRADE: IN-SUPT: RSSQL STD.1500 TO PROF.32000 TAG

Motion Control F-6200-R-H00AA BRUSHLESS MOTOR/ENCODER

44A726268-001 Terminal Block, Motion Mate APM300 Series I/O

IC200ALG230 ANALOG INPUT 12 BIT VOLTAGE/CURRENT 4CH

IC693MDL653 24 Vdc Input, Neg/Pos Logic, 2msec Filter (32 Points)

TRM-21006667 Connector, S2K Digital I/O, 20 pt.

VMEM-GMOD/PC VisualMEM MEMPort Gateway Module. One required for each PC that uses MEMPort Input Modules.

20BD022A0AYNAND0 PowerFlex 700 AC Drive 22 A at 15 Hp 20B

20G11FC037JA0NNNNN PowerFlex 755 AC Packaged Drive

22C-D022F103 PowerFlex 400 11 kW (15 Hp) AC Drive

140CRA93101C Quantum LMS RIO 站適配器, S908 RIO, 單電纜, CC

285-BRC25-M20D Source Brake Patchcord Cable, 20M, M25

已經(jīng)停產(chǎn)由H7CX-A代替

1492-SPM1D200-N MCB Supplementary Protector 20 A

通用型變頻器 6SE6 440-2UD34-5FB1 "45 KW,350 x 850 x 320"

電機(jī)啟動(dòng)器 3VU13401TE00

150-C84 Smart Motor Controller Accessory

1692-ZG66BB 24 V DC Electronic Circuit Protection

1771-IFF 1771 16 or 8 Point Analog Input Module

193-EC3FF E3 Plus 28-140 A Overload Relay

198-PL21R IEC Pilot Light Enclosure Accessory

2090-CPWM4DF-14AF03 MP-Series 3 m Length Power Cable

2094-BC01-M01-S Kinetix 6000 Integrated Axis Module

DEMOCD00002A Proficy Historian DEMO CD Online

GFK-0664 Series 90-30 Axis Positioning Module (Power Mate-APM) Programmer's Manual