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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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RSI Software Products 9301-2SE3503 RSVIEW32 RUNTIME 100K WITH RSLINX

RSI Software Products 9358-HSTATH RSBIZWARE HISTORIAN SINGLE USER AUTHORING CLIENT

Motion Control Y-2012-1-H04AA MOTOR,SERVO,1.35 NM,4500RPM,ENCDR,115V,BRK,3.09KG

525 MICRO GREYLINE. 2 LINE 20 CHARS, VF. NEMA 4

IC200DTX200 Operator Interface for changing timer/counter/register values. 2 x 16 character LCD backlight display and 6 operation keys. No stored messaging, PLC stores messages.

IC695CHS012 RX3i BASE 12 SLOTS

MSI-WEB-UNL Unltd Site Clients - Web or Excel Report

cRIO-9063

PCA-6743F

VIOLA NVSAT 957593-025 150A0674-52

SEGA 838-14487

PUD40(YK0-V0731)

NIPCI-6251

TERADYNE WC113

1492-SPM2D060 MCB Supplementary Protector 6 A

軟啟動(dòng)器 3RW30382BB04

電機(jī)啟動(dòng)器 3VU16400CP00

150-F317NBD SMC Flex Smart Motor Controller

1732E-IB16M12 ArmorBlock 16 Point Input Block

1771-RTP1 1771 Remote Terminal Panel

193-EEGF E1 Plus 18-90 A Overload Relay

20-750-1132C-2R PowerFlex 750 Series 24V DC EIO Kit

2090-CPWM7DF-08AF25 MP-Series 25m Continuous-Flex PWR Cable

2097-R6 Kinetix 300/350 75 Ohm Shunt Resistor

ENP2115M010 Male Industrial/Male Industrial, 1 meter

GFK-1687 User Manual-Mini OCS Hardware Manual

IC220BEM485 RS-485 Communications Module interfaces serial I/O devices to a VersaPoint I/O Station. Requires a NIU that supports PCP services, not compatible with IC220EBI002 Ethernet NIU. Supports the following protocols Transparent, End-to-end, Dual buffer,

IC647CSPC005 Proficy Cause+ for Inbligent HMI/SCADA Client Enabler - 5X CALs

IC647PSC000 Proficy Process Systems 5000+ I/O with CIMPLICITY

IC693MCD001 Beta series servo demo case

IC756ADV010J-99 DV Draw Development on AIX Op Sys, Japanese, Version 9.9

MSI-MGMT-100 Production Management Clients 100 Pack

PLC-5/1771 System 1771-DXPS CONTROL COPROCESSOR - SERIAL EXPANDER MODULE

Distributed I/O 1738-IR2M12 24VDC 2 INPUT RTD WITH M12 CONNECTORS

Communications 1784-PCD DEVICENET PCMCIA COMM CARD

Operator Interface 2711-NV6T ANTIGLARE OVERLAY PV1000 TOUCH

Support 9304-WRM300R 9304-WRM300 SOFTWRE SUPPORT CONTRACT REINSTATEMENT

Support 9393-EGLX500R SUPT REINSTATEMENT CONTRACT FOR 9393EGLX500

DeviceNet Products 2706-PDNETK DEVICENET COMMUNICATION MODULE FOR 2706-P7X & P9X

RSI Software Products 9301-2SE335ITU1R RSVIEW32 RUNTIME 150-5K UPGRADE OUT-SUPT (IT)

RSI Software Products 9371-EDES2 RSWIRE DESIGNER/JIC FOR AUTOCAD 14-14.01

Motion Control MPG-B010-031M22 MOTOR,SERVO,GEAR RATIO 31,25NM,208RPM,MULTI,460V

Silver Series 2711-K14C12 PV1400 COLOR KEY, PBUS & RS232 PRINT

HE693SER300 Slot One Sequential Event Recorder

IC670ALG620 RTD 4 Channel Isolated 3 wire

QPI-DEM-L02 QUICKPANEL DEMO 10.5" MONO LCD

ST-5651 STXi 1 Channels, Pulse Out module, 0.5A/5V (RS422), 20Khz

USB-9211

泓格 PIO-DA8

DMV600BTEPWCN

SP382-TS

JUMPtec 01022-0402-13-1

BCM5751

1492-SPM1B010 MCB Supplementary Protector 1 A

人機(jī)界面 6AV6545-0DB10-0AX0 MP370 觸摸面板，256 色，15.1 英寸，800? 600

6ES73317KF024AB2

1497B-A6-M13-0-N Control Power Transber

1606-XLS480G-3 36-42V Dc 480 Watt Power Supply

1769-IG16 CompactLogix 16 Pt TTL DC D/I Module

189-ASCR3 MCB Accessory Signal Contact

194R-HM4E 194R 100-400-625 A Operating Handle

2090-CPBM7DF-14AA07 MP-Series 7m Standard Cable

2090-XXNPMP-8S05 MP-Series 5 m Length Power Cable

CBL-3C-L1D-FLY-10 S2K flying lead feedback cable for special for 3rd party motors with hall commutating encoders. 10 feet

GF-0304 Connecting FlashCable to Edmunds Trendsetter (for use with the Combo G agePort). Contact Dave Chapman X5472 for additional electrical testing.

IC200TBX340 Tool box, Micro 40, operator interface and software. Includes (IC200UDR140) 24VDC In/Relay Out, requires 120/240VAC power, (IC200USB001) RS-232 option board with (2) 0 -10VDC analog in with VersaMax DataPanel DP 45 (IC200DTX450) with Proficy Logic

IC646TBSPMPW025 Smart Process Monitoring Process+ Web Clients 25 Pack

IC647NSP000 CIMPLICITY HMI SPC (Statistical Process Control) Option

IC693ACC341 Redundant Power Supply Base with 0.5 meter cable to connect to Power S upply Adapter module. Supports any Series 90-30 power supply.

IC752CBT023RR Datapanel 320T MEG (Mono Expansion w/Genius) w/ Advanced s/w: 320x240 1/4 VGA Mono LCD with 386SX/40 processor. Analog touch screen with te xt, bitmaps, bar graphs, real time clock. With Real Time Trends & Host Comms. With Genius PC/104.

IC800VMCP2200 Power cable for 2 kW VersaMotion servo motors- 20 meter

SLC/1746 System 1746-NI4 (4) ANALOG INPUT FOR PROGRAMMABLE CONTROLLER

Industrial Computers 6189V-CPUSTD1 STANDARD SBC (W/CPU AND COOLER) (1500W)

Application-specific products 1403-CF005 2 X 5 M F LINK FOR POWERMONITOR

Operator Interface 2711-B6C9L1 PV600 COLOR KEY&TOUCH, RS232 (DH485) & RS232 PRINT

Support 9301-2SE2400JPS SUPT RENEWAL CONTRACT FOR 93012SE2400JP

Support 9323-1003ENR SUPT REINSTATEMENT CONTRACT FOR 93231003EN