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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(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(shì)，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(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(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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RSI Software Products 9301-2SE2500PTE RSVIEW32 WORKS 100K (PORTUGUESE)

RSI Software Products 9358-BEPB10ENE RSBIZWARE BATCH AND EPROCEDURE BUNDLE 10 UNITS

Motion Control MPL-A4540C-MJ24AA MOTOR,SERVO,10.2 NM,1500RPM,MULTI,230V,BRK,13KG

Motion Control 2090-XXNFMP-S30 CABLE,NON-FLEX,MOTOR FEEDBACK,MP/1326AB,30M

CBL-T7-MB-20 Power/Brake Cable, MTR-3T1x & MTR-3T2x Series Servo Motors, 20 Ft.

IC641PCC016 Toolkit, Function Block, C

IC800SSD107RS1 7.2A, 115/230V, S2K Servo Drive for MTR Series Motors

PR-PAT-BRK01 Proficy PAT - Driver For Bruker Ftir Spectrometers

PXI-6120

ATX6022-14G

MIC-3390

AX98690

PCA-6184E2

PEAK639VL2

1492-MR8X12H1-50 Connection Products

1495-N34 Electrical Interlock

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1585J-M4TBJM-5 RJ45 Ethernet Media

1756-OF8 ControlLogix 8 Pt A/O I or V Module

188-K1C040 Miniature Circuit Breaker 4 A

194E-GA32E-P22 194E Load switch

2090-CFBM7DF-CEAA04 MP-Series 4m Servo Feedback Cable

2090-UXCK-D15 Ultra Series Breakout Board Kit

BC646PCN110 OP Operator Console Runtime S/W 700 I/O w/GC

GC647DMS010 GC DataMart 10 PA Connections

IC200ALG264 Analog b 15 bit current 15 channel

IC646IFCLNTCRO025K iFIX iClient Read Only 25 PK Keyless (M1 Kit Part)

IC647IFPRDV00075K iFIX Profsnl SCADA 75 I/O Development (M1 Kit Part)

IC660MLS101 Label for IC660BBS101 (Qty 100)

IC697BEM741RR FIP Bus Controller 9070

IC800BIHV010 BSVM1-10HVi Beta HVi 10 amp amplifier kit

ControlLogix/1756 System 1756-L55M23 LOGIX5555 PROCESSOR WITH 1.5MBYTE NV MEMORY

Industrial Computers 6182H-7BRH15B VVCE 700, KEY/TOUCH, STD MEM, CNET, AC

Process Control 9323-ATUNEENE LOOP TUNER FOR LOGIX5000 PIDE FUNCTION BLOCK

Operator Interface 2711P-K15C15B2 PV PLUS 1500, KEYPAD, CNET, AC PS, EXT MEM

Support 9240-WIN16SDKR SUPT REINSTATEMENT CONTRACT FOR 9240WIN16SDK

Support 6723-PCSS SUPPORT RENEWAL CONTRACT FOR 6723-PCS

Support F5130-RM2 FIRMWARE UPGRADE FOR 5130-RM2 PLC5250 PROCESSOR MO

RSI Software Products 9301-2SE2350ZHU2 RSVIEW32 WORKS 300-5K UPGRADE IN-SUPT (ZH)

RSI Software Products 9351-OSF INTERCHANGE FOR DIGIAL UNIX

RSI Software Products 9399-WINIG WINDOWS-BASED PRODUCTS INSTALLATION GUIDE

Motion Control 8720MC-VA-B 460VAC VARISTOR

BC646MRE150 Logic PC & View Runtime (HRT) 150 I/O

IC300STP100 Stepper Indexer. Single axis, supports-type signals only (pulse train out, quadrature or Up/Down in)

IC754VKI12CTD Starter Kit - 12" Color-TFT QuickPanel View Intermediate, Touch, 24VDC

MTR-3T57-H-R-0-M-0RR Servo Motor Metric

PCI-8431/4 (RS485/RS422)

HSB-460I

Asus/華碩P2L97

R2Z-6350P-R

NOVA-7896R

01-03450-00

1492-LG4 IEC Term Blck 6.1x62x35.7mm Spr Clp

1494G-BF3J6-421 NEMA 1494G Enclosed Disconnect

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