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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(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(guò)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(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(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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2097-V34PR3-LM Kinetix 350 1.0kW Servo Drive

ET-GT-9ES-1 9 RJ45 Port Ethernet Switch

GFK-2059 VMIC - Analog Output User's Manual - IC697VAL348

IC220MDL751 OUTPUT, 24VDC POSITIVE LOGIC 0.5A, 2PT (REQUIRES 1 IC220TBK082)

IC647DMC050 DataMart 50 Reporting Clients

IC647REAC REA:Reliance Electric Automate 15/20/30/40

IC693MDL330 120/240 Vac Output, 2 Amp (8 Points)

IC756CDV001K-98 DV Development - Compaq True64 Op Sys Addt'l User, Korean, Version 9.8

MSI-PROD-2-43 Product Mang Clients 2 Pack-43

PLC-5/1771 System 1771-DRS CONTROL COPROCESSOR, STATIC RAM MEMORY EXPANSION

Distributed I/O 1790-0W8X LDX I/O, 24VDC, 8 RELAY OUT EXPANSION , D-SHELL

Communications 1788-CNCR CNET LOGIX DAUGHTERCARD - REDUNDANT COAX MEDIA

Operator Interface 2711E-NT2 ANALOG TOUCH SCREEN REPLACEMENT KIT

Support 9304-WVR300S SUPT RENEWAL CONTRACT FOR 9304WVR300

Support 9324-RLD300ENR SUPT REINSTATEMENT CONTRACT FOR 9324RLD300EN

DeviceNet Products 2711-K10G10L1 PV1000 GRAYSCALE KEY, DNET & RS232 PRINT

RSI Software Products 9301-2SE3400ESE RSVIEW32 RUNTIME 32K (SPANISH)

RSI Software Products 9371-EJTI3 RSWIRE JIC TO IEC CONVERSION

Motion Control MPF-AIR-PURGE KIT,AIR PURGE, FOR ALL MPF,REQUIRES MPF-AIR-TOOL

2025 Greyline OS, 4 Line, (20) 4MM Chars, LCD, Quick Connect, NEMA 4

HE693THM666 6 channel thermocouple b module for Series 90-30 with 0.1癈 resolution, bus/channel isolation and 60Hz filtering.

IC670TBM001 Aux. Terminal Strip, Qty. 2 Barrier Style

QPJ-GEG-201 MODULE GE GENIUS

STXPBS232 STXi Profibus with 24VDC sink output, 32 points, expandable to 8 additional modules.

SCC-AI01

PCI-1733

IFRP-532NF

CQ04APC.2 CQ05APC

PCI-7031

MK620-PUC224

1492-SPM1B150-N MCB Supplementary Protector 15 A

直流電源 6EP1333-2AA01 120/230VAC 輸入，24VDC/5A 輸出

6ES71532BA100XB0

1497D-A13-M21-0-2 1EN PURPOSE TRANSFORMER

1606-XLSDNET4 1606 XLS 4 A DeviceNet Psy Power Supply

1769-L30ERMS Compact GuardLogix CPU, L30ERMS, 1M/0.5M

190E-BND2-CC16X 10-16 A Economy Starter W/Ckt-Bkr

194R-LNC17 194R UL Finger Safe Terminal Covers

2090-CPBM7DF-14AF40 MP-Series 40m Continuous-Flex Cable

2090-XXNPY-16S01 Y-Series 1 m Length Power Cable

CBL-71006243-10 Serial RTU cable for Data Panel DP40 connected to an S2K controller

GF-1326RS-10 Connecting FlashCable to Starrett Calipers, Micrometers - 10 ft.

IC200UDD020 Versamax Micro 20 point PLC,(12) 24VDC In, (8) 24VDC Outputs with ESCP protection, 24VDC Power Supply. (1) serial port and (1)optional communication port. Requires Machine Edition 5.7 or higher. Battery (IC200ACC414) is required for data retentio

IC646TMS001 CMPLCTY UPGRADE INTEL- NO COST

IC647OMFM OMF:Omron Fins

IC693ALG390LT Analog Output, Voltage, 2 Channels (LT)

IC752DFT000 DataPanel 150, GE Fanuc Label, 240x64 LCD display with LED backlight. Includes integrated keypad for data entry. Various sizes of text sup ported. No touch or PC/104 capability. UL, cUL, CE, UL1604

IC800VMM30LNKSE25 3 kW VersaMotion servo motor (14.3 Nm)

SLC/1746 System 1747-KFC15 SLC CNET SERIAL INTERFACE MODULE

Industrial Computers 6189V-SLFD144 FLOPPY DISK DRIVE SLIM

Application-specific products 1404-M405A-000 MASTER MODULE FOR POWERMONITOR

Operator Interface 2711-K6C9 PV600 COLOR KEY, RS232 (DH485) & RS232 PRINT

Support 9301-2SE2500ZHS SUPT RENEWAL CONTRACT FOR 93012SE2500ZH

Support 9380-RSBAR1000R SUPT REINSTATEMENT CONTRACT FOR 9380RSBAR1000

DeviceNet Products 1734-FPD FIELD POTENTIAL DISTRIBUTOR

RSI Software Products 9301-2SE3200FRU1 RSVIEW32 RUNTIME 150-300 UPGRADE IN-SUPT (FR)

RSI Software Products 9358-BPC60U3R UPGRADE: OUT-SUPT: RSBIZWARE PC PHASES 30 TO 60

Motion Control MPL-B430P-SJ24AA MOTOR,SERVO,6.55 NM,5000RPM,SINGL,460V,BRK,8.2KG

Motion Control 2090-SCNP10-0 SERCOS FBR CABL,CONN,HARSH DUTY,JKT,PLASTIC,10.0M

GFK-1277 Genius Modular Redundancy Flexible Triple Modular Redundant (TMR) System User's Manual

IC646MDD300 Logic Developer PC (HRT) 300 Tag Runtime & Development System

MSP-VOL-IN1 Obsolete - 0-10 VDC in / Pulse out

QPI-IBS-201 Communication Module for 7 inch/ 9 inch/ 10 inch & 12 inch: Interbus-S Slave