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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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BC646MVSU01 View Standard Edition Upgrade from QuickDesigner with Proficy GlobalCare Complete

GC647AUR010 GC Universal Reporting Client 10 Pak

IC200ACC405 VersaMax Micro 64 and Micro 40 spare parts kit. Kit includes (5) Micro 64 terminal blocks, (5) Micro 40 terminal blocks and (5) Micro 64 terminal block covers.

IC646CSPR005 Proficy Cause+ for Inbligent HMI/SCADA Runtime Server - 5X monitored KPIs

IC647IFPLSR00075K iFIX Plus SCADA 75 I/O Server (M1 Kit Part)

IC660MLA104 Label for IC660BBA104 (Qty 100)

IC697ALG441RR Analog Input Expander, Voltage, 16 Channels

IC758WMM100 iGlobalCare Complete 21+ Users (same site): DataViews for Windows

FlexLogix System 1794-STRT1 FLEXLOGIX STARTER KIT

GuardPLC Systems 1753-PCSPAR RSLOGIX GUARD PLUS FOR GUARDPLC -PARALLEL HARDLOCK

Process Control 1757-UPGSIFZ UPGRADE FLAME SFGRD QUICKBUILDER I/F

Operator Interface 2711P-T12C6D1 PV PLUS 1250, TOUCH, RIO/DH, DC PS, STD MEM

Support 9220-TGS SUPT RENEWAL CONTRACT FOR 9220TG

Support 2755-LHS1R SUPT REINSTATEMENT CONTRACT FOR 2755LHS1

Support F1785-V30BSERE FIRMWARE UPGRADE FOR 1785-V30B PLC5 PROCESSOR MODU

RSI Software Products 9301-2SE2350KOU1 RSVIEW32 WORKS 150-5K UPGRADE IN-SUPT (KO)

RSI Software Products 9701-VWSTMDEE RSVIEW STUDIO FOR MACHINE EDITION (GERMAN)

RSI Software Products 9399-WABOUG RSLINX OEM USER GUIDE

Motion Control 8720MC- -HASP STANDARD PROGRAMING ONLY HIM

BC646MRB700 Logic PC Runtime 700 I/O

IC300OSW232 Cscape programming software (CD ROM), RS-232 programming cable, and complete software/hardware documentation.

IC754CKL06CTD Starter Kit, 6 TFT Ctrl Loaded, 24VDC"

MTR-3T45-I-R-B-M-0-MODRR Servo Motor Metric 24V Brake Mod=Key

PCI-6711

GENE-4310

IPC-6106P4

C806MCP

PCM-9362

CS250LM 5.1/12.1

1492-LD4RB333 Terminal Block, Resistor, 33.2K Ohms

1494F-L4 Door Hardware Kit

軟啟動(dòng)器 3RW44352BC36

ET 200SP 6ES7193-6AP00-0AA0 BA 2×SCRJ (用于PROFINET 高性能接口模塊，光纖接口）

1585D-E4TB-5 Micro D-Code, QD Style Ethernet Media

1751-SL4SP SynchLink Fiber 4 Port Splitter Block

1794-IA8I Flex 8 Point Digital Input Module

194E-AA20E-P11 194E Load switch

2080-LC10-12QWB Micro810 12 I/O Smart Relay Controller

2090-CSWM1DF-14AA18 Kinetix Cable Single DSL 2090-Series

20AC2P1C3AYNNNC0 PowerFlex 70 AC Drive 20A

GC646MPP005 Proficy GlobalCare Complete for Logic Developer - PLC Professional - 5 Pack

HE693OIU277 Compact VF OIU with 4-line display, powered by 24VDC

IC610ABM100RR ASCII/Basic Module

IC647HSTSC20000KM Server to Server Collector for Historian - Standard Server 20,000,000 Points (M4 Key)

IC660BBA101 Block 115Vac/125Vdc RTD Input 6 Channels

IC694MDL752CA Conbal Coated Output module, 5/12-24VDC, 32 point NEG logic.

IC756WDJ009E-99 DV Development Sys VB and Java, English, Version 9.9

MicroLogix 1500/1769 System 9399-RL50GRES RSLOGIX 500 GETTING RESULTS GUIDE (SPANISH)

PLC-5/1771 System 1771-CP2 1771 I/O CHASSIS CABLE FOR 1771-P7 POWER SUPPLY

Distributed I/O 1797-PS1E 85-250 VAC IN QUAD-EX IS OUT POWER SUPPLY-IS TERM.

Operator Interface 2711P-B6C3A PV PLUS 600 COLOR, KEY/TOUCH, DH485, AC PS

Support 9323-PA1IS SUPT RENEWAL CONTRACT FOR 9323PA1I

Support 9358-HSTSSROLR SUPT REINSTATEMENT CONTRACT FOR 9358HSTSSROL

Support F1772-LXPSERC FIRMWARE UPGRADE FOR 1772-LXP PLC2 PROCESSOR MODUL

RSI Software Products 9324-RLD3U7ITE RSLOGIX 5000 STD. TO PRO UPGRADE, ITALIAN

RSI Software Products 9305-RSVADDCFRE RSVIEW32 ACTIVE DISPLAY DED. CLIENT (FRENCH)

RSI Software Products 9358-RTI10E RTI DATA COLLECTOR 10 CONFIGURATION

Motion Control 2092-DA5 DRIVE, 16.4A/43.4A, ULTRA1500 DIGITAL SERVO DRIVE

A06B-0143-B075#7076 A12/3000 Servo Motor, IP67 Sealing, 64K Serial Encoder

IC200UDD110-24 Qty of 24, 28 point PLC, (16) 24VDC In, (12) 24VDC Out (6) 1.0A, (6) 0.5A, 24VDC Power Supply. Battery (IC200ACC403) is required for data retention.

IC752BUU014 VT100 Upgrade for Datapanel K

MTR-1454-E-A-E-SRR Stepping Motor Nema42 Encoder Splashproof

NI 9220

ROCKY-3703E1V-AT-1.0

MIC-3056

PWR-C49E-300AC-R

PCA-6007VE