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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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CBL-14-ET-30 Encoder cable for MTR-1300 or MTR-1N series splashproof stepping motor. 30 feet

GF-0188S-15 Connecting FlashCable to Federal Micro Maxum Indicator, 15 ft.

IC200TBX020 Tool box, Micro 20 and software. Includes (IC200UDD020) 24VDC In/24VDC Out, requires 24VDC power, (IC200USB001) RS-232 option board with (2) 0 -10VDC analog in with Proficy software, manuals and cables (IC646MPM101)

IC646TBPAS025 Production Accounting Server 25 mass balance streams

IC647NMM000 CIMPLICITY Marquee Manager - supports up to 5 Marquees. Add multiple packs to increase device counts.

IC693ACC312 Extended battery (1.45 Amp-hours) for Series 90-30 CPU memory backup. The Battery Module replaces the standard CPU RAM backup battery in your control system. Approximaby 20% more capacity than the IC693ACC301. Qty of 2 batteries.

IC750LCD440RR PANELWARE 4-Line x 40-Character LCD Dislplay

IC800VMCE030 Encoder cable for 100 W to 750 W VersaMotion servo motors- 3 meter

SLC/1746 System 1746-OB32E ELECTRONICALLY PROTECTED DC OUTPUT MODULE

Industrial Computers 6155R-NPXPH VERSAVIEW NON-DISPLAY COMPUTER

Application-specific products 6556-SCBM44 SLC 5/04, 5/04 PROGRAMMABLE PRESS CONTROL KIT

Operator Interface 2711-B6C12 PV600 COLOR KEY&TOUCH, PBUS & RS232 PRINT

Support 9301-2SE2300JPR SUPT REINSTATEMENT CONTRACT FOR 93012SE2300JP

Support 9307-8MGDBPS SUPT RENEWAL CONTRACT FOR 93078MGDBPENE

DeviceNet Products 1734D-IA16S 120 VAC 16 IN, DNET COMMS, SPRING

RSI Software Products 9301-2SE250JPU5R RSVIEW32 WORKS 5K-100K UPGRADE OUT-SUPT (JP)

RSI Software Products 9358-BNT30ENE RSBATCH 30 UNITS

Motion Control MPL-B320P-RJ22AA MOTOR,SERVO,2.94 NM,5000RPM,RSLVR,460V,4.6KG

Motion Control 2090-K6CK-D15F CONNECTOR, AUX FDBK, D-SHELL/TERM BLOCK, 15 PIN F

GFK-0483 Series 90 Universal Simulator User's Manual

IC641VPS002 VersaPro programming software and documentation for VersaMax Micro and Nano Only. Programming cable not included. CD bat

MSC-FRQ-V Obsolete - 1KHz in / 0-10 V out

PSPC-DC25L Prof Shop Floor SPC DC 25 User

PXI-8464

AS5USA-24091-XD-N

SPCIE-3600AM2-R10

0GMV12-7451-281-0321-A00

IP-4GVP23

數(shù)據(jù)采集卡 MPC30

1492-N15 TERM BLCK Jumper 2 Pole

通訊處理器CP 6ES7 870-1AA01-0YA1 ModbusRTU 主站，單授權(quán)，不包含軟件

行程開(kāi)關(guān) 3SE53221SE21

TIA 博途 WinCC 選件 6AV2107-0KD00-0BB0 SIMATIC WinCC WebNavigator for Runtime Professional 3 Clients

1585J-M8HBJM-1 RJ45 Ethernet Media

1757-SRC1 System Redundancy Module

188-K1D630-N Miniature Circuit Breaker 63 A

194E-Y63-1753-6N 63 A 194E Load switch

2090-CHBIFS8-12AA07 Kinetix 6000M IPIM hybrid cable

2090-UXNPBMP-8S03 MP-Series 3 m Length Power Cable

BC647MBT001 Machine Edition Traditional Development Suite with Proficy GlobalCare Complete and USB Hardware key

GC647IFPRDV00900 GCC iFIX Profsnl SCADA 900 I/O Dev

IC200CHS003 I/O carrier connector style

IC646MQPS99 Machine Edition View for Quick Panel Unlimited Site License

IC647IFSTDV00150M iFIX Standard HMI 150 I/O Development (M4 Part)

IC670ALG330 Analog Output, Current, 8 Channel

IC697CPU789RR CPU, 2K Triplex (voted) I/O, GMR Redundancy

IC800SKCBV050 Power/brake cable for SDM100 or SLM100 or SDM250 or SLM250 or SGM450 S-series servo motor connected to an S2K. 5 meters

ControlLogix/1756 System 1756-IF4FXOF2F FAST ANALOG 4 CUR-VOLT IN/2 CUR-VOLT OUT (36 PIN)

Industrial Computers 6182H-10TEH15D VVCE 1000, TOUCH, EXT MEM, CNET, DC

Process Control 1757-FIMUL035 FOUNDATION FIELDBUS FIM MODULE USAGE LICENSE

Operator Interface 2711P-RDT10C PV PLUS 1000, TOUCH SCREEN DISPLAY MODULE

Support 9355-WABESR SUPT REINSTATEMENT CONTRACT FOR 9355WABES

Support 9351-WKTSRTR SUPT REINSTATEMENT CONTRACT FOR 9351WKTSRT

ControlNet Products 1771-ACNR15 CONTROLNET 1.5 AND BEYOND, 1771 I/O ADAPTER

RSI Software Products 9301-2SE2400ITU3 RSVIEW WORKS 150-32K UPGRADE IN-SUPT (IT)

RSI Software Products 9355-WABOEMPTE RSLINX OEM - PORTUGESE

Motion Control MPL-A320P-HK24AA MOTOR,SERVO,2.94NM,5000RPM,ENCDR,BRK,5.1KG

Motion Control 2090-U3BC-D4403 BREAKOUT BOARD CABLE,CN1,ULTRA 3000,3M

CBL-121-1 Cable. KOYO DL405 (RS-232) (T.I)

IC600CP615RR 13" Series Six Plus CPU 125Vdc Power Supply (8 Slots)

IC800S2KDEM1 S2K Case Demo with 4.3A DeviceNet Controller & MotorCube