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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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IMC-200D-X-DRR IMC-D Series Ampless Servo Motor Controller, Standard

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Industrial Computers 6189V-MRA17 RACK ADAPTER FOR 17" PLATFORMS

Application-specific products 1404-M605A-CNT 1404-M6 CONTROLNET PM3000 120/240V P.S.

Operator Interface 2711-K10C3 PV1000 COLOR KEY, DH485 & RS232 PRINT

Support 9301-2SE3200PTR SUPT REINSTATEMENT CONTRACT FOR 93012SE3200PT

Support 9380-RSBVB2500S SUPT RENEWAL CONTRACT FOR 9380RSBVB2500

DeviceNet Products 1792D-4BVT4D 4 SINK/SOURCE INPUTS, 4 SOURCING 0.5 AMP OUTPUTS

RSI Software Products 9301-2SE320JPU1R RSVIEW32 RUNTIME 150-300 UPGRADE OUT-SUPT (JP)

RSI Software Products 9358-BTDS30U1R UPGRADE: OUT-SUPT: RSBW TNG & SIMULATION 3 TO 10

Motion Control MPL-B4530K-MJ22AA MOTOR,SERVO,8.36 NM,4000RPM,MULTI,460V,8.2KG

Motion Control 2090-SCVP32-0 SERCOS FBR CABL,CONN,STANDARD PVC JKT,PLASTIC 32.0

GQBH2D100S2P QUICKPANEL 6" STN HAND HELD BUNDLE GE LABEL

IC646MPS005 Logic Developer - PLC Standard - 5 pack

MTR-1350-E-A-E-S Stepping Motor Nema34, Parallel Wdg, Encoder, Splashproof

QPKCTDE0000 6 inch TFT QuickPanel with TCP label/ Ethernet/ Compact Flash/ 24VDC/ UL/cUL & CE Approvals

PXIe-6363

PCI-1735U

Enhanec ATX-752B

PCL-745

MATROX Meteor-Ⅱ MET2-MC/4/8F 751-0201

PPC-L128T

1492-PDL3111 175 A Power Distribution Block

模擬量輸入/輸出模塊 6ES7431-1KF10-0AB0 AI/8 14BIT，光隔離，U/I，THERMOEL/PT100

變送器 3RS10101CD00

1497-A-HXJX-0-N Control Circuit Transber

1585J-M8UBJM-25 RJ45 Ethernet Media

1761-L16NWB MicroLogix 1000 16 Point Controller

188-K3C010 Miniature Circuit Breaker 1 A

194L-E25-1753 25 A 194L Load Switch

2090-CPBM6DF-16AA07 TL-Series 7m Power and Brake Cable

2090-XXNFMP-S15 MP-Series 15 m Length Feedback Cable

BC647OPPSK01 OEM Edge Process M4 Key includes 1 physcial M4 key that authorizes Proficy Process System as well as all core products

GC647PATRX00 "Proficy PAT - Process Analytical Software Suite, Pharmaceutical - Assist Support"

IC200MDL140LT INPUT 120VAC (1 GROUP OF 8) 8PT (LT)

IC646NSL899 Proficy SQL 2008 - Processor License

IC647MELM MEL:Mitsubishi Melsec

IC676ACC003 Protective Caps - Female (For unused incoming power connectors) - Qty 5

IC697MEM715RR Expansion RAM, 128 KBytes,CMOS (Used w/77X CPUs & PCM)

IC800SSD228RS1 28 amp 230 VAC S2K servo drive for MTR series motors

ControlLogix/1756 System D1756-UM058CENP CONTROL LOGIX DIGITAL I/O MODULES USER MANUAL

Industrial Computers 6182H-15KRH4D VVCE 1500, KEYPAD, STD MEM, ENET, DC

Process Control 1757-DNBUL50 DEVICENET USAGE LICENSE, 50 DNB MAX

Operator Interface 2711-START300DE START KIT PV300 KEY,GERMAN(PV300,PB32, CABLES)

Support 9326-AD5APR SUPT REINSTATEMENT CONTRACT FOR 9326AD5APENE

Support 9371-EDETISAS SUPT RENEWAL CONTRACT FOR 9371EDETISA

ControlNet Products 1797-TPR CONTROLNET EX T-TAP RIGHT ANGLE

RSI Software Products 9301-2SE240ZHU1R RSVIEW32 WORKS 1500-32K UPGRADE OUT-SUPT (ZH)

RSI Software Products 9358-BA60U1R UPGRADE: OUT-SUPT: RSBIZWARE ARCHIVER 03 TO 60

Motion Control MPL-A4520P-HJ22AA MOTOR,SERVO,6.10NM,5000RPM,ENCDR,230V,6.8KG

Motion Control 2090-UXNPAN-16R01 CABLE,NON-FLEX, MOTOR POWER, N,R/A,16AWG,1M

CBL-30-JP-06 AC Power Cord with 3-Prong Plug, 6 Ft.

IC640MWS901RR Workmaster System, 1-35" Disk Drive

IC800SLCS020 Cable, SL Amplifier Serial Communication, 2 Meters

OC647IPWRCLNRNM iPower Option - Run Client

PXI-2599

RUBY-9713VG2AR

W26361-W64-Z2-06-36

COSMO PCPG-46

FB2502

MT6101I-2416-10

1492-MCBA2HA0 100A Miniature Circuit Breaker

1494V-DJX622 NEMA Flange Mtd Rod Switch Disconnect Sw

軟啟動(dòng)器 3RW44576BC36

運(yùn)行版軟件 6AV2103-4KX04-0AE5 SIMATIC WinCC V7.0..V7.3 RC 8192 ->WinCC 專(zhuān)業(yè)版 max. PowerTags V14 Combo 和 WinCC RT 專(zhuān)業(yè)版 8192 PowerTags

1585D-M8UGDM-40 Gigabit Ethernet Media

1756-L75 ControlLogix 32 MB Controller

1799-DNETSCON DeviceNet I/O Accessories

194E-FA32E 194E Load switch

2090-CFBM7DD-CEAA25 MP-Series 25m Servo Feedback Cable

2090-SCVP8-0 Kinetix 8-8m Fiber Optic Cable

BC646MPS050 Logic Developer PLC Standard 50 Pack with Proficy GlobalCare Complete