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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。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，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)，如對夾具、被焊件、監(jiān)測精度等要求嚴(yán)格，焊接后檢測評價(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6 mm以下板材下料。車輛轉(zhuǎn)向架選用激光切割機(jī)對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12 mm以下板材下料[17]。

 

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IC646NRX000 System Sentry

IC647MBL001 Machine Edition Lite Development Suite with USB Hardware key

IC675GSD001 Profibus Station IP67 GSD Configuration Files

IC697MDL740 24/48 Vdc Output, 2 Amp, Positive Logic (16 Points)

IC800SLR003 External regeneration resistor rated 20 ohm 300 Watt for SL and S2K series

ControlLogix/1756 System 1756-BATM CONTROLLOGIX BATTERY MODULE

Industrial Computers 6182H-15BRH15D VVCE 1500, KEY/TOUCH, STD MEM, CNET, DC

Process Control 1757-DNBEXP100 DEVICENET MODULE EXPANSION, 80-100 MAX

Operator Interface 2711P-ST6KC PV PLUS 600 COLOR, KEYPAD STARTER KIT

Support 9326-AD10WDR SUPT REINSTATEMENT CONTRACT FOR 9326AD10WDENE

Support 9371-EDES1S SUPT RENEWAL CONTRACT FOR 9371EDES1

ControlNet Products 1734-EP24DC 24V DC POWER/BUS EXTENSION MODULE

RSI Software Products 9301-2SE240ITU3R RSVIEW32 WORKS 150-32K UPGRADE OUT-SUPT (IT)

RSI Software Products 9358-B60U3R UPGRADE: OUT-SUPT: RSBIZWARE BATCH 30 TO 60

Motion Control MPL-A430P-SK22AA MOTOR,SERVO,5.42 NM,5000RPM,SINGL,230V,6.4KG

Motion Control 2090-UXNFM-S03 CABLE,ULTRA, DRIVE CN2 TO N/C,3M

CBL-1C-ET-20 Encoder Cable, MTR-1216, 1221 & 1231 Stepping Motors, 20 Ft.

IC630MDL303RR 5-12Vdc (TTL) Sink Input Module, D Connector (32 points)

IC800SLCFLYV010 Flying Lead Cable, 1-5 kW SL Amplifier I/O to OCS or 3rd Party Controller, 1 Meter

OC647IFSETKTC iFIX Optn: System Extension Toolkit (M1Component Part)

PXI-2569

ROBO-8712VLA

PHILIPS HEALTHCARE SNGBP 459800079641

N2200-PAC-400W

NUPRO-A301 NuPRO-852

4036A H9MSER40XX

1492-MCBA180 80 A UL489 Miniature Circuit Breaker

1494V-DJ622-A-B-D NEMA Flange Mtd Rod Switch Disconnect Sw

軟啟動(dòng)器 3RW44566BC35

工程組態(tài)編程軟件 6AV2103-2DH04-0BD5 SIMATIC WinCC 專業(yè)版 Powerpack 512 PowerTags -> 4096 PowerTags V14

1585D-M4UBJM-4 Ethernet Media M12, Patchcord

1756-L72 ControlLogix 4 MB Controller

1799-BRKD Embedded Input/Output DIN Rail Bracket

194E-FA16-P11-PE 194E Load switch

2090-CFBM6DF-CBAA15 TL-Series 15m Feedback Cable

2090-SCNP32-0 Kinetix 32-32m Fiber Optic Cable

BC646MPM001 Logic Developer PLC Nano/Micro with Proficy GlobalCare Complete

GC647AHC001 GC PA Historian Connector

HMI-CAB-ETH 6 feet, Ethernet Cross-over cable for direct connection to CE devices

IC641VPD010 VersaPro Distributor Demo 10 Pack

IC647IFGLBLDPNSRVRM-55 iFIX WebSpace v5.5 Dependent Server

IC660EBD120RR High Speed Counter Electronic Assembly

IC697ACC644 24VDC fan tray for Series 90-70 or RX7i short racks.

IC756WRE499E-27 Runtime License Windows 100+ Users English v2.7

FlexLogix System 1794-IE8 ANALOG INPUT MODULE, 12 BIT, 8 POINT

PLC-5/1771 System D6200-6.4.11RU PLC5 PROG. SW INSTRUCTION REFERENCE MNL (RUSSIAN)

Process Control 1757-PLXSU300 PLX SERVER 100 TO 300 POINT EXPANSION

Operator Interface 2711P-T10C4D1 PV PLUS 1000, TOUCH, ENET, DC PS, STD MEM

Support 6001-A1CS SUPT RENEWAL CONTRACT FOR 6001A1C

Support 2711-END1FRR SUPT REINSTATEMENT CONTRACT FOR 2711END1FR

Support F1785-L46BSERD FIRMWARE UPGRADE FOR 1785-L46B PLC5 PROCESSOR MODU

RSI Software Products 9301-2SE2303ZHE RSVIEW32 WORKS 1500 WITH RSLINX (CHINESE)

RSI Software Products 9701-VWSS000FRU2 RSVIEW SE 100 TO UNLTD DISP UPGRADE (FRENCH)

RSI Software Products 9399-RSBADMIN RSBATCH ADMINSTRATOR'S GUIDE

Motion Control 1394C-SJT05-T-RL MODULE,SYSTEM,5KW,IMCS TURBO,W/RIO,W/AXIS LINK

BC646MODEV05PK Motion Developer 5-pack Proficy Global Care Complete for the S2K Series Amplifiers/Controllers

IC300OCS056 8 DC Inputs (12/24vdc), 6 Relay Outputs (3.0A ea), 4 Analog Inputs (0-20mA, 0-5v, thermister), 2 Analog Outputs (0-20mA, 0-10v)

IC752WFB203 Display Station 2020 w/ touch - 12.1" SVGA (800x600), Pentium 233 MHz, 64MB RAM, 6.4 GB HD, expansion slots, Ethernet, floppy drive, CD ROM front access, built-in keypad, unlimited point count CIMPLICITY HMI R&D, Win 95

MTR-3T21-G-R-0-M-SRR Servo Motor Metric with Seal