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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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IC647PDCH050 Ruggedized PDC Historian Base with 5000 Tags

IC693CHS393 Base, Remote Expansion, 10 Slots (700 ft.)

IC754CSL06MTD Ctrl Loaded 6 In Mono Touch DC

KIT-GFS-356 RX3i Workshop Student Kit

SLC/1746 System D1746-UM026AENP SLC 500 8 CHANNEL ANALOG OUTPUT MANUAL

Distributed I/O 1734D-IA16 120 VAC 16 IN, DNET COMMS, SCREW

Application-specific products 1405-M620-400 MINI POWERMONITOR M620 400V

Operator Interface 2711-T10C20L1 PV1000 COLOR TOUCH, ENET & RS232 PRINT

Support 9301-2SE3400ZHS SUPT RENEWAL CONTRACT FOR 93012SE3400ZH

Support 9381-PA250ENR SUPT REINSTATEMENT CONTRACT FOR 9381PA250EN

DeviceNet Products 1790D-8BV8V DNET LDX, 24VDC,8 UNIV IN/8 SINK OUT BASE, D-SHELL

RSI Software Products 9301-2SE3303KOE RSVIEW32 RUNTME 1500 WITH RSLINX (KOREAN)

RSI Software Products 9358-PBANT60ENE RSBATCH NT FOR PROCESSLOGIX ARCHIVER 60 UNITS

Motion Control MPL-B540K-SK24AA MOTOR,SERVO,19.4 NM,4000RPM,SINGL,460V,BRK,19.1KG

Motion Control 2090-UXLF-106 AC LINE FILTER,ULTRA,6 AMPS,1 PHASE

GQPL-DEM-C02 QUICKPANEL DEMO COLOR 12.1" GE LABEL

IC646MSP101 Logic Developer - State Professional w/Programming Cable

MTR-3T45-H-R-0-M-0 MTR-Series Servo Motor, Resolver, Metric

ST-121F STXi b module 16 points, Positive Logic, 12V/ 24VDC (connector type)

SCXI-1122

PCI-1750

超微 X7DWE

GA-X48-DS5

CANON SC-01A AG9-0498-02

AT-COM/V53A2 C24B1000-0A

1492-RCDA2C40 Residual Current Device 40 A

存儲(chǔ)卡 6ES7952-1KM00-0AA0 FEPROM 存儲(chǔ)卡， 4M

變送器 3RS11211DW30

1497-G-AXSX-3-N Control Circuit Transber

1606-XLBUFFER 1606 1606-XL Buffer Module Power Supply

1762-OB32T MicroLogix 32 Point D/O Module

188-K3D040 Miniature Circuit Breaker 4 A

194L-HC4L-175I 194L Control and Load Switch Actuator

2090-CPBM7DF-06AA30 MP-Series 30m Power and Brake Cable

2090-XXNPMF-10S60 Kinetix Drives 60m Standard Cable

BC647TPD700 CIMPLICITY HMI ProServer 700 I/O Development and Runtime System with Proficy GlobalCare

GC647PRTHE100 GlobalCare Complete - Proficy Portal Historian Edition Client Pack 100 Users Ver 3.0

IC200MDL741LT OUTPUT 24VDC POS LOGIC 0.5A PER PT (1 GROUP OF 16) W/ESCP 16PT (LT)

IC646PEW100 OpenProcess Engineering Workstation

IC647MRA700 View Runtime 700 I/O with USB Hardware key

IC677DBO085 Profibus VersaMax IP Modular slave with (8) 24VDC outputs

IC697RCM711 Hot Standby Redundancy Communications Module

IC800SSI216RP2RR 16A, 230V, Profibus S2K Servo Controller for MTR Series Motors

SLC/1746 System 1747-L531 SLC 5/03,WITH 8K USER INSTRUCTION CAPACITY

Industrial Computers 6181H-15TS2KH VERSAVIEW 15" DISPLAY COMPUTER HAZARDOUS LOCATIONS

Application-specific products 9358-PBA10ENE RSBIZWARE BATCH FOR PROCESSLOGIX ARCHIVER 10 UNITS

Operator Interface 2711-B5A9 PV550 MONO KEY&TOUCH, RS232 (DH485) & RS232 PRINT

Support 9303-3CS0EFFS SUPP RENEWAL CNTRCT FOR 9303-3CS0EFF

Support 9391-SDVEKS 9391-SDVEK SOFTWARE SUPPORT CONTRACT RENEWAL

ControlNet Products 2711-K5A15L2 PV550 MONOCHROME KEY, CNET & RS232 PRINT

RSI Software Products 9301-2SE2500KOU3 RSVIEW32 WORKS 300-100K UPGRADE IN-SUPT (KO)

RSI Software Products 9358-BEBNT30ENE RSBATCH / EPROCEDURE FOR NT BUNDLE 30 UNITS

Motion Control MPL-A4540C-HK22AA MOTOR,SERVO,10.2NM,1500RPM,ENCDR,230V,9.5KG

Motion Control 2090-XXNFMP-S15 CABLE,NON-FLEX,MOTOR FEEDBACK,MP/1326AB,15M

CBL-OIJR-12-RA Serial Cable, Operator Interface Panel (OIP) to S2K, Rt. Ang, 12 Ft.

IC641PCC010 Toolkit for integration of Visual Basic Applications

IC800SLT004 SL Amplifier Breakout Terminal Block for Third Party Controller Interface

PR-PAT-ABB01 Proficy PAT - Driver For Ethernet-Coupled Abb Bomem Ftir Spectrometers