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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(xiàn)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(guān)，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(xiàn)、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(chǎng)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(chǎng)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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RSI Software Products 9351-HPUSRT INTERCHANGE FOR HP-UX RUNTIME

RSI Software Products 9399-WGSUG RSSERVER FOR GE FANUC SERIES 90 USER'S GUIDE

Motion Control 8720MC-RPS190BM MASTER 460V 190AMP RPS

BC646MRE000 Logic PC & View Runtime (HRT) 8,000 I/O

IC300RTD000 2 channel RTD Inputs (Pt-100, Pt-200, Pt-500, Pt-1000), 18 bit

IC754VKI06STD Starter Kit - 6" Color-STN QuickPanel View Intermediate, Touch, 24VDC

MTR-3T57-G-R-B-M-0RR Servo Motor Metric 24V Brake

20AD-DB1-B PowerFlex 70 Resistor Kit

20DC037A0EYNANANE PowerFlex 700S AC Drive 20D

20G1ANC205JN0NNNNN PowerFlex 755 AC Packaged Drive

25B-E9P9N104 PowerFlex 525 5.5kW (7.5Hp) AC Drive

280-FAM35M Field Attachable Receptacle, Male, M35

FR-F740-7.5K 12.2KVA 16A 7.5KW 3相AC380V/50Hz/60Hz

1492-LG3Q IEC Term Blck 5.1x79x31.3mm Spr Clp

1494F-V2 Combination Starter Door Hardware

軟啟動(dòng)器 3RW44362BC36

ET 200SP 6ES7132-6BF00-0AA0 DO 8x24VDC/0.5A 基本型，基座單元類(lèi)型 A0

1585D-E4UBDE-2 1585D Ethernet Media Patchcord

1753-L32BBBM-8A GuardPLC 1800 Safety Controller

1794-IE4XOE2 Flex 4 Input 2 Output Analog Module

194E-AA40EX-PE-TN 194E Load switch

2080-LC30-24QBB Micro830 24 I/O Controller

2090-CSWM1DF-18AA04 Kinetix Cable Single DSL 2090-Series

20AC3P5A3AYNANC0 PowerFlex 70 AC Drive 20A

GC646MPSS99 Proficy GlobalCare Complete for Logic Developer - PLC Standard Unlimited Seat Site License

HE693RTD600 RTD Input, 6 channel, 3-wire, 0.5C res., -100 to +850C range (Pt-100 )

IC610CPU106RR Series One Plus CPU, 3.7K Words

IC647HSTSC5KM Server to Server Collector for Historian - Standard Server 5000 Points (M4 Key)

IC660BBD021 Block 24/48Vdc Sink I/O 16 Circuits, 3 Wire Sensor Compatible

IC694PWR321CA Conbal Coated Power Supply 120/240VAC, standard.

IC756WDN009E-275 "DataViews Development System for Visual Basic, Java, C++ & Native C, 1 User, English v2.7.5"

MicroLogix 1500/1769 System 1769-RL2 REPLACEMENT DOOR LABELS FOR SPEC. I/O (2 PER KIT)

PLC-5/1771 System 1771-P5EK CONFORMALLY COATED,POWER SUPPLY,SLOT,8A,24V DC

Distributed I/O 1798-OB4E FLEXARMOR 4 POINT 24VDC SOURCING OUTPUT

Operator Interface 2711P-B6M5A PV PLUS 600 GRAYSCALE, KEY/TOUCH, RS232, AC PS

Support 9323-PA2JS SUPT RENEWAL CONTRACT FOR 9323PA2J

Support 9358-PB30R SUPT REINSTATEMENT CONTRACT FOR 9358PB30ENE

Support F1772-LZSERC FIRMWARE UPGRADE FOR 1772-LZ PLC2 PROCESSOR MODULE

RSI Software Products 9324-RLD6U7FRR RSLOGIX 5000 FULL TO PRO UPGRADE, EXP >90, FRENCH

RSI Software Products 9305-RSVADFVCENE RSVIEW32 ACTIVE DISPLAY FLOAT. VIEW CLNT (ENGLISH)

RSI Software Products 9301-PCI1500S7 APPLICOM PCI1500S7 PROFIBUS INTERFACE FOR SIEMENS

Motion Control 2094-BM02 MODULE, AXIS, 400/460V, 15A INV.

A06B-0158-B175#7008 A40/2000 Servo Motor, Fan Package, Holding Brake, 64K Serial Encoder

IC200UDR010-24 Qty of 24, 28 point PLC, (16) 24VDC In, (11) Relay Out, (1) 24VDC Out, 24VDC Power Supply

IC752CBT050 Mature. Order QuickPanel instead. DataPanel 320T CB (Color Base): 320x240 1/4 VGA Passive Color with 80386SX/40 PC processor. Analog touch screen with text, bitmaps, bar graphs, real time clock.

MTR-1N33-N-A-S-0-MODRR Stepping Motor N34 MOD+0.5 Shft Dia

ZA06B-0128-B575#7008 A6/3000 servo motor with 64k serial encoder

20BD5P0A0AYNAND0 PowerFlex 700 AC Drive 5 A at 3 Hp 20B

20G11TF500JN0NNNNN PowerFlex 755 AC Packaged Drive

25-PM1-D4P0 PowerFlex 520 1.5kW (2Hp) Power Module

396MMC50004 Quantum MMF 程序員包

FRN1.5E1S-2J 3.0KVA 8A 1.5KW 3相AC220V/50Hz/60Hz

A20B-0005-0610

1492-SPM3D040 MCB Supplementary Protector 4 A

軟啟動(dòng)器 3RW40281TB05

SIMATIC HMI 系列面板 6AV2123-2DB03-0AX0 KTP400 Basic PN 4 寸觸摸 + 按鍵

150-SD3NBD SMC-50 SOLID STATE MOTOR CONTROLLER 520A

1738-ADN18P ArmorPoint DeviceNet Network Adaptor

1783-US8T Stratix 2000 Unmanaged Switch

193-KA16 0.10-.16 A IEC Bibllic Overload Relay

20-750-NEMA1-F6 PowerFlex 750 Frame 6 Conduit Box Kit

2090-CPWM7DF-16AF12 MP-Series 12m Length Power Cable

20AB022A3AYNANC0 PowerFlex 70 AC Drive 22 A at 7.5 Hp 20A

GA647IFESGSRUNLMT GCA iFIX Optn: ESig & ERec Unl I/O Srv

GP647IFCLNTCRN GCP iFIX iClient Run

IC600BF810RR 115V Isolated Input Module (6 points)

IC647HSTCC300M Calculation Collector for Historian - Standard Server 300 Points (M4 Key)

IC647TBLCPVC050 Virtual Campus for Proficy Troubleshooter and Cause+ - 50 Users

IC693MDL916 Output module, Isolated Relay, Normally Open, 4 Amp, 16 point. Requires High Density Terminal Block (IC694TBBx32 or IC694TBSx32). Compatible with RX3i and Series 90-30.

IC756LDV001E-97 DV Development - Inb/Linux RedHat Addt'l User, English, Version 9.7

Pico Controllers 1760-CBL-INT05 PICO-LINK CONNECTIVITY CBL 1.5M 1 PCS/PACK

PLC-5/1771 System 1771-OG TTL OUTPUT MODULE

Distributed I/O 1791-16B0 BLOCK I/O, 24V DC, 16 POINT MODULE (16 INPUT)

Communications 1786-TNCJ4 CONTROLNET TNC COAXIAL CONN - JACK TO JACK

Operator Interface 2707-MVH232 MICROVIEW, HAND-HELD, 2 LINE LCD, RS-232

Support 9701-VWSS100AR SUPT REINSTATEMENT CONTRACT FOR 9701VWSS100AENE

Support 9324-RL0100ITS SUPT RENEWAL CONTRACT FOR 9324RL0100IT

EtherNet/IP Products 1734-AENT 24V DC ETHERNET ADAPTER

RSI Software Products 9301-2SE340ZHU2R RSVIEW32 RUNTIME 300-32K UPGRADE OUT-SUPT (ZH)

RSI Software Products 9356-PRO2450U1R UPGRADE: OUT-SUPT: RSSQL STD.150 TO PROF.32000 TAG

Motion Control F-4075-R-H04AN MOTOR,F-,NEMA 56C W/24V BRAKE,82 IN LB CONT.

4363-H 4363 WITH 0-10 V OR 4-20 mA OUTPUT

IC200ACC415 RS-232 to RS-485 Converter requires IC200CBL500 or equivalent.

IC693MCM001 Series 90-30 Digital Servo Interface Module

TRM-21000422 Screw Terminal Connector 14 Pt. Obsolete Whedco PowerCube Replacement Only

VMEM-ADM VisualMEM Admin Seat

20BD022A0AYNANA0 PowerFlex 700 AC Drive 22 A at 15 Hp 20B