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PXI-4496,

PXI-4496

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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(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(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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Communications 9399-WABOUG RSLINX OEM USER GUIDE

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Support 9358-BRE01R SUPT REINSTATEMENT CONTRACT FOR 9358BRE01ENE

Support F1771-KGM FIRMWARE UPGRADE FOR 1771-KGM COMMUNICATION MODULE

RSI Software Products 9324-RLD0U6PTE RSLOGIX 5000 SERVICE ED TO FULL UPG, PTG

RSI Software Products 9301-2SE350ZHU1R RSVIEW32 RUNTIME 32K-100K UPGRADE OUT-SUPT (ZH)

RSI Software Products 9358-MTRCK03U1 UPGRADE: IN-SUPT: RSBW MATERIALTRACK 1 TO 10

Motion Control 8720SM-018S2FBS2 18.5 KW/47.1 AMP, 460VAC,AC MOTOR WITH SRM60 ENC.

840 SLDERLSS Field CONN Adapter. Converts 16 Conductor Ribbon Cable to 16 IND. WIRES

IC200MDL741 OUTPUT 24VDC POS LOGIC 0.5A PER PT (1 GROUP OF 16) W/ESCP 16PT

IC697VAL232 Analog Input, 32 Channel, jumper selectable for jumper selectable for 0 to 5VDC, 0-10VDC, +/-2.5VDC, +/-5VDC, +/-10VDC. 16 bit resolution.

MTR-1331-J-E-D-E-0 MTR series NEMA 34 stepping motor with series winding connection and encoder

ZA06B-0061-B203 B2/4000is servo motor with 128k serial encoder

20BD125A3ANNAND0 PowerFlex 700 AC Drive 20B

20G11ND077AA0NNNNN PowerFlex 755 AC Packaged Drive

22F-RF6P0-AS PowerFlex 4M EMC Filter Kit

140CFB03200 Quantum CABLEFAST, 數(shù)字輸入塊, 單獨(dú)保險(xiǎn)

294E-FD1P5Z-G3 Variable Frequency Drive

WLD2 觸點(diǎn):1開/1閉,10A 250VAC機(jī)械壽命:1500萬次?撞壓式?頂部滾珠柱塞型

1492-SPM3B300 MCB Supplementary Protector 30 A

軟啟動(dòng)器 3RW40261BB04

主站模塊 6ES7 278-4BD32-0XB0 CM1278 I/O 主站模塊

150-F84L SMC Flex Protective Module

1734-IJ POINT I/O Incremental Encoder Interface

1783-EMS04T Stratix 6000 4 port Managed Switch

193-EOS-SDS-BP E300 Diagnostic Station

20-750-EMC2-F2 PowerFlex 750 Size 2 Frame EMC Core Kit

2090-CPWM7DF-12AA25 MP-Series 25m Power Cable

2098-DSD-030-DN Ultra 3000 Servo Drive

G-C497 GagePort to Burr-Brown Vax Keyboard Wedge

GFK-2200 Target ARS Hardware Manual (requires GFK-2205 Programming Manual)

IC220TBK082 I/O TERMINAL STRIP, 8 POSITION SPRING STYLE, QTY 10

IC647FSHC FSH:Fisher CHIPS (UNIVOX and PROVOX)

IC647SDB001 Scheduler Extra Server Database

IC693MDL644RR 24 Vdc Input, Negative Logic (16 Points)

IC756DVE010E-99 EO GECK (Graphical Editor Construction Kit) - Inb x87, English, Vers ion 9.9

MSI-QUAL-5-43 Quality Mang Clients 5 Pack-43

PLC-5/1771 System 1771-A3BK CONFORMALLY COATED,I/O CHASSIS ASSEMBLY 12 SLOT,19

Distributed I/O 1790D-T0W6 DNET LDX I/O, 6 RELAY OUT BASE, TERMINAL BLOCK

Communications 1770-CD8 DATA HWY TWINAXIAL CABLE, 800 FT/244 M

Operator Interface 2711E-UT14ET10 PANELVIEW 1400E TOUCH TO 1000E TOUCH MIGRATION KIT

Support 9305-RSVADFCFRR SUPT REINSTATEMENT CONTRACT FOR 9305RSVADFCFR

Support 1754-PCSS SUPT RENEWAL CONTRACT FOR 1754PCS

EtherNet/IP Products 2706-P22R INVIEW PANEL MOUNT DISPLAY

RSI Software Products 9301-2SE3400KOU3 RSVIEW32 RUNTIME 150-32K UPGRADE IN-SUPT (KO)

RSI Software Products 9515-RSAAMRCTENE RSMACC AUTO ASSET MGMT, REACTIVE MAINT

Motion Control 1326AB-B430E-M2L MOTOR,SERVO,460V,6.6NM,3000RPM,MULTI,IP67

3414-24 Greyline OS, 2 Line, (20) 9MM Chars, VFD, Quick Connect, 24VDC, NEMA 4

HMI-BEZ-202 BEZEL 9" STAINLESS STEEL

IC693ADC311 CIMPLICITY 90-ADS Coprocessor (Repeat Systems)

QPL21100C2P/B QUICKPANEL COLOR 12.1" TFT BLANK

TGT-DI0L-64-0 Target series digital I/O module with 32 bs and 32 bs/outputs

20BC5P0A0AYYANC0 PowerFlex 700 AC Drive 5 A at 2.2 kW 20B

20F1ANE289AA0NNNNN PowerFlex 753 AC Packaged Drive

22B-D2P3N104 PowerFlex 40- 0.75 kW (1 HP) AC Drive

140ACI03000C Quantum 模擬量輸入,單極性高速,8通道,4-20mA或1-5V

284E-FVD4P0Z-10-RR-3-DB1-SB EtherNet Variable Frequency Drive

E2E-X2E1 2mm,電感式,三線,常開 200mA NPN電源:10-30VDC圓M12

1492-SPM1C030 MCB Supplementary Protector 3 A

通用型變頻器 6SE6 420-2UC25-5CA1 "5.5 KW，185 x 245 x 195"

電機(jī)啟動(dòng)器 3VU13400NJ00

1497D-A18-M21-0-2 1EN PURPOSE TRANSFORMER

1608N-025A220V2S 25 A Mini DySC Sag Corrector

1769-OV16 CompactLogix 16 Pt 24VDC Sink D/O Module

190S-BND2-CC10D-TE Compact Comb Starter W/Ckt-Bkr

194R-NHR3 194R Internal Operating Handle

2090-CPBM7DF-16AF04 MP-Series 4 m Length Pwr and Brake Cable

2090-XXTPMP-10S20 MP-Series 20 m Length Power Cable

CFDA-7WPB-0070-AZ "AHVi, AHVis, Bis and BHVis Series Motor Encoder Feedback Cable, 90 Degree Connector, 7 M"

GF-4-20MA Connecting FlashCable to Analog 4-20MA Devices (Combo GagePort).

IC200UDR040 VersaMax Micro 40 point PLC,(24) 24VDC In, (16) Relay Out, 24VDC Power Supply. (1) serial port and (1)optional communication port. Requires Machine Edition 5.7 or higher. Battery (IC200ACC414) is required for data retention. Battery not included

IC646TRT999 Viewer Runtime System

IC647PATH115 Proficy PAT - Historian. The capability is to store spectra data from the driver into the Proficy Historian. This for a three driv

IC693APU305RR Special I/O Processor

IC752PWS000RR Datapanel 320T Power Supply

IMC-105P-1-D 5 amp IMC enhanced stepping motor controller with Devicenet

SLC/1746 System 1746-P7 POWER SUPPLY - RACK MOUNT, 12/24V DC

Industrial Computers 6189V-MMAPS EXTERNAL AC PWR SPLY ADAPTER MOUNTING KIT

Application-specific products 1404-M505B-ENT 1404-M5 ETHERNET PM3000

Operator Interface 2711-K10C16L1 PV1000 COLOR KEY, DF1 & RS232 PRINT

Support 9301-2SE3200ITR SUPT REINSTATEMENT CONTRACT FOR 93012SE3200IT