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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(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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1794-TB3TSK Flex Terminal Base

194E-E16-1753-4N 16 A 194E Load switch

2090-CFBM4DF-CDAF04 MP-Series 4m Feedback Cable

2090-KFBM6-AA TL-Series Feedback Connector Kit

BC-FDT-DTM-SW2 FDT-DTM Software for use in FDT frame applications (NV project version). extension of the existing DTM, enhanced to better support E thernet.

GC646TDV999 Proficy GlobalCare Complete for Viewer Development System

HMI-BEZ-201 Stainless Steel Bezel: 5 inch Color & Mono (QPJ2xxxx-L2P/ -S2P)/ NEMA 4X

IC640WMI910RR Series 90 XT/AT Parallel/Serial Interface Card

IC647I3EC I3E:IEEE 488.2

IC660CBB902RR Series Six Genius I/O Bus Controller w/Diagnostics (Ph B)

IC695FTB001 Fiber Optic Terminal Board for PMM335

IC756WRE024E-99 DataViews Runtime for Windows 1-24, Per User, English, Version 9.9

FlexLogix System 1794-ACN15K CONFORMAL COATED, SINGLE MEDIA ADAPTER, CONTROLNET

PLC-5/1771 System D1771-6.5.76 RTD INPUT MODULE(1771-IR/B)USER MANUAL

Process Control 1757-PLXNW OPEN DATA ACCESS - 10 USER

Operator Interface 2711P-T7C15B2 PV PLUS 700, TOUCH, CNET, AC PS, EXT MEM

Support 6626-PLPR 6626-PLP SOFTWARE SUPPORT REINSTATEMENT

Support 8520-ODSS SUPT RENEWAL CONTRACT FOR 8520ODS

Support F1785-L20C15SERE FIRMWARE UPGRADE FOR 1785-L20C15 PLC5 PROCESSOR MO

RSI Software Products 9301-2SE220JPU1R RSVIEW32 WORKS 150-300 UPGRADE OUT-SUPT (JP)

RSI Software Products 9701-VWSB100ENU1 RSVIEW SE STATION 25 - 100 DISPLAY UPGRADE

RSI Software Products 9399-HDWAREREFPT HARDWARE INTERFACE CONFIG. USER GUIDE (PORTUGUESE)

Motion Control 2098-DSD-HV150-DN HIGH VOLTAGE DRIVE, 34A/68A, ULTRA3000 W/DNET

BC646CSCEMK ControlStation CE Development Software with 1 year SAFE

IC300DIQ627 8 AC Input (120 VAC) , 8 AC Output (250 VAC max, 2A)

IC752MNH899 Monitor -- 18" flat panel LCD active matrix monitor. No touch.

MTR-3S46-H-R-0-E-SRR Servo Motor with Seal

ZA06B-6110-K210 AHVi Amplifier CXA2A/B Connector

20BP205A0ANNANC0 PowerFlex 700 AC Drive 20B

20G14TF500JN0NNNNN PowerFlex 755 AC Packaged Drive

25A-B032N104 PowerFlex 523 7.5kW (10Hp) AC Drive

2711P-T12W22A9P PanelView Plus 7 Graphic Terminal

OPC-G11S-DEV(通訊卡)

1492-JG16 16 square mm Ground Terminal Block

1492-WFB424 IEC Term Blck 8x47.6x41mm Screw

軟啟動(dòng)器 3RW44223BC44

性能信號(hào)模塊 6ES7 522-1BF00-0AB0 DQ 8：數(shù)字量輸出模塊，高性能 DQ 8x 24VDC/ 2A HF, 35mm 模塊，不含前連接器

156-B32CB3 32 A Contactor

1746-N3 SLC Mating Connector

1786-TPYS ControlNet Coaxial Straight Y-Tap

193-T1DC60 45-60 A IEC Bibllic Overload Relay

20-IP20DR-600 PowerFlex 700H/S Door Kit

2090-CSBM1DF-14AF07 Kinetix Cable Single DSL 2090-Series

20AC022A3AYNANC0 PowerFlex 70 AC Drive 22 A at 11 kW 20A

GA647TRT915 Proficy GlobalCare Assist for CIMPLICITY HMI Server 1500 I/O Runtime System

GPA-602-F LVDT Expansion Unit (Full Bridge), includes G-0602 connecting cable.

IC600CM544RR 4K CMOS Logic Memory Module (for use in Model 600 or 6000)

IC647HSTCSEO10KM eSignature Option for Historian - Enterprise Corporate Server 10000 Points (M4 Key)

IC647WFL000 Proficy Workflow - Site License

IC694ACC003 Door labels for the IC694MDLxxx I/O modules. The kit includes two each of the following modules. IC694ACC300, IC694ACC310, IC694ALG220, IC694ALG221, IC694ALG222, IC694ALG223, IC694ALG390, IC694ALG391, IC694ALG392, IC694ALG442,IC694APU300, IC694APU3

IC756RDV001K-97 DV Development - Irix Op Sys Addt'l User, Korean, Version 9.7

MicroLogix 1200 System 1762-L40BWAR ML 1200 40DC/RLY/AC 2 PORT

PLC-5/1771 System 1771-LC3B LOOP CONTROLLER W/RTD OPTION, 120V AC SUPPLY

Distributed I/O 1794-IC16 FLEX 48 VDC INPUT MDL

Communications 9355-WABOEMESE RSLINX OEM - SPANISH

Operator Interface D6195-6.5.3 USER MANUAL CONTROLVIEW BUILDER

Support 9358-BEPB60R SUPT REINSTATEMENT CONTRACT FOR 9358BEPB60ENE

Support F1770-FLASH FIRMWARE UPGRADE FLASH UPDATE TOOL

RSI Software Products 9324-RL0300ITE RSLOGIX 500 STANDARD ITALIAN CD

RSI Software Products 9301-2SE3503ZHE RSVIEW32 RUNTIME 100K WITH RSLINX (CHINESE)

RSI Software Products 9358-HSTS2300U1R UPGRADE: OUT-SUPT: HISTORIAN 150 TO 1500 TAG

Motion Control W-4030-M-H00AB MOTOR,SERVO,WASHDOWN,BF,2.8 NM,3000RPM,12.0KG

5612 Greyline Micro MC. 4 Lines, (20) 5MM Chars. VFD. ASCII/Serial Interface. NEMA 4

IC200MDD840 MIXED 24VDC POS LOG INPUT GRP 20PT / OUTPUT RELAY 2.0A PER PT GRP 12PT

IC695PSA040 RX3I Power supply 120/240VAC and 125VDC 40 watts occupies two slots on system base

MTR-1220-E-A-E-0RR Stepping Motor Nema23 Encoder

VSPCSE-SF5 VisualSPC SE ShopFloor includes Attribute Data Collection, Measurement Systems Analysis and A-681 interface cable. 5 license pack.

20BD077A0ANNANC0 PowerFlex 700 AC Drive 77 A 60 Hp 20B

20G11NC011AA0NNNNN PowerFlex 755 AC Packaged Drive

22F-A8P0N103 PowerFlex 4M- 1.5 kW (2 HP) AC Drive

490NAA27106 Quantum MODBUS PLUS電纜,5000'

291E-FBP-G1-3FR Direct Online Reversing Starte

PF083A-E 導(dǎo)軌安裝型，MK2P-I

1492-SPM2D250 MCB Supplementary Protector 25 A

軟啟動(dòng)器 3RW30472BB04

電機(jī)啟動(dòng)器 3VU16401CM00

150-F361NBD SMC Flex Smart Motor Controller

1732E-IT4IM12R ARMORBLOCK 4 POINT TC INPUT

1771-WC FIELD WIRING ARM 10 TRMLS GOLD PLATED

193-EELG E1 Plus 100-500 A IEC Overload Relay

20-750-ACTE1-F6 PowerFlex 750 AC Terminal Extension Kit

2090-CPWM7DF-10AA04 MP-Series 4m Servo Power Cable

2097-V32PR0-LM Kinetix 350 400W Servo Drive

ET-GT-3ES-2SC 2 RJ45 Ports, 1 Multimode Fiber Port Ethernet Switch

GFK-1886 ViewStation/ControlStation CE Iix (10 inch) HW User's Guide