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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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RSI Software Products 9301-2SE3400KOU1 RSVIEW32 RUNTIME 1500-32K UPGRADE IN-SUPT (KO)

RSI Software Products 9515-RSAAMPRDENE RSMACC AUTO ASSET MGMT, PREDICTIVE MAINT

Motion Control 1326AB-B420H-S2L MOTOR,SERVO,460V,5.1NM,6000RPM,SINGL,IP67

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

HMI-AGO-204 ANTI-GLARE OVERLAY 6"

IC693ACC341 Redundant Power Supply Base with 0.5 meter cable to connect to Power Supply Adapter module. Supports any Series 90-30 power supply.

QPKSTDN0000 6" Color STN, TCP Label, No Ethernet, CF, 24Vdc,UL,cUL,CE,UL1604

TGT-DI0L-32-0 Target series digital I/O module with 16 bs/outputs

20BC5P0A0AYNANC1 PowerFlex 700 AC Drive 5 A at 2.2 kW 20B

20F1ANE192AN0NNNNN PowerFlex 753 AC Packaged Drive

22B-D2P3F104 PowerFlex 40 0.75 kW (1 Hp) AC Drive

Quantum Analog Input Module 模擬量輸入模板

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

E2E-X1C1 1mm,電感式,三線,常開5-100mA NPN電源:10-30VDC圓M5

1492-SPM1C020 MCB Supplementary Protector 2 A

通用型變頻器 6SE6 420-2UC23-0CA1 "3.0 KW，185 x 245 x 195"

電機(jī)啟動(dòng)器 3VU13400MP00

1497D-A17-M22-0-N 1En Purpose Transber

1608N-012A240V2S 12 A Mini DySC Sag Corrector

1769-OF8V CompactLogix 8 Pt A/O Voltage Module

190S-BND2-CB63C 4.0-6.3 A Compact Comb Starter W/Ckt-Bkr

194R-NE630-1753 Disconnect Non-Fused IEC 3 Poles 630A

2090-CPBM7DF-16AF02 MP-Series 2 m Length Pwr and Brake Cable

2090-XXTPMP-10S12 MP-Series 12 m Length Power Cable

CFDA-3WPB-0070-AZ This cable has been replaced by cable CFDA-7WPB-0070-AZ

GF-3910R Connecting FlashCable to Ohaus Model C/ E/ GT/ MB/ TP/ TS series.

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

IC646TRT915 1500 I/O Point Runtime System

IC647PATH105 Proficy PAT - Historian. The capability is to store spectra data from the driver into the Proficy Historian. This for a single dri

IC693APU302RR Axis Positioning Module (APM), 2 Axis, requires (1) or (2) CBL311

IC752PBI100 PC/104 Profibus Card

IMC-105E-1-D 5 amp IMC enhanced stepping motor controller

SLC/1746 System 1746-P5 POWER SUPPLY - RACK MOUNT

Industrial Computers 6189V-MMA15 MNTG ADAPTER FOR CONVERTING 6185-C OR J TO 1500M

Application-specific products 1404-M505B-CNT-02 1404-M5 CONTROLNET PM3000 CLASS 0.2 24V P.S.

Operator Interface 2711-K10C15L1 PV1000 COLOR KEY, CNET & RS232 PRINT

Support 9301-2SE3200FRR SUPT REINSTATEMENT CONTRACT FOR 93012SE3200FR

Support 9380-RSBS SUPT RENEWAL CONTRACT FOR 9380RSB

DeviceNet Products 1792D-16BVT0CD MAXUM 16 IN WITH POINT LEVEL DIAGNOSTICS

RSI Software Products 9301-2SE3203ZHE RSVIEW32 RUNTIME 300 WITH RSLINX (CHINESE)

RSI Software Products 9358-BPMGR03ENE RSBATCH PRODUCTION MANAGER (SUPT 1-10 BATCH SVR)

Motion Control MPL-B4530F-RK22AA MOTOR,SERVO,8.36 NM,2800RPM,RSLVR,460V

Motion Control 2090-SCVP1-0 SERCOS FBR CABL,CONN,STANDARD PVC JKT,PLASTIC 1.0M

GHMI-KPN-302 QUICKPANEL KEYPAD FOR 10.5" GE LABEL

IC646MPP010 Logic Developer - PLC Professional - 10 Pack

MTR-1337-E-D-E-S Stepping Motor Nema34, Series Wdg, Encoder, Splashproof

QPJ-PBS-201 Communication Module for 5 inch & 6 inch: Profibus Slave

20BC037A3AYNANC0 PowerFlex 700 AC Drive 20B

20F11NC085AA0NNNNN PowerFlex 753 AC Packaged Drive

22-HIM-C2S PowerFlex IP66 UL-NEMA Type 4X-12 HIM

2711P-RGT12 PV Plus 1250 Touch Antiglare Overlay

280S-MTR22-M3 ArmorStart Spare Parts

C200HW-COM05-EV1 二個(gè)RS-232C 端口和一個(gè)通訊協(xié)議宏功能

1492-PDEC1 HOLE PLUG

數(shù)字量輸入/輸出模塊 6ES7422-1BL00-0AA0 DO/32 24V DC，0.5A，光隔離

變送器 3RS10002CD00

1497-A-AXJK-0-N Control Circuit Transber

1585J-M8UBJM-0M6 RJ45 Ethernet Media

1761-L10BXB MicroLogix 1000 10 Point Controller

188-K3B500 Miniature Circuit Breaker 50 A

194L-E20-1756 20A 194L Load Switch

2090-CPBM4E2-14TR MP-Series 0.5m Length Transition Cable

2090-XXNFMP-S03 MP-Series 3 m Length Feedback Cable

BC647OEMK1M4 OEM Edge Additional M4 Key includes 1 physical M4 key.

GC647PATKASR Proficy PAT - Driver For Kaiser - Assist Support

IC200MDD848LT MIXED OUTPUT 120VAC 0.5A PER PT ISOLATED 8PT / INPUT 120VAC GRP 8PT (L T)

IC646NSL010 Proficy SQL 2000 - 10 Client Access License

IC647MDA075 View Development/Runtime 75 I/O with USB Hardware key

IC675PDO081 Profibus Station IP67 24VDC Positive Logic 8 Outputs 0.5A

IC697MDL753RR 5/48 Vdc Output, 05 Amp, Negative Logic (32 Points)

IC800SSD107RS1RR 7.2A, 115/230V, S2K Servo Drive for MTR Series Motors

ControlLogix/1756 System D1756-6.5.14 USER MANUAL - 1756-DHRIO DH+/RIO INTERFACE MODULE

Industrial Computers 6182H-15KEH4D VVCE 1500, KEYPAD, EXT MEM, ENET, DC

Process Control 1757-DNBUL03 DEVICENET USAGE LICENSE, 3 DNB MAX

Operator Interface 2711-K3A17L1 PV300 MONOCHROME KEY, DF1 & RS232 PRINT

Support 9326-AD25UR SUPT REINSTATEMENT CONTRACT FOR 9326AD25UENE