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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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Operator Interface 2711-T10G14 PV1000 GRAYSCALE TOUCH, MBUS & RS232 PRINT

Support 9301-2SE3500PTS SUPT RENEWAL CONTRACT FOR 93012SE3500PT

Support 9381-PEDRCPENR SUPT REINSTATEMENT CONTRACT FOR 9381PEDRCPEN

DeviceNet Products 1790D-N4C0 DNET LDX, 4 INPUT ANALOG CURRENT BSE,D-SHELL CONN

RSI Software Products 9301-2SE330JPU1R RSVIEW32 RUNTIME 300-1500 UPGRADE OUT-SUPT (JP)

RSI Software Products 9358-PBNT03ENE RSBATCH NT FOR PROCESSLOGIX 03 UNITS

Motion Control MPL-B640F-SJ24AA MOTOR,SERVO,36.0NM,3000RPM,SINGL,460V,BRK

Miscellaneous

GQSK2D100S2P QUICKSTART KIT 6" STN GE LABEL

IC646NSL001 CIMPLICITY SQL 1 Client User

MTR-3T69-G-R-B-M-0 MTR-Series Servo Motor, Resolver, Metric, 24V Brake

ST-222F STXi output module 16 points, Positive Logic, 24VDC/ 0.3A

SCXI-1175

Znyx LK6-ZX312

canopus NHX-E2

0B0KEIS80200B200

AIMB-256G2

AR-B9140

1492-RCDA4C40S Residual Current Device 40 A

有源導(dǎo)軌 6ES7195-1GA00-0XA0 有源導(dǎo)軌/480mm

變送器 3RS11 40-2GD60

1497-K-BAJK-0-N Control Circuit Transber

1606-XLE240EP Power Supply XLE 240 W Power Supply

1763-L16BBB MicroLogix 1100 16 Point Controller

188-K3D200-N Miniature Circuit Breaker 20 A

194L-HE4A-451 IEC Control And Load Sw Actuator Type A

2090-CPBM7DF-08AA25 MP-Series 25m Power and Brake Cable

2090-XXNPMF-14S30 Kinetix Drives 30m Standard Cable

BC647TRT150 CIMPLICITY HMI Server 150 I/O Runtime System with Proficy GlobalCare

GC647PSC300 Global Care for Proficy Process Systems 3000 I/O with CIMPLICITY

IC200MDL940CA OUTPUT RELAY 2A ISO FORM A 16PT MODULE CONFORMAL COATED

IC646PME050 Proficy Change Management for ME 50 user pack

IC647MX1M MX1:Leeds and Northrup Max1

IC687BEM713 Half Slot Bus Transmitter Module

IC697VAL324 Discontinued, replacement is Embedded VME-6550. Contact GE IP Embedded for details.

IC800SSI407RS1 7.2 amp 480 VAC S2K servo controller for MTR series motors

SLC/1746 System 1747-M2 EEPROM MEMORY, 4K FOR PROGRAMMABLE CONTROLLER

Industrial Computers 6181P-15NP2KH VERSAVIEW INTEGRATED DISPLAY COMPUTER 15-INCH

Application-specific products 9358-PBEBNT60ENE RSBATCH NT & EPROCEDURE BNDLE PROCESLGIX 60 UNITS

Operator Interface 2711-K5A15L1 PV550 MONOCHROME KEY, CNET & RS232 PRINT

Support 9306-4PXP01S SUPT RENEWAL CONTRACT FOR 93064PXP01ENE

Support 9393-RSTLX500R SUPT REINSTATEMENT CONTRACT FOR 9393RSLTX500

ControlNet Products 2711P-K7C15D1 PV PLUS 700, KEYPAD, CNET, DC PS, STD MEM

RSI Software Products 9301-2SE2500U3 UPGRADE: IN-SUPT: RSVIEW32 WORKS 300 TO 100K

RSI Software Products 9358-BEPB60U1R UPGRADE: OUT-SUPT: RSBW BATCH & EPROCEDURE 03 TO60

Motion Control MPL-A4540F-HK24AA MOTOR,SERVO,10.2NM,3000RPM,ENCDR,230V,BRK,13KG

Motion Control 2090-XXNFY-S12 CABLE,NON-FLEX,MOTOR FEEDBACK,Y,12M

GABI31200C2P/AR QUICKPANEL 10.5" TFT W/AB RIO GE LABEL

IC641PCC804 Annual Maintenance for IC641PCC004

IC800SSI104RD2 4.3A, 115/230V, DeviceNet S2K Servo Controller for MTR Series Motors

PR-PAT-RX-1.2 Proficy PAT - Process Analytical Software Suite, Pharmaceutical

PXI-6229

PCI-14S3-RS-R30

YOKOGAWA LR4100E

EMACS P1U-6200P

TEKNOR T936IB

NEXCOM ICES101-C65-TY

1492-MS5X9H1-10 Connection Products

1495-N68 Protective Fuse Cover

行程開關(guān) 3SE53120SG12

運(yùn)行版軟件 6AV2105-0MA14-0AA0 SIMATIC WinCC Runtime 專業(yè)版 65536 PowerTags ASIA V14

1585J-M4UBJM-1 RJ45 Ethernet Media

1756-OV32E ControlLogix 32 Point D/O Module

188-K1C160 Miniature Circuit Breaker 16 A

194E-KA16E-P11 194E Load switch