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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，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(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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GC646TDV300 Proficy GlobalCare Complete for 300 I/O Point Runtime / Development System.

HMI-AGO-201 ANTI-GLARE OVERLAY 9 inch/ 5 per pack

IC640WDB400 Cable, 9-Pin D to 3 BNC

IC647HSTSSEO50KM eSignature Option for Historian - Standard Server 50000 Points (M4 Key)

IC660BSM021RR Bus Switching Module, 115 Vac/125 Vdc

IC695DEM006 PMM Demo Case: RX3i and PACMotion

IC756WRE024E-26 DV Runtime Win 1-24 Per User Eng v2.6

CompactLogix System 1769-STRT2PT COMPACTLOGIX STARTER KIT PORTUGUESE

PLC-5/1771 System D1771-6.5.49 INJECTION CONTROL MODULE (1771-QD) USR. MANUAL

Process Control 1757-PLXNS EXTENDED EVENT ARCHIVING

Operator Interface 2711P-K7C6D2 PV PLUS 700, KEYPAD, RIO/DH, DC PS, EXT MEM

Support 6620-NMUR 6620-NMU SOFTWARE SUPPORT REINSTATEMENT

Support 8100-HSMMLS SUPT RENEWAL CONTRACT FOR 8100HSMML

Support F1785-L20BSERC FIRMWARE UPGRADE FOR 1785-L20B PLC5 PROCESSOR MODU

RSI Software Products 9301-2SE220DEU1R RSVIEW32 WORKS 150-300 UPGRADE OUT-SUPT (DE)

RSI Software Products 9701-VWSB100AFRE RSVIEW SE STATION 100 DISPLAY (FRENCH)

RSI Software Products 9399-HDWAREREFDE HARDWARE INTERFACE CONFIG. USER GUIDE(GERMAN)

Motion Control 2098-DSD-HV050-DN HIGH VOLTAGE DRIVE, 11A/22A, ULTRA3000 W/DNET

BC5105KAW0000 15 Inch Panel-C Industrial Computer - Bundled - w/ Windows2000

IC300DIQ612 8 DC Inputs (12/24vdc, pos/neg logic), 6 Relay Outputs (4.0A per point isolated)

IC752FPY000 Industrial Floppy Drive in Case for Display Stations

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

ZA06B-6110-K200#XXS CZ4 AC power connector kit for BSVM1-40i Beta i series amplifier

20BP105A0ANNANC0 PowerFlex 700 AC Drive 20B

20G14TF370JN0NNNNN PowerFlex 755 AC Packaged Drive

25A-A8P0N114 PowerFlex 523 1.5kW (2Hp) AC Drive

2711P-T12C4D8K PanelView Plus Terminal

OPC-G11S-AIO(模擬量接口卡)

1492-JDG4 GROUNDING TERM. BLOCK

1492-WD4 IEC Term Blck 8x47.6x41mm Screw

軟啟動(dòng)器 3RW44221BC45

性能信號(hào)模塊 6ES7 522-1BH01-0AB0 DQ 16：數(shù)字量輸出模塊，晶體管 DQ 16 x 24 VDC/ 0.5A HF, 35mm 模塊，不含前連接器

156-B32AA2 32 A Contactor

1746-ITB16 SLC 16 Point Digital Input Module

1786-TPRT2T C-Net TNC IP67 T-TAP/TNC-TNC RIGHT THICK

193-T1CC36 24.5-36 A IEC Bibllic Overload Relay

20-HIM-C5S PowerFlex Programmer Only HIM

2090-CSBM1DF-14AA50 Kinetix Cable Single DSL 2090-Series

20AC022A0AYYANC0 PowerFlex 70 AC Drive 22 A at 11 kW 20A

GA647TRT075 Proficy GlobalCare Assist for CIMPLICITY HMI Server 75 I/O Runtime System

GP647IFSTRN00900 GCP iFIX Std HMI 900 I/O Run

IC600CB536RR Communications Control Module Type 2

IC647HSTCSEO10000KM eSignature Option for Historian - Enterprise Corporate Server 10,000,000 Points (M4 Key)

IC647WATERINFOCENTER Water InfoCenter Solution Pack - Hist, iFIX, IGS, WebSpace, Water SP (M4 Key)

IC693UDR005RR 28 pt DC In/Relay Out/DC Out, AC Power Supply

IC756RDV001J-97 DV Development - Irix Op Sys Addt'l User, Japanese, Version 9.7

MicroLogix 1200 System 1762-L40AWA MICROLOGIX 1200, 40 PT.

PLC-5/1771 System 1771-ES SERVO ENCODER FEEDBACK EXPANDER

Distributed I/O 1794-IB16XOB16P 24 VDC COMBO MODULE, 32 POINTS

Communications 9355-WABJBENE RSLINX OEM/RSJUNCTIONBOX BUNDLE

Operator Interface D6195-6.5.1IT CONTROLVIEW 300 INSTALLATION MANUAL (ITALIAN)

Support 9358-BEPB10R SUPT REINSTATEMENT CONTRACT FOR 9358BEPB10ENE

Support F1747-SDNSERB FIRMWARE UPGRADE FOR 1747-SDN MODULE

RSI Software Products 9324-RL0300ENE RSLOGIX 500 STANDARD CD-ROM

RSI Software Products 9301-2SE3503JPE RSVIEW32 RUNTIME 100K WITH RSLINX (JAPANESE)

RSI Software Products 9358-HSTS2200U1R UPGRADE: OUT-SUPT: HISTORIAN 150 TO 300 TAG

Motion Control W-3016-N-H00AA MOTOR,SERVO,WASHDOWN,AF,1.7 NM,3000RPM,6.4KG

5412-128 Greyline Micro MC. 4 Lines, (20) 5MM Chars. VFD. Quick Connect. 128K Memory. NEMA 4

IC200ERM001 EXPANSION RECEIVER ISOLATED

IC695DEM002 RX3i type 2 demo case. Demo includes CPU, power supply, Ethernet, bsimulator, output, high speed counter, analog combo, Universal analog, and digital servo modules. Demo also includes QuickPanel control/view

MTR-1216-N-D-E-0 MTR series NEMA 23 stepping motor. Winding connection type is determined by cable

VSPCSE-REPTS VISUALSPC SECURE EDITION REPORTS

20BD077A0ANNACC1 PowerFlex 700 AC Drive 77 A 60 Hp 20B

20G11LF710JN0NNNNN PowerFlex 755 AC Packaged Drive

22F-A2P5N113 PowerFlex 4M- 0.4 kW (0.5 HP) AC Drive

490NAA27102 Quantum MODBUS PLUS電纜,500'

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

PYF08A-E 導(dǎo)軌安裝型，MY2J，MY2NJ

1492-SPM2D150 MCB Supplementary Protector 15 A

軟啟動(dòng)器 3RW30462BB14

電機(jī)啟動(dòng)器 3VU16401CJ00

150-F317NCDB SMC Flex Smart Motor Controller

1732E-IB8M8SOER ARMORBLOCK 8 POINT SOE INPUT

1771-VHSC 1771 Combination Module

193-EEJZ E1 Plus 40-200 A Overload Relay

20-750-2262C-2R PowerFlex 750 24V DC IO Option module

2090-CPWM7DF-08AF60 60 m Length SpeedTec Pwr and Brake Cable

2097-V31PR0-LM Kinetix 350 400W Servo Drive

ENP2335M010 Male Standard/Male Standard, 1 meter

GFK-1848 S2K Series Standalone Motion Controller User's Manual

IC220DEM011 VERSAPOINT STATIC DEMO, DEVICENET NIU

IC647CSPR001 Proficy Cause+ for Inbligent HMI/SCADA Runtime Server - 1X monitored KPI

IC647PSC200 Proficy Process Systems 2000 I/O with CIMPLICITY

IC693MDL230CA Conbal Coated Input module, 120VAC 8 point isolated.

IC756CAU001 Architecture Change/Addt'l User - Unix

MSI-MGMT-25 Production Management Clients 25 Pack

PLC-5/1771 System 1785-L20E ETHERNET/IP PLC-5/20 CONTROLLER, 16K WORD SRAM