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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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IC800SGM450M2KE25 4500W, 230V S-Series Servo Motor, 322 in-lb (36.4 Nm)

OC647IFESGRN00300C iFIX Optn: ESig & ERec 300 I/O Runtime (M1Component Part)

20AD040A3AYNAEC0 PowerFlex 70 AC Drive 40 A at 30 Hp 20A

20DC590N0ENNBDANE PowerFlex 700S AC Drive 590 A 315 kW 20D

20LD1K2N0ENNXNW0WA PowerFlex 700L AC Drive 20L

2707-NC10 DTAM MICRO-MICROLOGIX COMMS CBL. 6 F

280-PWRM22E-M025 ArmorStart Three-Phase Power Media

FX2N-16EYT 擴(kuò)展16出 晶體管輸出

1492-M6X5 IEC 6 x 5 mm Marker Card

1494R-N2 Lug Kit

軟啟動(dòng)器 3RW44476BC35

ET 200SP 6ES7193-6PA00-0AA0 服務(wù)模塊 (備件)

1585D-M4UBDE-0M6 1585D Ethernet Media Patchcord

1756-IB16DK ControlLogix 16 Point D/I Module

1794-TB3GSK Flex Terminal Base

194E-E100-1756 100 A 194E Load switch

2090-CFBM4DD-CDAA05 MP-Series 5 m Length Feedback Cable

2090-K6CK-D44M Kinetix 6000 Low Profile Connector Kit

ADP-SCM-STF-S SC to ST single mode adapter

GC646TDV050 Proficy GlobalCare Complete for Server 50 I/O Develop/Runtime System

HE800CBL219 I/O Extension Cable, 19-pin, 2.0m. For use in conjunction with TRM519

IC640MWS902RR Workmaster System/ 2-35 inch Disk Drive

IC647HSTSSEO5000KM eSignature Option for Historian - Standard Server 5,000,000 Points (M4 Key)

IC660BRD024 Genius 12/24VDC Source Block for Redundancy T Output Configurations

IC695CRU320CA Conbal coated. 1Ghz CPU with 64Meg of memory 2 SERIAL PORTS (occupies two slots on system base) redundant CPU. External high capacity battery IC693ACC302 required. The CRU320 will only work with RX3i ENIU remote I/O and Genius LAN.

IC756WET200K-99 Custom Datasource Toolkit, Korean, Version 9.9

CompactLogix System 1769-STRT2ES COMPACTLOGIX STARTER KIT SPANISH

PLC-5/1771 System D1771-6.5.3 ANALOG OUTPUT SYSTEM(1771-OF,SER.B & 1771-E4)MNL

Process Control 1757-PLXNB POINT CONTROL SCHEDULER

Operator Interface 2711P-K7C4D2 PV PLUS 700, KEYPAD, ENET, DC PS, EXT MEM

Support 6556-SPLSR SUPPORT REINSTATEMENT CONTRACT FOR 6556SPLS

Support 8100-HSKARS SUPT RENEWAL CONTRACT FOR 8100HSKA

Support F1785-L11BSERD FIRMWARE UPGRADE FOR 1785-L11B PLC5 PROCESSOR MODU

RSI Software Products 9301-2SE2203KOE RSVIEW32 WORKS 300 WITH RSLINX (KOREAN)

RSI Software Products 9701-VWSB025FRU1 RSV SE STATION 25 - SE SRV 25 UPG (FRENCH)

RSI Software Products 9399-FW5FBGR RSLGIX FRAMWRKS FUNCTION BUILD.GET'G RESULTS GUIDE

Motion Control 2098-DSD-150-DN DRIVE, 65A/150A, ULTRA3000 W/DEVICENET

BC5008TBN0000 18 Inch Inbligence Industrial Computer - Bundled - Perbance Series - w/ Windows NT

IC300DIM210 8 DC Inputs (12/24vdc, pos/neg logic).

IC752ECD550 Display Station 1493 - 14" XGA (1024x768) resistive touch screen, Pentium 133, 32MB, 2 Gig hard drive, expansion slots, Ethernet, with CIMPLICITY HMI and Win NT

MTR-3S45-G-R-B-E-SRR Servo Motor 24V Brake, Seal

ZA06B-6093-K001 Replacement serial encoder battery for Beta series amplifiers

20BH140A0ANNANC0 PowerFlex 700 AC Drive 20B

20G14TD740AN0NNNNN PowerFlex 755 AC Packaged Drive

25A-A2P5N114 PowerFlex 523 0.4kW (0.5Hp) AC Drive

2711P-T10C4D9 PanelView Plus Terminal

FRN280P11S-4CX 400KVA 520A 280KW 3相AC380V/50Hz/60Hz

1492-JD4C 4 square mm Double Level Terminal Block

1492-W6 IEC Term Blck 8x47.6x41mm Screw

軟啟動(dòng)器 3RW40766BB45

性能信號(hào)模塊 6ES7 521-1BH50--0AA0 DI 16：數(shù)字量輸入模塊，源型，DI 16x 24VDC SRC BA, 35mm 模塊，不含前連接器

156-B30BV1 30 A Contactor

1746-IB8 SLC 8 Point DC Input Module

1786-TNCL10 ControlNet Media TNC Connector Plug

193-T1BC30 24.5-30.0 A IEC Bibllic Ovld Relay

20-HIM-A5 PowerFlex Architecture Class HIM

2090-CSBM1DF-14AA20 Kinetix 20m Smartb Single Cable

20AC015C3AYNANC0 PowerFlex 70 AC Drive 20A

GA647TPR915 Proficy GlobalCare Assist for CIMPLICITY HMI ProServer 1500 I/O Runtime System

GP647IFSTDVUNLMT GCP iFIX Std HMI Unlmt Dev

IC600CB524RR Arithmetic Control Module

IC647HSTCSCCP25M Historian Enterprise Corporate Client Enterprise Connection Pack 25 Users (M4 Key)

IC647UDCC UDC:Honeywell UDC Controllers

IC693UAA007RR 28 pt AC In/AC Out, AC Power Supply

IC756RDV000K-99 DV Development - Irix Op Sys, Korean, Version 9.9

MicroLogix 1200 System 1762-L24BWA MICROLOGIX 1200, 24 PT.

PLC-5/1771 System 1771-CFMK CONFORMALLY COATED, CONFIGURABLE FLOW METER

Distributed I/O 1794-IB10XOB6 10/6 24VDC COMBO

Communications 9355-WABGWFRE RSLINX GATEWAY - FRENCH

Operator Interface D6190-6.5.9 CONTROLVIEW NETWORKER(CAT.NO.6190-NET)USER'S MNL

Support 9358-BCMPN01R SUPT REINSTATEMENT CONTRACT FOR 9358BCMPN01ENE

Support F1403-MMVER2X FIRMWARE UPGRADE FOR 1403-MMV POWERMONITOR MODULE

RSI Software Products 9324-RL01U3PTER UPGRADE: OUT-SUPT: PORTUGUESE RS500 START TO RS500

RSI Software Products 9301-2SE3503DEE RSVIEW32 RUNTIME 100K WITH RSLINX (GERMAN)

RSI Software Products 9358-HSTCLTENE RSBIZWARE HISTORIAN SINGLE USER RUN TIME CLIENT

Motion Control Y-2012-2-H00AA MOTOR,SERVO,1.35 NM,4500RPM,ENCDR,230V,2.31KG

5401 Greyline Micro MC. 2 Lines, (20) 5MM Chars. LCD. Quick Connect. NEMA 4

IC200DTX450 Operator Interface with up to 200 stored messages. 2 x 16 character LCD backlight display and 6 function keys

IC695CHS016 RX3i BASE 16 SLOTS

MSI-WEB-UNL-43 Unltd Site Clients - Web or Excel Rep-43

VSPCSE-OPC10 Secure Edition OPC Client Option includes VisualSPC Importer (licensin g is per client PC), Support for up to 10 Points/Tags.

20BD065A0AYNAND0 PowerFlex 700 AC Drive 65 A 50 Hp 20B

20G11LE825JN0NNNNN PowerFlex 755 AC Packaged Drive