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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。中國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。
隨著中國政府“十三五”規(guī)劃的提出，國家發(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，也持續(xù)為其提出新方向、新課題。

由于中國的城市軌道交通起步較晚，因此為了縮短與國外先進(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)測精度等要求嚴(yán)格，焊接后檢測評(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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IC752WFC552 Display Station 2050 Series-15" active matrix SVGA (1024x768) resistive touchscreen, Pentium 350 Mhz, 128 MB RAM, 6.4 GB removable HD, expansion slots (2 PCI/3 ISA), unlimited pt ct CIMPLICITY HMI, field detachable front/rear housing,Win NT

MTR-3T23-G-R-0-M-S MTR series metric servo motor with resolver and shaft seal

ZA66L-6001-0023#L150R0 "A22/3000HVi & A12/4000HVis & A22/4000HVis, Fiber Optic Command Cable, 15 CM"

20D-P2-SLB0 PowerFlex 700S Synchb Board

20G1AJC650AN0NNNNN PowerFlex 755 AC Packaged Drive

25B-A4P8N104 PowerFlex 525 0.75kW (1Hp) AC Drive

2711P-T9W22A9P-B PanelView Plus 7 Graphic Terminal

6SE6430-2UD37-5FB0 75KW

1492-L3Q-Y IEC Term Blck 5.1x79x31.3mm Spr Clp

1494C-CMX13 Cable Mechanism

軟啟動(dòng)器 3RW44263BC44

附件 6ES7 592-1AM00-0XB0 35 mm 模板前連接器，螺釘型，40 針，含 4 根跳線

1585BP-MCAP 1585 Ethernet Media Accessories

1747-AIC SLC Isolated Link Coupler

1790D-T16BV16B CompactBlock LDX 32 Point Base Block

194E-A32-PE 194E Earthing-Grounding Terminal

20-PP13100 WIRE SET FI13 400/480V

2090-CSBM1DF-18AF25 Kinetix Cable Single DSL 2090-Series

20AC060A3AYNANC0 PowerFlex 70 AC Drive 60 A at 30 kW 20A

GC646MDA000 Proficy GlobalCare Complete for View Development/Runtime 8,000 I/O

HE693ADC410 4ch., +/-10Vdc Analog Input Module, 2000Vac Isolation, 14-bit resoluti on

IC600PM506RR CPU Power Supply, 115Vac

IC647HSTESEO15KM eSignature Option for Historian - Enterprise Server 15000 Points (M4 Key)

IC655MDL502RR 12-24Vdc Input, Negative Logic (32 points)

IC694MDL241CA Conbal Coated Input 24 VAC 16 points.

IC756SDV010E-99 DV Draw Development on Solaris Op Sys, English, Version 9.9

MicroLogix 1500/1769 System 1769-OB16 16 POINT 24 VDC SOURCING OUTPUT MODULE

PLC-5/1771 System 1785-TR10B2 AUI TO THIN WIRE ENET TRA

Distributed I/O 1794-TB3TS 3-WIRE TEMPERATURE TERMINAL BASE - SPRING CLAMP

Communications D1784-6.2.4 REF.MNL CONTROLNET KT EMU

Support 9311-PLC3S SUPT RENEWAL CONTRACT FOR 9311PLC3

Support 9358-CTATEENR SUPT REINSTATEMENT CONTRACT FOR 9358CTATEEN

Support F1771-PM FIRMWARE UPGRADE FOR 1771-PM I/O MODULE

RSI Software Products 9324-RLD200PTE RSLOGIX 5000 MINI, PTE

RSI Software Products 9301-VIEW3U3 UPGRADE: IN-SUPT: CTRVW TO RSVIEW32 WKS 300/RSLX

RSI Software Products 9358-PLTM2300U2 UPGRADE: IN-SUPT: PLANTMETRICS 10 TO 25 WORKCELL

Motion Control 8720SM-030S4JAS3 30 KW/63.1AMP,750 VDC,AMP AC MOTOR WITH SNS60 ENC.

888 SLDERLSS Field CONN Adptr. For W/4161 (6-8 Digit). Screw Terminal O/I For Data Lines

IC200PKG014 VersaMax Ethernet NIU starter kit with I/O.

IC697VDQ120 Digital Output, 64 point, 24VDC at 500mA, Sink or Source, 64 point

MTR-1337-E-D-E-0 MTR series NEMA 34 stepping motor with series winding connection and encoder

ZA06B-0064-B203 B4/4000HVis servo motor with 128k serial encoder

20BD180A0ANNANC0 PowerFlex 700 AC Drive 20B

20G11NE2P7AA0NNNNN PowerFlex 755 AC Packaged Drive

23C-X012A103NNAANN Fan/Pump Packaged Drive 23C

140CFX00110 Quantum CABLEFAST 端子塊接地條, 10位置

294E-FD2P5Z-G3-SB Variable Frequency Drive

SHL-Q2155 觸點(diǎn):1開/1閉,10A 250VAC機(jī)械壽命:1000萬次 交叉滾輪柱塞型

1492-SPM3C010 MCB Supplementary Protector 1 A

軟啟動(dòng)器 3RW40371BB04

中央處理單元 6ES7 215-1AG40-0XB0 CPU 1215C DC/DC/DC

150-FPP135B SMC Flex Repair Part

1734-OB2 POINT I/O 2 Point Digital Output Module

1783-HMS4SG8EG4CGN Stratix 5400 16 Port Managed Switch

193-ESM-I-100A-E3T E300/E200 100 Amp Sensing Module

20-750-FAN3-F8 PowerFlex 750 Frame 8 Door Fan Kit

2090-CPWM7DF-14AA15 MP-Series 15m SpeedTec Standard Cable

2098-DSD-150X-DN Ultra 3000 Servo Drive

GA646PCM050 GlobalCare Assist for Change Management 50 user pack

GFS-351 S2K Workshop Course Manual

IC5000HAX0000 Host PC with Windows XP

IC647GIOC GIO:GE Fanuc Genius

IC647SHR050 "Scheduler Prepay 50+ hours,per hour"

IC693MDL654CA Conbal Coated Input module 32 points 5/12VDC TTL POS/NEG logic. Termination is a Fujitsu connector.

IC756HDV000E-99 DV Development - HP/UX Op Sys, English, Version 9.9

MSI-ROLLDEF-43 Roll Map - Defect Mapping Function-43

PLC-5/1771 System 1771-IB INPUT MODULE, 12-24V DC, 8 INPUT

Distributed I/O 1790D-TN0C2 DNET LDX, 2 OUTPUT ANALOG CURRENT BSE, TERM BLOCK

Communications 1784-CP12 CABLE ASSY, 10 FT/3.2 M

Operator Interface 2727-MRT15 15M MOBILEVIEW CONNECTION CABLE

Support 9305-RSVADFVCENR SUPT REINSTATEMENT CONTRACT FOR 9305RSVADFVCEN

Support 9515-RSCHM025S SUPT RENEWAL CONTRACT FOR 9515RSCHM025ENE

EtherNet/IP Products 2706-P94C INVIEW MESSAGE DISPLAY

RSI Software Products 9301-2SE3400U3R RSVIEW RUNTIME 150 TO 32K UPGRADE:OUT-OF-SUPPORT

RSI Software Products 9515-RSEOL056ENE RSMACC CONDITION MONITOR, 56XM & 8 ENWATCH

Motion Control 1326AB-B515G-M2L MOTOR,SERVO,460V,10.4NM,5000RPM,MULTI,IP67