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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(xiàn)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(xiàn)、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(chǎng)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(chǎng)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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IC200CBL002 CABLE EXPANSION NIU FIRMWARE UPGRADE

IC694ALG223 INPUT MODULE ANALOG 16 SINGLE ENDED 8 DIFFERENTIAL CURRENT

MSI-SDK-UNL-43 Unlimited SDK Connections (per site)-43

VSPC32-IMP VisualSPC Importer.

20BD034A0AYNANA0 PowerFlex 700 AC Drive 34 A at 25 Hp 20B

20G11GC060JA0NNNNN PowerFlex 755 AC Packaged Drive

22D-B024F104 PowerFlex 40P 5.5 kW (7.5 Hp) AC Drive

600544000 Quantum 用于 RG-6 F 連接器壓接工具

290-G3-A5 Gland Kit, G3-A5 (Pkg of 5 Plt)

E5CZ-Q2 NEW 外型：48×48mm開(kāi)孔；45×45電源：100V-240VAC

1492-SPM2B150 MCB Supplementary Protector 15 A

軟啟動(dòng)器 3RW30142BB14

電機(jī)啟動(dòng)器 3VU16401MM00

150-F108NBDB SMC Flex Smart Motor Controller

1715-TASIF16 1715 16 Simplex A/I Termination Assembly

1771-NOV 1771 Analog Module

193-EC5GF E3 Plus 42-210 A Overload Relay

198E-C2S4 Plastic IP66 and NEMA 4/4X/12K Enclosure

2090-CPWM4E2-14TR MP-Series 0.5m Length Transition Cable

2094-BNINV-2 Kinetix 6000 Connector Set

DEMOCD00060 Driver CD

GFK-0846 Pro-Log GRI Genius I/O Interface for the Allen-Bradley PLC-5 PLC-3 Reference Manual

IC210EDD008 Expansion unit, 24V DC Power Source, (4) 24VDC in/(4) out (Transistor)

IC647AUR002 PA Universal Reporting Client 2 Pak

IC647PRTEE005M Proficy Portal Enterprise Edition Client Pack 5 Users (M4 Key)

IC693CPU331RR CPU 331 Module, 8K Words, Manual

IC754VKL06CTD Starter Kit/ 6 inch TFT View Loaded/ 24VDC

MSI-DASHBOARD-50 Dashboard Client 50 Pack

SLC/1746 System 1746-RL47 REPLACEMENT OCTAL LABEL KIT FOR CTLG # 1746-ITV16

Distributed I/O 1734-SSI SSI ABSOLUTE ENCODER INTERFACE

Application-specific products 9307-64MGDBPENE RSEMETRIX MGR(9-64 METERS),W/1MSSQL PROCESSOR LIC

Operator Interface 2711-CBL-PM05 5METER RS232 CABLE, PV300MICRO TO SLC/PLC

Support 9302-GEDS SUPT RENEWAL CONTRACT FOR 9302GED

Support 9510-PB10000ENS SUPT RENEWAL CONTRACT FOR 9510PB10000EN

DeviceNet Products 1799-DNC5MMS DNET 5-POS. TO MICRO MALE CONNECTOR (LOTS OF 5)

RSI Software Products 9301-2SE3350KOU1 RSVIEW32 RUNTIME 150-5K UPGRADE IN-SUPT (KO)

RSI Software Products 9307-EM8MGRENE RSENERGYMETRIX MANAGER (0 - 8 METERS)

Motion Control MPL-B980B-SJ24AA MOTOR,SERVO,122.0NM,1000RPM,SINGL,460V,BRK

Silver Series 1398-DDM-075X DRIVE,75A PEAK, ULTRA 200 W/INDE

HE693ADC405 4ch., +/-10Vdc Analog Input Module, 700Vac Isolation, 14-bit resolution

IC646TPR935 Pro Server 35,000 I/O Point Run Time System

QPGCGDE0000 7.4" Color TFT, Ethernet, CF Card, 24VDC, UL, cUL, CE

ST-3702 STXi analog b module 2 Channels, RTD

20BC140A0AYNANA0 PowerFlex 700 AC Drive 20B

20F14NF212JN0NNNNN PowerFlex 753 AC Packaged Drive

22A-D2P3N104 PowerFlex 4- 0.75 kW (1 HP) AC Drive

140CPS52400C Quantum 電源, 125 VDC, 冗余, 8A, CC

284D-FHD7P6Z-25-CR DeviceNet Variable Frequency Drive

CJ1W-AD081 8點(diǎn)模擬量輸入單元（1-5V,0-5V,0-10V,-10-10V,4-20MA）分辨率：1/4000

1492-RTB12N 12 Pole RTB Plug Assembly

WinCC 上位監(jiān)控軟件 6XV1820-5AH10 FIBER OPTIC CABLE 標(biāo)準(zhǔn)電纜/每米

變送器 3RS17031DD00

1497A-A3-M18-1-N Machine Tool Transber

1606-XLP60BQT AC or DC Input 12VDC Out 54W Low Temp PS

1768-ENBT CompactLogix L4X EtherNet/IP Module

188-K4C130 Miniature Circuit Breaker 13 A

194R-30-MTL3 194R 30 Ampere Multi-tap Terminal Lugs

2090-CPBM7DF-10AA30 MP-Series 30m Standard Cable

2090-XXNPMP-10S40 MP-Series 40 m Length Power Cable

CBL-12-MPS-30 Power cable for MTR-1221-*-D and Power cable for MTR-1231-*-D stepping motor connected to S2K. 30 feet

GC647STA001 GCScheduler Time & Attendance Adapter

IC200PWR101 POWER SUPPLY 120/240VAC INPUT

IC646TBLSS100K Proficy Troubleshooter for Inbligent Historian for Hist 100000 Points

IC647NGL000 CIMPLICITY HMI OMRON HOST LINK Communications

IC692MDR541RR 16 AC b/ 12 Relay Output 120 Vac PS

IC698CRE020CA RX7i 700mhz Redundant CPU w/Ethernet Conbal Coated

IC800VMCB050 Motor power and brake power cable for 200 W to 750 W VersaMotion servo motors-5 meter

SLC/1746 System 1746-IO12 COMBINATION MODULE FOR PROGRAMMABLE CONTROLLER

Industrial Computers 6180W-15KS2KH VERSAVIEW 15-INCH WORKSTATION, KEYPAD

Application-specific products 6556-PA0PM1 CLUTCH/BRAKE KIT WITH ARMED CONTINUOUS PUSHBUTTON

Operator Interface 2711-T5A10L1 PV550 MONO TOUCH, DNET & RS232 PRINT

Support 9301-2SE2200JPS SUPT RENEWAL CONTRACT FOR 93012SE2200JP

Support ABTS-W102S ABT-SW102 PATHFINDER SW SUPPORT RENEWAL

ControlNet Products D1785-6.5.24 CONTROLNET PLC-5 HOT BACKUP USER MANUAL

RSI Software Products 9301-2SE250ESU5R RSVIEW32 WORKS 5K-100K UPGRADE OUT-SUPT (ES)

RSI Software Products 9358-BERP03U2R UPGRADE: OUT-SUPT: RSBW BATCH ERP 3 TO 10 SERVER

Motion Control MPL-B310P-MJ24AA MOTOR,SERVO,1.58 NM,5000RPM,MULTI,460V,BRK,4.1KG

Motion Control 2090-XXNPMP-16S30 CABLE,NON-FLEX,MOTOR POWER,MP/1326AB,16 GAUGE,30M

GC646TDV300 Proficy GlobalCare Complete for Server I/O 300 Develop/Runtime System

IC641SWP066 Series 90 Digital Event Recorder Software

IMC-200E-X-D IMC-D Series Ampless Servo Motor Controller, Enhanced

PSPC-DC100-220 Prof Shop Floor SPC DC 100 User 220v

20BB9P6A3AYNBNC0 PowerFlex 700 AC Drive 9.6 A 3 Hp 20B

20DJ248A3NNNACGNE PowerFlex 700S AC Drive 20D

2198-H040-AD-T K5500 FR1,2 AC,DC bus conn

2711P-K7C4D9 PanelView Plus Terminal

280-PWRM35F-M2 ArmorStart Three-Phase Power Media

CP1H-XA40DR-A XA型主單元，24入16點(diǎn)繼電器輸出. 高速計(jì)數(shù)50/100khz 4軸 .usb端口編程.集成模擬量4入2出.

1492-MS8X12V1-10 Connection Products

模擬量輸入/輸出模塊SM 6ES7 331-1KF01-0AB0 AI/8，電壓、電流、電阻、PT100，光電隔離，40pin前連接器

行程開(kāi)關(guān) 3SE53220SD21

運(yùn)行版軟件 6AV2107-3DB04-0AE0 SIMATIC WinCC Client for Runtime 專(zhuān)業(yè)版 V14 Upgrade V11..V13 -> V14

1585J-M8CBJM-5 RJ45 Ethernet Media

1756-PSCA2XT Extended Temp Redundant Supply Adapter