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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)，如對夾具、被焊件、監(jiān)測精度等要求嚴(yán)格，焊接后檢測評價(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6 mm以下板材下料。車輛轉(zhuǎn)向架選用激光切割機(jī)對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12 mm以下板材下料[17]。

 

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1492-SPM1B010 MCB Supplementary Protector 1 A

人機(jī)界面 6AV6545-0DB10-0AX0 MP370 觸摸面板，256 色，15.1 英寸，800? 600

6ES73317KF024AB2

1497B-A6-M13-0-N Control Power Transber

1606-XLS480G-3 36-42V Dc 480 Watt Power Supply

1769-IG16 CompactLogix 16 Pt TTL DC D/I Module

189-ASCR3 MCB Accessory Signal Contact

194R-HM4E 194R 100-400-625 A Operating Handle

2090-CPBM7DF-14AA07 MP-Series 7m Standard Cable

2090-XXNPMP-8S05 MP-Series 5 m Length Power Cable

CBL-3C-L1D-FLY-10 S2K flying lead feedback cable for special for 3rd party motors with hall commutating encoders. 10 feet

GF-0304 Connecting FlashCable to Edmunds Trendsetter (for use with the Combo G agePort). Contact Dave Chapman X5472 for additional electrical testing.

IC200TBX340 Tool box, Micro 40, operator interface and software. Includes (IC200UDR140) 24VDC In/Relay Out, requires 120/240VAC power, (IC200USB001) RS-232 option board with (2) 0 -10VDC analog in with VersaMax DataPanel DP 45 (IC200DTX450) with Proficy Logic

IC646TBSPMPW025 Smart Process Monitoring Process+ Web Clients 25 Pack

IC647NST000 CIMPLICITY HMI Stratus High Availability Server License

IC693ACC350 Redundant Power Supply Adapter (RPSA) Module. The RPSA replaces the p ower supply on a CPU base or expansion base and connects to a Redundan t Power Supply Base.

IC752CBT050RR Datapanel 320T CB (Color Base): 320x240 1/4 VGA Passive Color with 803 86SX/40 PC processor. Analog touch screen with text, bitmaps, bar gra phs, real time clock.

IC800VMCP3030 Power cable for 3 kW VersaMotion servo motors- 3 meter

SLC/1746 System 1746-NI8 (8) ANALOG INPUT FOR PROGRAMMABLE CONTROLLER

Industrial Computers 6189V-CPUSTD2 STANDARD SBC (W/CPU AND COOLER) (1400R)

Application-specific products 1403-CF010 10 M F LINK FOR POWERMONITOR

Operator Interface 2711-K6C1 PV600 COLOR KEY, RIO & RS232 PRINT

Support 9301-2SE2400PTR SUPT REINSTATEMENT CONTRACT FOR 93012SE2400PT

Support 9323-1003ENS SUPT RENEWAL CONTRACT FOR 93231003EN

DeviceNet Products 1734-OB2EP 24V DC 2 AMP 2 CHANNEL SOURCE OUTPUT MODULE

RSI Software Products 9301-2SE3100ITE RSVIEW32 RUNTIME 150 (ITALIAN)

RSI Software Products 9358-BNTK30U1R UPGRADE: OUT-SUPT: RSBATCH BACK-UP KEY 03 TO 30

Motion Control MPL-B420P-MJ22AA MOTOR,SERVO,4.74 NM,5000RPM,MULTI,460V,5.0KG

Motion Control 2090-UXBB-DM09 BREAKOUT BOARD, CN3, ULTRAX000 DRIVE MOUNTED

GFK-0771 C Programmer's Toolkit for Series 90 PCM User's Manual

IC646MDA075 View 75 Tag Runtime & Development System

MSC-TC-V Obsolete - Type J (0 to 760C) in / 0-10 V out

PSPC-MONITOR10 Prof Shop Floor SPC Monitor 10 User

20BC022A0AYNACB0 PowerFlex 700 AC Drive 22 A at 11 kW 20B

20F11GC011JA0NNNNN PowerFlex 753 AC Packaged Drive

2198-P070 Kinetix 5700 DC Bus Supply

2711P-RCH PanelView Plus Accessory

280D-F12B-10A-CR ArmorStart Direct Online Starter

CQM1-OA221 輸出 8點(diǎn).可控硅 100-240V AC 0.4A

1492-N49 TERM BLCK 10 Pole Side Jumper

連接電纜 6ES7368-3CB01-0AA0 IM360/361 連接電纜， 10m

變送器 3RS18001BP00

TIA 博途 WinCC 選件 6AV2107-0LH00-0BB0 SIMATIC WinCC DataMonitor for Runtime Professional 25 Clients

1585J-M8PBJM-1 RJ45 Ethernet Media

1760-L12BWB-ND Pico 12 Point DC Controller

188-K2C130 Miniature Circuit Breaker 13 A

194L-A25-1753-6N 25 A 194L Load Switch

2090-CNSRPRS-AA07 Kinetix 6000M Network Cable

2090-XB120-03 107 Amp 3 Ohm Resistive Brake Module

BC647MRA075 View Runtime 75 I/O with Proficy GlobalCare Complete with USB Hardware key

GC647IFSTRN00900 GCC iFIX Std HMI 900 I/O Run

IC200CPU005 CPU 128K user configurable user memory, 0.8MSEC/K Boolean one RS232 and one RS485 serial ports

IC646NAP000 Applicom Communications

IC647IFSTRN00900C iFIX Standard HMI 900 I/O Runtime (M1Component Part)

IC670GBI102RR 120Vac/125Vdc Powered Genius Bus Interface Unit

IC697MCS704 This part is obsolete

IC800SLCAPM010 Control cable to connect the SL servo amplifier terminal block to an APM300 motion controller module. 1 meter

ControlLogix/1756 System 1756-M03SE 1756 3 AXIS SERCOS INTERFACE SERVO MODULE

Industrial Computers 6182H-12BRH4B VVCE 1250, KEY/TOUCH, STD MEM, ENET, AC

Process Control 1757-PFBEXP005 PROFIBUS INTERFACE MODULE EXPANSION

Operator Interface 2711P-RN15S CONTROLNET COMMUNICATIONS MODULE

Support 9355-WABSNS SUPT RENEWAL CONTRACT FOR 9355WABSNEN

Support 9361-CHARTR SUPT REINSTATEMENT CONTRACT FOR 9361CHART

ControlNet Products 1734-IV2 24V DC 2 CHANNEL SOURCE INPUT MODULE

RSI Software Products 9301-2SE2400U2R UPGRADE: OUT-SUPT: RSVIEW WORKS 300 TO 32K

RSI Software Products 9357-DNETL3U UPGRADE: IN-SUPT: DNET MGR TO RSNETWORX FOR DNET

Motion Control MPL-A330P-SK24AA MOTOR,SERVO,4.18 NM,5000RPM,SINGL,230V,BRK,6.1KG

Motion Control 2090-UXNFBMP-S03 CABLE,ULGRF50ON-FLEX,MOTOR FEEDBACK,MP,3M

CBL-139 Cable. SIMATIC T.I. 545, 555 Port 2 (RS-422)

IC600WD025 I/O Cable, 25 feet (7.5m)

IC800SKCI030 Interface Cable, S2K Aux. I/O Connector to 44A726268-001 Terminal Block, 3 Meter

OC647IFESGSR00900M iFIX Optn: ESig & ERec 900 I/O Server (M4 Part)

20AD065A3AYNADC0 PowerFlex 70 AC Drive 65 A at 50 Hp 20A