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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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IC800VMCB100 Motor power and brake power cable for 200 W to 750 W VersaMotion servo motors- 10 meter

SLC/1746 System 1746-IO12DC COMBINATION MODULE FOR PROGRAMMABLE CONTROLLER

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

Application-specific products 6556-PA0PM3 CLUTCH/BRAKE KIT W/ARMED CONTINUOUS PUSHBUTTON

Operator Interface 2711-T5A12L1 PV550 MONO TOUCH, PBUS & RS232 PRINT

Support 9301-2SE2200PTR SUPT REINSTATEMENT CONTRACT FOR 93012SE2200PT

Support ABTS-W103R ABT-SW103 PATHFINDER SW SUPPORT REINSTATEMENT

ControlNet Products D9220-6.5.1 DEVELOPERS GUIDE-CONTROL

RSI Software Products 9301-2SE250FRU1R RSVIEW32 WORKS 32K-100K UPGRADE OUT-SUPT (FR)

RSI Software Products 9358-BIZ1C0PENE RSBIZWARE SINGLE-USER RUNTIME CLIENT

Motion Control MPL-B310P-MK22AA MOTOR,SERVO,1.58 NM,5000RPM,MULTI,460V

Motion Control 2090-XXNPMP-16S60 CABLE,NON-FLEX,MOTOR POWER,MP/1326AB,16 GAUGE,60M

GC646TDV700 Proficy GlobalCare Complete for Server 700 I/O Develop/Runtime System

IC641SWP303 LM 90-30/20/Micro Serial Software Demo Version, 3.5", 5.25" Format

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

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

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

20DJ300N3ENNBCASE PowerFlex 700S AC Drive 20D

2198-H040-ADP-IN K5500 FR1,2 b connectors

2711P-RAAK10 PanelView Plus 7 Series Accessory

280-PWRM35F-M20 ArmorConnect 3-PH Power Media trnk cable

CP1H-X40DT-D X型主單元，24入16點(diǎn)晶體管輸出. 高速計(jì)數(shù)50/100khz 4軸 .脈沖輸出100khz 2軸 30khz 2軸 usb端口編程.

1492-MS8X12V1-20 Connection Products

模擬量輸入/輸出模塊SM 6ES7 331-7KB02-0AB0 AI/2，電壓、電流、電阻、PT100，光電隔離，20pin前連接器

行程開(kāi)關(guān) 3SE53220SE22

運(yùn)行版軟件 6AV2105-4BB04-0AE0 SIMATIC WinCC Runtime 專(zhuān)業(yè)版 V14 Upgrade WinCC V7.0..V7.3 Runtime 128 PowerTags -> WinCC Runtime 專(zhuān)業(yè)版 128 PowerTags V14

1585J-M8CBJM-6 RJ45 Ethernet Media

1756-RIO ControlLogix Remote I/O Scanner Module

188-K1D130 Miniature Circuit Breaker 13 A

194E-Y25M-1753-6N 25 A 194E Load switch

2090-CFBM7E7-CDAF30 MP-Series 30 m Length Feedback Cable

2090-UXNFBY-S09 Y-Series 9 m Length Feedback Cable

BC646TPR935 ProServer 35,000 I/O Runtime Sys with Proficy GlobalCare

GC647IFPLDV00900 GCC iFIX Plus SCADA 900 I/O Dev

IC200CBL520 Series 90, SNP 15-Pin, RS-485 Cable to DataPanel 20/40/60

IC646MPP005 Logic Developer PLC Professional 5 Pack

IC647IFPRSR00900M iFIX Profsnl SCADA 900 I/O Server (M4 Part)

IC660TSD020 Terminal Assembly for IC660BBD020

IC697CPM915RR CPU, 32 MHz, 12K Discrete I/O, 1024K RAM, 80486DX

IC800MCUB12310XNRR Stepping MotorCube 175 oz-in, Pulse/Direction

ControlLogix/1756 System 1756-OA8E 74-132 VAC ELEC FUSED 2A OUTPUT 8 PTS (20 PIN)

Industrial Computers 6182H-10BRH6B VVCE 1000, KEY/TOUCH, STD MEM, RIO/DH, AC

Process Control 9358-PBPCNT60ENE RSBATCH NT FOR PROCESLGIX PC BASED PHASES 60 UNITS

Operator Interface 2711P-RBK10 PV PLUS 1000 KEYPAD REPLACEMENT BEZEL

Support 9355-TKTOPCS SUPT RENEWAL CONTRACT FOR 9355TKTOPC

Support 9351-OSFRTS SUPT RENEWAL CONTRACT FOR 9351OSFRT

ControlNet Products 1786-RPFM CONTROLNET FIBER REPEATER - MEDIUM

RSI Software Products 9301-2SE2400DEU5 RSVIEW32 WORKS 5K-32K UPGRADE IN-SUPT (DE)

RSI Software Products 9355-WABGWEU3R UPGRADE: OUT-SUPT RSLINX PROF TO RSLINX GW

Motion Control MPL-A320H-HJ24AA MOTOR,SERVO,2.94NM,3500RPM,ENCR,230V,BRK,5.1KG

Motion Control 2090-DANPT-16S07 CABLE, NON-FLEX, MTR PWR, CABLE-MTD CONN, 16AWG, 0

BC647MQP001 View Development for QuickPanels with Proficy GlobalCare Complete and a hardware key

IC5005TBX0000 15" Unbundled Inbligence Industrial Computer with WIN XP Perbance Series

IC800MCUB12210XE Stepping MotorCube 100 oz-in, Pulse/Direction, Encoder Feedback

OC647IFDBTKTM iFIX Optn: Database Dynamo Toolkit (M4 Part)

20AD022A3AYNANG0 PowerFlex 70 AC Drive 22 A at 15 Hp 20A

20DC260A0EYNANANE PowerFlex 700S AC Drive 20D

20G1ANF082JA0NNNNN PowerFlex 755 AC Packaged Drive

25C-E012N104 PowerFlex 527 7.5kW (10Hp) AC Drive

280-PWRM22B-M025 ArmorStart Three-Phase Power Media

FX1N-232-BD RS232C 通信用適配器

1492-M5X5H1-50 Connection Products

1494H-DN3H6 Heavy Duty Fusible Safety Discon Switch

軟啟動(dòng)器 3RW44456BC46

ET 200SP 6ES7193-6BP00-0BA0 基座單元 BU15-P16+A0+2B，類(lèi)型A0，直插式端子，15mm寬

1585D-M4TBDM-80 Micro D-Code, QD Style Ethernet Media

1756-EN3TR ControlLogix Ethernet Motion Module

1794-OF4I Flex 4 Point Analog Output Module

194E-CA63EX-TN-PE 194E Load switch

2090-CBUSPSS Kinetix 6000M network bulkhead connector

2090-DANPT-16S01 TL-Series 1 m Length Power Cable

ABICTDE0000/DVN 10.5 inch Color TFT/ TCP Label/ 24VDC/ with DeviceNet/ UL/ cUL/ CE/ UL1604

GC646PCMS10 GlobalCare Complete for Change Management Electronic Signature Module 10 Pack

HE697THM160 Series 90-70 Thermocouple Input Module, 16 Channel

IC630MDL375RR 115/230Vac Output Module (16 points)

IC647HSTSS75KM Historian Standard Server 75000 Points (M4 Key)

IC660BLD021 Cover w/Label for IC660BBD021

IC695CBL001 Energy Pack Cable, 3 ft. (0.91m)

IC756WET100E-23 Custom Editor Toolkit, English, Version 2.3

CompactLogix System 1769-CRL3 3.28 FT (1M) RIGHT-TO-LEFT BUS EXPANSION CABLE

PLC-5/1771 System 9399-RL53GRIT RSLOGIX 5 GETTING RESULTS GUIDE(ITALIAN)

Distributed I/O D1794-6.5.7 FLEX I/O THERM'CPL/MILLV'T MOD.1794-IT8 USR MANUAL

Operator Interface 2711P-T6M8D PV PLUS 600 GRAYSCALE, TOUCH, DH+, DC PS

Support 6411-SDSCR 6411-SDSC SOFTWARE SUPPORT REINSTATEMENT

Support 9358-PLTM2200S SUPT RENEWAL CONTRACT FOR 9358PLTM2200ENE

Support F1784-KTCX15SERA FIRMWARE UPGRADE FOR 1784-KTCX15 COMMUNICATION MOD