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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、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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1492-W4 IEC Term Blck 8x47.6x41mm Screw

軟啟動(dòng)器 3RW40762BB34

安全 CPU 模塊 6ES7 515-2FM01-0AB0 SIMATIC S7-1500F，CPU 1515F-2 PN，中央處理單元，帶有 750KB 工作存儲(chǔ)區(qū)和 3MB 數(shù)據(jù)存儲(chǔ)區(qū)

156-B25CA2 25 A Contactor

1746-HSCE2 SLC Analog Combination Module

1786-RPFRXL ControlNet Fiber Ring Ex Long Repeater

193-T1AC16 11.3-16 A IEC Bibllic Overload Relay

20-FR09825 RECTIFIER MOD SUB-AS.(WITH BRK),FR9,600V

2090-CSBM1DF-14AA11 Kinetix Cable Single DSL 2090-Series

20AC015A3AYNADG1 PowerFlex 70 AC Drive 20A

GA647TPD700 Proficy GlobalCare Assist for CIMPLICITY HMI ProServer 700 I/O Development and Runtime System

GP647IFPRSR00150 GCP iFIX Profsnl SCADA 150 I/O Srv

IC600CB508RR 1K Register Memory Module (for use in Model 600 or 6000)

IC647HSTCS30KM Historian Enterprise Corporate Server 30000 Points (M4 Key)

IC647TSSRV005 Proficy Troubleshooter 5 User Server License

IC693PWR330RR Power Supply, 120/240 Vac, 125 Vdc, High Capacity

IC756RDV000E-97 DV Development - Irix Op Sys, English, Version 9.7

MicroLogix 1000/1761 System D1761-6.4 AIC + ADVANCED INTERFACE CONVERTER USER MANUAL

PLC-5/1771 System 1771-OFE1K CONFORMALLY COATED, ANALOG OUTPUT MODULE

Distributed I/O 1794-APB 1794-APB 12 MBPS PROFIBUS DP ADAPTER FOR FLEX I/O

Communications 9355-RSLETENE RSLINX ENTERPRISE

Operator Interface D6190-6.5.4DE CONTROLVIEW ALARMING USER MANUAL (GERMAN)

Support 9358-BBKEY03R SUPT REINSTATEMENT CONTRACT FOR 9358BBKEY03ENE

Support 9392-KBCDRSR SUBSCRIPTION RENEWAL FOR KNOWLEDGEBASE CD

RSI Software Products 9324-RL01U3ENER UPGRADE: OUT-SUPT: RS500 STARTER TO RS500

RSI Software Products 9301-2SE3500U5R UPGRADE: OUT-SUPT: RSVIEW32 RUNTIME 5000 TO 100K

RSI Software Products 9356-STD2350U2 UPGRADE: IN-SUPT: RSSQL STD 300 TO STD 5000 TAG

Motion Control Y-1003-2-H00AA MOTOR,SERVO,0.35 NM,4500RPM,ENCDR,230V,1.04KG

510-1000-004 POWER SUPPLY 24VDC 1.3AMP

IC200CPU001 CPU 12K USER PROG 1.80MSEC/K BOOLEAN ONE RS232 AND ONE RS485 SERIAL PORTS

IC694MDL754 12/24VDC Output (0.75 amps per point)Module 32 point. The module can be used on expansion bases (uses high speed serial bus). The module requires a terminal block (IC694TBB032 box style or IC694TBS032 spring clamp style terminal block).

MSI-WEB-25 Web or Excel Reporting Clients 25 Pack

VSPCSE-IMP VisualSPC SE Importer

20BD052A3AYNACD1 PowerFlex 700 AC Drive 52 A 40 Hp 20B

20G11LC2K1AN0NNNNN PowerFlex 755 AC Packaged Drive

22D-E1P7N104 PowerFlex 40P- 0.75 kW (1 HP) AC Drive

140NOC77100 Quantum Quantum Ethernet/IP通訊模板

291D-FAZ-G1 Direct Online Reversing Starte

MY2NJ-CR NEW 220VAC，有阻容吸收回路，2開(kāi)2閉，觸點(diǎn)5A.中國(guó)制

1492-SPM2C630 MCB Supplementary Protector 63 A

軟啟動(dòng)器 3RW30362BB14

電機(jī)啟動(dòng)器 3VU16400CG00

150-F251NCD SMC Flex Smart Motor Controller

1732E-16CFGM12P5QCWR Armor WeldBlock 16 Point Configurable QC

1771-P6R 1771 Power Supply

193-EEEB E1 Plus 5.4-27 A IEC Overload Relay

199-MSMD1 Surge Suppressor

2090-CPWM7DF-08AF04 4 m Length SpeedTec Pwr and Brake Cable

2097-F5 Kinetix 300/350 6.90 A Line EMI Filter

EDS-WK Wall mount kit for EDS series switches

GFK-1533 Manual VersaMax DeviceNet Network Communications

IC220ALG221 Analog Input module, 8 channels, voltage/current. 15bit resolution. Requires 4 out of the 5 IC220TBK062 (5 in a pack) terminal strips.

IC647CGMS35 CIMPLICITY HMI Server GM Site License with 35 Thinview Clients

IC647PRTOSIM Proficy Portal OSI PI Connector (M4 Key)

IC693DSM314 DSM314 motion controller module

IC756ADV001K-98 DV Development - AIX Op Sys Addt'l User, Korean, Version 9.8

MSI-MAINT 5 Day x 9 Hour Support

SLC/1746 System 1746-RT35 TERMINAL BLOCK FOR THE 1746-NR8 MODULE

Distributed I/O 1738-OB8EM12 24VDC 8 SOURCING OUTPUTS WITH M12 CONNECTORS

Communications 2760-SFC1 PROTOCOL CARTRIDGE (RS-232 & RS-422)

Operator Interface 2711-NP3 MOUNTING STUDS PV1400

Support 9302-SCAS SUPT RENEWAL CONTRACT FOR 9302SCA

Support 9324-RL5300ITS SUPT RENEWAL CONTRACT FOR 9324RL5300IT

DeviceNet Products 2706-P44R INVIEW MESSAGE DISPLAY. 1 OR 2 LINE

RSI Software Products 9301-2SE335DEU3R RSVIEW32 RUNTIME 1500-5K UPGRADE OUT-SUPT (DE)

RSI Software Products 9371-DOCXENE RSWIRE DOCX DOCUMENT VIEWER

Motion Control MPG-A025-031M24 MOTOR,SERVO,GEAR RATIO 31,100NM,168RPM,MULTI,BRK

Silver Series 1789-SL5 SOFTLOGIX5 SOFTWARE-BASED PROGRAMMABLE CONTROLLER

HE693RTD600 RTD Input, 6 channel, 3-wire, 0.5癈 res., -100 to +850癈 range (Pt-100)

IC660ELB906 PCIM (XT/AT Interface Board) & S/W Driver (IC641GBE647)

QPICGDE0000 10.4" Color TFT, Ethernet, CF Card, 24VDC, UL, cUL, CE

ST-5272 STXi Serial Interface module RS-485, 2 Channels,32 Bytes,

20BC205A0AYNANA0 PowerFlex 700 AC Drive 20B

20F1ANC140JA0NNNNN PowerFlex 753 AC Packaged Drive

22B-A8P0C104 PowerFlex 40 1.5 kW (2 Hp) AC Drive

140DDI67300 Quantum 開(kāi)關(guān)量 DC 輸入, 24點(diǎn), 125 VDC, 3組隔離

284D-FVD4P0B-N-R-3-DB-EMI Cntl Mod. Variable Frequency Drive

E3S-2E4 2m,對(duì)射型 , 晶體管輸出80mA, 電源:12-24VDC水平安裝

1492-SJS TERM BLCK Side Jumper INSLG Sleeve

人機(jī)界面 6AV6545-0CA10-0AX0 TP270-6 觸摸屏，256 色，5.7 英寸，320? 240

6ES78331FC000YM2

1497B-A14-M15-0-N Control Power Transber

1606-XLS480E-D Power Supply XLS 480 W Power Supply

1769-IF16C CompactLogix 16 Pt A/I Current Module

189-AL20 MCB Accessory Auxiliary Contact

194R-HM1-N1 194R 100-400 A Operating Handle

2090-CPBM7DF-12AA40 MP-Series 40m Power and Brake Cable

2090-XXNPMP-16S25 MP-Series 25 m Length Power Cable

CBL-30-JP-06 AC power cord with 3-prong plug to flying lead. 6 feet

GF-0205 Connecting FlashCable to Fowler Maxcal / Digitrix.

IC200TBX214 Tool box, 14 point, (IC200UDR001) 24VDC In/Relay Out, AC powered (requires AC power), VersaMax SE (IC200SET001) with all software, cables and manuals. (IC640VPS002 and IC646MPM001)

IC646TBSPMPS700 Smart Process Monitoring Process+ server 700 loops