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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(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(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(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(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(guò)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(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(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(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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EtherNet/IP Products 2711P-K6M20A PV PLUS 600 GRAYSCALE, KEYPAD, ETHERNET, AC PS

RSI Software Products 9301-2SE340FRU3R RSVIEW32 RUNTIME 150-32K UPGRADE OUT-SUPT (FR)

RSI Software Products 9356-PRO2300U5 UPGRADE: IN-SUPT: RSSQL PROF.150 TO 1500 TAG

Motion Control 1326AB-B740C-M2K7L MOTOR,SERVO,460V,53.0NM,2200RPM,MULTI,BRK,IP67

4162-L-2 4162 CONTINUOUS LENS KIT. FOR (2) 4162s

HMI-KPN-201/B QUICKPANEL KEYPAD FOR 5" & 6" BLANK

IC693CPU352LT CPU 352 Module (240K Bytes configurable user memory, 4K I/O, 8 Racks, Hardware FLOATING POINT MATH), two built-in Serial Ports .22msec/K (LT)

SPS-120W 24 VDC PS, 5.0A, 85-265 VAC Input

TRM-21006691 9 point screw terminal AC power connector for S2K stepper controller

20BD011A3NYNACD0 PowerFlex 700 AC Drive 20B

20G11BC1K6JN0NNNNN PowerFlex 755 AC Packaged Drive

22B-V6P0C104 PowerFlex 40 1.1 kW (1.5 Hp) AC Drive

140XBP00300 Quantum 背板, 3槽

284R-360P500-M05 360 Ohm Dynamic Brake Resistor

面板安裝，觸點(diǎn):5A

1492-SPM1D020-N MCB Supplementary Protector 2 A

通用型變頻器 6SE6 440-2UC31-5DA1 "15 KW,275 x 520 x 245"

電機(jī)啟動(dòng)器 3VU13403MD00

150-C317NBD SMC-3 317A Smart Motor Controller

1609-EXBAT External Battery Housing

1770-XYV PLC-5 Battery

193-EC1JG E3 84-420 A Overload Relay

195-GL01 Auxiliary Contact Block, Side Mounting

2090-CPBM7E7-14AF07 MP-Series 7 m Length Pwr and Brake Cable

2093-PRS4 Kinetix 2000 4 Axis Slim Power Rail

CP9B-0WPB-0140-AZ Power cable for B2/4000is or B4/4000is motors. 14 meters

GFK-0255 Series 90 Programmable Coprocessor Module & Support Software User's Manual

IC200UEX211-24 Qty of 24, 28 point expansion. (16) 24VDC In, (12) Relay Out, 120V/24 0AC Power Supply (includes IC200CBL501)

IC647AMK0441 PA Media Kit v4.4.1

IC647PCMSCH Proficy Change Management Scheduler

IC693CHS392 Base, Expansion, 10 Slots

IC754CKL06MTD Starter Kit 6 In Mono Ctrl Loaded 24 VDCVDC

KIT-GFS-350 QP View & Control Workshop Student Kit

SLC/1746 System D1746-6.7 SLC 500 RTD/RESISTANCE INPUT MOD USER MANUAL

Distributed I/O 1732P-OB8EM8 PROFIBUS 24VDC 8 0.5A OUTPUT W/M8

Application-specific products 1404-M805B-RIO-02 MASTER MODULE-PQ RIO COM-24V P/S-CLASS 0.2

Operator Interface 2711-T10C16 PV1000 COLOR TOUCH, DF1 & RS232 PRINT

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Support 9381-PA2500ENR SUPT REINSTATEMENT CONTRACT FOR 9381PA2500EN

DeviceNet Products 1790D-0V16 DNET LDX I/O, 24VDC, 16 SINK OUT BASE, D-SHELL

RSI Software Products 9301-2SE3303ESE RSVIEW32 RUNTIME 1500 WITH RSLINX (SPANISH)

RSI Software Products 9358-PBA60ENE RSBIZWARE BATCH FOR PROCESSLOGIX ARCHIVER 60 UNITS

Motion Control MPL-B540K-MK24AA MOTOR,SERVO,19.4NM,4000RPM,MULTI,460V,BRK,19.1KG

Motion Control 9101-1779 CABLE, ADAPTOR,50 POS, PCB TO J1 D PLUG

GQPK-DEM-L02 QUICKPANEL JR DEMO 6" MONO LCD GE LABEL

IC646MRE300 Logic PC & View (HRT) 300 Tag Runtime System

MTR-3T43-J-R-0-M-0 MTR-Series Servo Motor, Resolver, Metric

ST-1114 STXi input module 4 points, Positive Logic, 5VDC

20BC072A3AYNACC0 PowerFlex 700 AC Drive 72 A 37 kW 20B

20F11RC015AA0NNNNN PowerFlex 753 AC Packaged Drive

22A-A1P4N113 PowerFlex 4- 0.2 kW (0.25 HP) AC Drive

140CPU65150C Quantum CC QUANTUM PROCESS- UNITY W/ 1024/7

281E-F23Z-25D-CR-3FR ArmorStart Direct Online RVSG Starter

C200H-DA001 模出單元,2路12位?D/A 4-20mA/1-5V/0-10V 可選

1492-RCDA2A40 Residual Current Device 40 A

存儲(chǔ)卡 6ES7952-0KF00-0AA0 FEPROM 存儲(chǔ)卡， 64K

變送器 3RS11202DD20

1497-F-M4-0-N Control Circuit Transformer

1606-XL960E-3S Power Supply XL 960 W Power Supply

1762-MM1RTC MicroLogix 1200 with RTC Memory Module

188-K3D020-N Miniature Circuit Breaker 2 A

194L-HC4A-825 Actuator For Control Switch

2090-CPBM7DF-06AA15 MP-Series 15m Power and Brake Cable

2090-XXNPMF-10S25 Kinetix Drives 25m Standard Cable

BC647TPD075 CIMPLICITY HMI ProServer 75 I/O Development and Runtime System with Proficy GlobalCare

GC647PRTHE010 GlobalCare Complete - Proficy Portal Historian Edition Client Pack 10 Users Ver 3.0

IC200MDL740LT OUTPUT 12/24VDC POS LOGIC 0.5A PER PT (1 GROUP OF 16) 16PT (LT)

IC646PCN110 OpenProcess Operator Console (700 I/O)

IC647MRA150 View Runtime 150 I/O with USB Hardware key

IC677CBLY006 IP67 Sensor/actuator cable, 3-pos., PUR halogen-free black, straight M12 Y-socket, on 2x angled M12 connector, cable length: 0.6 meters

IC697PWR732RR Replacement Power Supply, 125 Vdc, 60 Watts

IC800SSI216RD2 16 amp 230 VAC Devicenet S2K servo controller for MTR series motors

SLC/1746 System 1747-L511 SLC 5/01 CONTROLLER, 1K MEMORY - DH 485

Industrial Computers 6189-RW2 VVCE COMPACT FLASH 128MB W/ME

Application-specific products 9358-PB30ENE RSBIZWARE BATCH FOR PROCESSLOGIX 30 UNITS

Operator Interface 2711-B5A8L1 PV550 MONO KEY&TOUCH, DH+ & RS232 PRINT

Support 9303-3CS0E80S SUPP RENEWAL CNTRCT FOR 9303-3CS0E80