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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，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，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脈，具有運(yùn)量大、能耗低、效率高、污染小、準(zhǔn)點率高等優(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)計思路，加快軌道交通技術(shù)儲備，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，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，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；同時減少了設(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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ControlNet Products 2711P-K10C15B1 PV PLUS 1000, KEYPAD, CNET, AC PS, STD MEM

RSI Software Products 9301-2SE2500U4 UPGRADE: IN-SUPT: RSVIEW32 WORKS 150 TO 100K

RSI Software Products 9358-BEPB60U2R UPGRADE: OUT-SUPT: RSBW BATCH & EPROCEDURE 10 TO60

Motion Control MPL-A4540F-MJ24AA MOTOR,SERVO,10.2 NM,3000RPM,MULTI,230V,BRK,13KG

Motion Control 2090-XXNFY-S20 CABLE,NON-FLEX,MOTOR FEEDBACK,Y,20M

GABI31200C2P/SE QUICKPANEL 10.5" TFT W/SE GE LABEL

IC641SWC301 LM 90-30/20/Micro Software, 3.5"/5.25" disks + CD-ROM docs.

IC800SSI104RS1 4.3A, 115/230V, S2K Servo Controller for MTR Series Motors

PROFICY-SW Proficy Software Billing Only

20BB028A0AYNBNC0 PowerFlex 700 AC Drive 28 A at 10 Hp 20B

20DE011A0EYNANANE PowerFlex 700S AC Drive 20D

2198-5700-CLAMPSPACER Kinetix 5700 Cable Clamp Spacer

2711P-K12C4D9 PanelView Plus Terminal

280-PWRM35D-M12 ArmorStart Three-Phase Power Media

CPM2A-40CDT-D 40點主機(jī) DC24V 24點入16點晶體管輸出 自帶RS232C口

1492-MS5X9H21-30 Connection Products

1495-N72 1 in. Hub

行程開關(guān) 3SE53120SH11

運(yùn)行版軟件 6AV2105-0RA14-0AA0 SIMATIC WinCC Runtime 專業(yè)版 153600 PowerTags ASIA V14

1585J-M4UBJM-2 RJ45 Ethernet Media

1756-OW16IK ControlLogix 16 Point Digital Output Rel

188-K1C160-N Miniature Circuit Breaker 16 A

194E-KA20 194E Load switch

2090-CFBM7DF-CEAA90 MP-Series 90m Servo Feedback Cable

2090-UXLF-HV350 Ultra Series 50A AC Line Filter

BC646SPD365 Solution Provider Batch Key

GC647IFCLNTSRO025 GCC iFIX iClientTS Read Only 50 PK Runtime Version

IC200ALG326 Analog Output, 13 Bit Current, 8 Channel

IC646MBPS99 Machine Edition Professional Development Suite with Unlimited Seat Site License

IC647IFPRDVUNLMTC iFIX Profsnl SCADA Unlimited Development (M1Component Part)

IC660SLA106 Red Safety Label Kit for IC660BBA106 Genius Blocks

IC697CGR935 Hot Standby Genius Dual Bus CPU, 486DX4, 12K Discrete I/O, 1M fixed us er memory, Floating Pt.

IC800CBL023 Encoder cable for B2/3000 or B6/2000 motor. 14 meters

ControlLogix/1756 System 1756-M23 LOGIX5555 1.5MBYTE NONVOLATILE MEMORY

Industrial Computers 6182H-7KEH6D VVCE 700, KEYPAD, EXT MEM, RIO/DH, DC

Process Control 9358-PBANT10ENE RSBATCH NT FOR PROCESSLOGIX ARCHIVER 10 UNITS

Operator Interface 2711P-T15C15B1 PV PLUS 1500, TOUCH, CNET, AC PS, STD MEM

Support 9352-WDN100S SUPT RENEWAL CONTRACT FOR 9352WDN100

Support 9324-RSECSENS SUPT RENEWAL CONTRACT FOR 9324RSECSEN

ControlNet Products 1786-BNC2TNC CONTROLNET BNC-TNC COAXIAL CONN - ISOL BULKHEAD

RSI Software Products 9301-2SE235DEU1R RSVIEW32 WORKS 150-5K UPGRADE OUT-SUPT (DE)

RSI Software Products 9352-WABGW WINTELLIGENT LINX GATEWAY

RSI Software Products 9399-WVDUG WINTELLIGENT VIEW USER GUIDE

Motion Control 2090-DANBT-18S01 CABLE, NON-FLEX, MTR BRK FOR CABLE-MTD CONNS, 01M

BC646MVSU02 View Standard Edition with SAFE - Upgrade from View for QuickPanel View Standard Edition

IC300TRM008 Spring-clamp style I/O plug, 8-terminal

IC800APK080 80 Amp Alpha Series Amplifier Package

MTR-3T69-G-R-0-M-0 MTR series metric servo motor with resolver

20AD011A3NYYAEG0 PowerFlex 70 AC Drive 11 A at 7.5 Hp 20A

20DC043A3NYNACGNE PowerFlex 700S AC Drive 20D

20G1ANC456AN0NNNNN PowerFlex 755 AC Packaged Drive

25C-B024N104 PowerFlex 527 5.5kW (7.5Hp) AC Drive

280-MTR22-M20 ArmorConnect Brake and Motor Cable

FR-F740-S220K 330KVA 432A 220KW 3相AC380V/50Hz/60Hz

1492-LS2-BR IEC Sensor Blck 5.1x68x38.5mm Spr Clp

1494G-EF3N-420 NEMA 1494G Enclosed Disconnect

軟啟動器 3RW44436BC34

ET 200SP 6ES7134-6HB00-0CA1 AI 2xU/I 2/4 線制 高性能型，基座單元類型 A0、A1

1585D-M4HBDM-10 Micro D-Code, QD Style Ethernet Media

1756-A7K ControlLogix 7 Slot Chassis

1794-IJ2 Flex 2 Point Input Frequency Module

194E-CA16-P11 194E Load switch

2080-LC50-48QWB Micro850 48 I/O EtherNet/IP Controller

2090-CSWM1DF-18AA18 Kinetix Cable Single DSL 2090-Series

20AC5P0A0AYNANC0 PowerFlex 70 AC Drive 5 A at 2.2 kW 20A

GC646MRB150 Proficy GlobalCare Complete for Logic PC Runtime 150 I/O

HE693STG883 8 channel +/-20mV, +/-25mV, +/-30mV strain gage input module for Serie s 90-30 with 16-bit resolution and weighing functions.

IC610MDL176RR 115/230Vac Isolated Output Module (4 points)