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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(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(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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MTR-3T23-G-R-0-M-S MTR-Series Servo Motor, Resolver, Metric, Seal

SNAP 3C5 PC Port is 9-pin male and port on CNC is 25-pin female. This is for ha rdware handshake communications.

PXIe-8431/8

PCI-6208V

NuPRO-E340

DEXON SYSTEMS LTD DX-702

METEOR2-MC/4 751-0201

D945GSEJT

1492-RAFB424 IEC Term Blck 10 x 110 x 44.8mm Spr Clp

連接器 6ES7492-1AL00-0AA0 48 針前連接器，用于信號(hào)、功能模板，螺釘型

變送器 3RS11011CD40

1497-E-M2-0-N Control Circuit Transber

1606-XL480EPT Power Supply XL 480 W Power Supply

1762-L24BXBR MicroLogix 1200 24 Point Controller

188-K3C500-N Miniature Circuit Breaker 50 A

194L-G3667 Add. Legend Plate For Size 4 Or 6 Bezels

2090-CPBM7DF-04AA90 MP-Series 90 m Length Cable

2090-XXNPMF-10S03 Kinetix Drives 3m Standard Cable

BC647SPR030 "Solution Provider Renewal < 30 keys includes up to 30 key flashes which could be M4 or M1, Global Care Complete (iGC SP1), and one

GC647PRTEE002 GlobalCare Complete - Proficy Portal Enterprise Edition Client Pack 2 Users Ver 3.0

IC200MDL644 Input 5/12VDC POS/NEG logic (4 groups of 8) 32 points

IC646PCMS05 Proficy Change Management Electronic Signature Module 5 Pack

IC647MPS005 Logic Developer PLC Standard 5 Pack with USB Hardware key

IC676PBI008 IP67 Input Block - 24 VDC Positive Logic - 8 Pt - Profibus

IC697PWR711RR Power Supply, 120/240 Vac, 100 Watts

IC800SSI107RS1 7.2 amp 115/230 VAC S2K servo controller for MTR series motors

SLC/1746 System 1747-L30A 30 I/O FIXED HARDWARE STYLE

Industrial Computers 6189-RPEH VVCE LOGIC MODULE, 256MB FLASH, 256MB RAM

Process Control 9399-SAPRG RSBATCH SERVER API REFERENCE GUIDE

Operator Interface 2711-B5A3L1 PV550 MONO KEY&TOUCH, DH485 & RS232 PRINT

Support 9303-3CS0E20S SUPP RENEWAL CNTRCT FOR 9303-3CS0E20

Support 9371-RSWDI1R SUPT REINSTATEMENT CONTRACT FOR 9371RSWDI1

ControlNet Products 2706-P74CN2 INVIEW MESSAGE DISPLAY. 1 TO 4 LINE

RSI Software Products 9301-2SE2500ITU4 RSVIEW32 WORKS 150-100K UPGRADE IN-SUPT (IT)

RSI Software Products 9358-BBKEY10U1R UPGRADE: OUT-SUPT: RSBW BACK-UP KEY 03 TO 10

Motion Control MPL-A4530K-HK24AA MOTOR,SERVO,8.36NM,4000RPM,ENCDR,230V,BRK,11KG

Motion Control 2090-UXPC-D0909 CABLE,9/9 POS,45 DEG D/STRAIGHT D,9M

CBL-3T-RD-30 Resolver Cable for MTR-3T Series Servo Motors, 30 Ft.

IC641HBR302 Max-ON "Extended" Software for 90-30 Hot Stand By Redundancy

IC800SLMCONKITV Connector Kit, 1 kW to 2.5 kW S-Series Servo Motors without Brake

OC647TSSTDB000 Proficy Troubleshooter Connector: Tabular Database Read & Write

PXI-5402

PCE-5B13-08

PDSLA 945G

DSA628/328

HS486VGA

92-506966-XXX

1492-RIFM40D24 Connection Products

軟啟動(dòng)器 3RW30382BB14

軟啟動(dòng)器 3RW44662BC44

運(yùn)行版軟件 6AV2104-3DD04-0AE0 SIMATIC WinCC Runtime Advanced 512 PowerTags V14 Upgrade ： V11..V13 -> V14

1585J-M4TBJM-0M6 RJ45 Ethernet Media

1756-OB16EK ControlLogix 16 Point Digital Output

188-K1B400 Miniature Circuit Breaker 40 A

194E-FA80E-P11 194E Load switch

2090-CFBM7DF-CDAF09 MP-Series 9m Feedback Cable

2090-U5PM-D0909 Ultra 5000 9m Interface Cable

BC646MVSU02 View Standard Edition Upgrade from View for QuickPanel View Standard Edition with Proficy GlobalCare Complete

GC647AUR025 GC Universal Reporting Client 25 pak