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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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Industrial Computers 6189V-DIMM512 DIMM MEMORY 512MB

Application-specific products 1403-DMB DISPLAY UNIT FOR POWERMONITOR

Operator Interface 2711-K6C15 PV600 COLOR KEY, CNET & RS232 PRINT

Support 9301-2SE2500DER SUPT REINSTATEMENT CONTRACT FOR 93012SE2500DE

Support 9323-P1003ENS SUPT RENEWAL CONTRACT FOR 9323P1003EN

DeviceNet Products 1734-OW4 24V DC COIL N.O. DPST 4 RELAY MODULE

RSI Software Products 9301-2SE3103DEE RSVIEW32 RUNTIME 150 WITH RSLINX (GERMAN)

RSI Software Products 9358-BNTK60U3R UPGRADE: OUT-SUPT: RSBATCH BACK-UP KEY 30 TO 60

Motion Control MPL-B420P-RJ24AA MOTOR,SERVO,4.74 NM,5000RPM,RSLVR,460V,BRK,7.7KG

Motion Control 2090-UXBK-D1515 BREAKOUT BOARD KIT,MTR FDBK,CN2,ULTRA X000,15M

GFK-0825 Field Control Distributed I/O and Control System Genius Field Processor User's Manual

IC646MDB000 Logic Developer PC w/Runtime 8,000 I/O

MSDIS-1200 Marathon 12" Display, Touch

PSPC-MONITOR25/E Prof Shop Floor SPC Monitor 25 User eSig

PXIe-2575

OMRON XM2C-0912

C79040-A6420-C849-03-85

PCLTA-20

MATROX METEOR2/4 750-03

PCM-9371

1492-NM16 TERM BLCK End Barrier

前連接器 6ES7392-1AJ00-0AA0 20 針前連接器，螺釘型

變送器 3RS18001HP00

TIA 博途 WinCC 選件 6AV2107-2LK00-0BD0 SIMATIC WinCC DataMonitor for Runtime Professional Powerpack 25 -> 50 Clients

1585J-M8PBJM-1X 1585J Ethernet Media Cables

1760-L18AWA-EXND Pico 18 Point AC Controller

188-K2C400 Miniature Circuit Breaker 40 A

194L-E12-1752 12A 194L Load Switch

2090-CNSRPRS-AAP5 Kinetix 6000M Network Cable

2090-XNRBM-2 RBM CONN SPARE PARTS KIT (75A)

BC647MRC000 Logic PC and View Runtime 8000 I/O with Proficy GlobalCare Complete with USB Hardware key

GC647IPWRPLDV00300M iPower Option - Nwk 300 I/O Dev Globalcare Complete part

IC200DEM004 VersaMax MicroMotion and VersaMotion Simulator is prewired and ready to use. The simulator includes a IC200UMM102 MicroMotion Module, Serial Port on VersaMotion Motor, Amplifier, communications cable (1meter)from VersaMotion to Micro, programming ca

IC646NDF000 Allen-Bradley DF1 Communications

IC647IFUBSTSC iFIX iClientTS User Base Support (M1Component Part)

IC670MDL241 240VAC Input, 16 Point, 2 Groups of 8

IC697MDL250RR 120 Vac Input (32 Points)

IC800SLCBZ050 Brake cable for any 30 Watt to 750 Watt S-series servo motor with brake. 5 meters

ControlLogix/1756 System 1756-DMCF010 10 M DUPLEX FIBER OPTIC CABLE FOR DRIVE MODULE

Industrial Computers 6182H-12KEH4B VVCE 1250, KEYPAD, EXT MEM, ENET, AC

Process Control 1757-PFBEXP080 PROFIBUS INTERFACE MODULE EXPANSION

Operator Interface 2711P-RR128 PVP/VVCE RAM SO-DIMM 128MB

Support 9357-ANETMDAD3S SUPT RENEWAL CONTRACT FOR 9357ANETMDAD3E

Support 9361-POWERTOOLSR SUPT REINSTATEMENT CONTRACT FOR 9361POWERTOOLS

ControlNet Products 1734-OB8E 24V DC8 CHANNEL SOURCE OUTPUT MODULE

RSI Software Products 9301-2SE2400U5R UPGRADE: OUT-SUPT: RSVIEW32 WORKS 5000 TO 32000

RSI Software Products 9357-ENETMDAD3E RSNETWORX MD ENET ADD-ON

Motion Control MPL-A420P-MJ24AA MOTOR,SERVO,4.74 NM,5000RPM,MULTI,230V,BRK,6.8KG

Motion Control 2090-UXNFBN-K09 CABLE,ULTRA, NON-FLEX,SKWD,R/A,9M

CBL-13-ET-30 MTR-1300 and MTR-1N Series Stepping Motor Encoder Feedback Cable, 30 Ft.