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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(jì)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(shì)，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(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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IC320CGM502 ISA CsCAN Interface Board, (2) CsCAN ports

IC800CBL023 B2/3000 & B6/2000 Motor Encoder Feedback Cable, 14 Meters

OC647APS30005 CSense Predictive Soft Sensor 5 KPI's

20AD014A3AYNAEG0 PowerFlex 70 AC Drive 14 A at 10 Hp 20A

20DC085A0EYNANASE PowerFlex 700S AC Drive 85 A 45 kW 20D

20G1AND248AN0NNNNN PowerFlex 755 AC Packaged Drive

25C-D010N114 PowerFlex 527 4kW (5Hp) AC Drive

280-MTR35-M6 ArmorConnect Brake and Motor Cable

FX1N-60MT-D 直流主機(jī)36入/24出?晶體管輸出

1492-M5X10H21-30 Connection Products

1494H-BA3N Heavy Duty Non-Fus Safety Discon Switch

軟啟動(dòng)器 3RW44442BC45

ET 200SP 6ES7135-6FB00-0BA1 AO 2xU 標(biāo)準(zhǔn)型，基座單元類型 A0、A1

1585D-M4TB-10 Micro D-Code, QD Style Ethernet Media

1756-CN2R ControlLogix Communication Module

1794-IV16 Flex 16 Point Digital Input Module

194E-CA20EX-6 194E Load switch

2080-REMLCD Micro800 Remote LCD Display

2090-CTHP8 Kinetix 6000M Hybrid Terminator

20AC5P0A3AYNAEG0 PowerFlex 70 AC Drive 5 A at 2.2 kW 20A

GC646MRC700 Proficy GlobalCare Complete for Logic PC & View Runtime 700 I/O

HE693STP310 Discontinued Part. Check with GE IP on migration path.

IC630CCM300RR Series Three Data Communications Module (DCM)

IC647HSTSS20KM-35 Historian v3.5 Standard Server 20000 Points (M4 Key)

IC660BBS102 Block 115Vac/125Vdc Low Leak Isol I/O, w/Failed Sw Diag, 8 Ckt

IC695ALG508CA Conformal Coated RX3i Isolated RTD Input module provides eight isolated differential RTD input channels. Each channel can be individually configured for 2, 3, 4 wire RTD or Resistance. Requires high capacity terminal block IC694TBB032 or IC694TBS032

IC756WDS000K-23 Dataviews Development Suite (All Windows Languages, Custom Editor Tool kit, Custom Datasource Toolkit, 1 yr SAFE), Korean, Version 2.3

CompactLogix System 1769-OW16 16 PT.AC/DC RELAY OUTPUT

PLC-5/1771 System 9399-CCDUG CONTROLGUARDIAN DETECTOR5 USERS GUIDE

Distributed I/O 1799-D16U16B 24VDC 32 POINT SOURCE OUT I/O BOARD

Operator Interface 2711P-K6M8D PV PLUS 600 GRAYSCALE, KEYPAD, DH+, DC PS

Support 9325-PI140R SUPT REINSTATEMENT CONTRACT FOR 9325PI140

Support 9358-PBEPB10S SUPT RENEWAL CONTRACT FOR 9358PBEPB10ENE

Support F1779-KFLRSERA FIRMWARE UPGRADE FOR 1779-KFLR COMMUNICATION MODUL

RSI Software Products 9301-2SE2100ITE RSVIEW32 WORKS 150 (ITALIAN)

RSI Software Products 9701-VWMR030FRU1 RSVIEW ME STATION RT 15 TO 30 DISP UPGRADE(FRENCH)

RSI Software Products 9361-PTL10USR RSPORTAL PER CONNECTION LICENSE FOR 10 CONNECTIONS

Motion Control 2098-DSD-010X DRIVE, 5.0A/15A,ULTRA 3000

A06B-6114-K230#E Connector Kit, BM Servo Motor Power

IC200UEX222 28 point expansion. (16) 24VDC In, (12) 24VDC Out with ESCP, 24VDC Power Supply (includes IC200CBL501)

IC752CTD550 Display Station - 10.4" active matrix VGA (640x480) resistive touch screen, Pentium 133, 32M, 2 Gig hard drive, expansion slots, Ethernet, with CIMPLCITY HMI and Win NT

MTR-3N33-G-R-0-N-SRR Servo Motor Nema34 with Seal

ZA06B-0239-B500 Alpha 12/4000HVis servo motor with straight shaft with key and brake

20BD8P0A3AYNAND0 PowerFlex 700 AC Drive 8 A 5 Hp 20B

20G14ND077AA0NNNNN PowerFlex 755 AC Packaged Drive

25-PM2-D024 PowerFlex 520 11kW (15Hp) Power Module

Safety Quantum系統(tǒng)

FRN1.5C1S-7C 3. 0KVA 8.0A 1.5KW 單相AC220V/50Hz/60Hz

1492-J4-RE 4 square mm Feed-Through Terminal Block

1492-SPM3D300-N MCB Supplementary Protector 30 A

軟啟動(dòng)器 3RW40556BB45

配件 6ES7 297-0AX30-0XA0 S7-1200 電池板

150-TC3 SMC-50 IEC Line Or Load Terminal Covers

1738-IV8M12 ArmorPoint 8 Point Digital Input Module

1784-PKTX Data Highway Plus PC Card

193-NCRID E1 Plus Remote Indication Display

20-750-PUB-IN1-EN PowerFlex 750 Series Install Publication

2090-CSBM1DE-14AF01 Kinetix Cable Single DSL 2090-Series

20AB6P8A0AYNNEC0 PowerFlex 70 AC Drive 6.8 A at 2 Hp 20A

GA647IFPRRN00300 GCA iFIX Profsnl SCADA 300 I/O Run

GP647IFESGRNUNLMT GCP iFIX Optn: ESig & ERec Unl I/O Run

IC600BF907RR 12Vdc Source Output Module (8 points)

IC647HSTCR1250KM Collector Redundancy Option for Historian - Standard Server 1,250,000 Points (M4 Key)

IC647TMS001 CIMPLCTY UPGRADE INTEL- NO COST

IC693PCM300LT Prog. Coproc. Mdl., 160 KB (35 KB Basic Prgm), w/Port Exp. Cbl. (LT)

IC756LDV010J-99 DV Draw Development on Intel/Linux RedHat Op Sys, Japanese, Version 9. 9

MicroLogix 1000/1761 System 1761-L16NWA MICROLOGIX 1000 16PT. WITH 24V AC INPUTS AC POWER

PLC-5/1771 System 1771-SIM 8 POINT DISCRETE INPUT/OUTPUT SIMULATOR MODULE

Distributed I/O 1792D-12BVT4D 12 SINK/SOURCE INPUTS, 4 SOURCING 0.5 AMP OUTPUTS

Communications 1788-MCHKR NETWORK MEDIACHECKER (ENET, CNET, DNET, DH+/RIO)

Operator Interface D1784-6.5.6 T35 PLANT FLOOR TERMINAL (1784-T35) USER'S MANUAL

Support 9356-PRO2500S SUPT RENEWAL CONTRACT FOR 9356PRO2500