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IC693MDL646

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激光制造業亟需組建優秀的激光加工團隊，大力普及激光加工技術，設立激光加工教學、科研和生產基地，加大相關技術同步研究，將機器人技術、仿真技術應用等大規模地應用到城市軌道車輛制造中，發展我國自主特色的激光加工設備以及加工工藝。激光加工技術在城市軌道車輛制造中的應用，包括焊接、切割、表面改性、打標、快速成型、打孔及微細加工等。文章以城市軌道車輛為研究對象，闡述了先進激光焊接、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在城市軌道車輛制造中的特點和應用前景，為縮短與國外先進技術的差距，加快軌道交通技術儲備提供參考。

城市軌道交通已成為現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、準點率高等優勢。中國如今已成為全球城市軌道交通建設投入的主力軍，甚至連許多二線城市都具備了軌道交通建設的條件與需求。
隨著中國政府“十三五”規劃的提出，國家發改委已批復了多地軌道交通的規劃，到2020年投資預計將超萬億。目前城市軌道車輛制造行業中，激光加工制造技術備受矚目，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技術的差距，應引進、研究和消化當前最新技術及設計思路，加快軌道交通技術儲備，探究激光加工技術在城市軌道車輛制造中的應用。車輛激光焊接車輛轉向架以及車體是城市軌道車輛上的關鍵構成，材質也經歷了普通合金鋼、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，區別于電阻滾壓縫焊，通過自由組合，使得構件變輕，零件變少，不僅提高可靠性，為寬體車制造奠定基礎，同時也改善了焊接質量，提高了鋼材收得率，并降低了生產成本。

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件，焊接成白車身分總成，進而總裝成整車車身。激光組焊因其焊接強度高，可明顯改善車身強度、剛度及密閉性。焊接同時結合面小、變形小、焊接速度快、可焊材料范圍廣，適合于柔性化生產，投資效益好。但激光組焊技術也有明顯的缺點，如對夾具、被焊件、監測精度等要求嚴格，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重，因此為改善外觀，過去常常進行涂裝作業，而現在則選用激光或電阻焊進行作業。

通過長期加工技術應用的實踐、積累及分析，不銹鋼接頭焊接技術規范、疲勞曲線、硬度、抗拉強度、屈服強度、等技術指標相繼被取得或檢驗，車體激光焊接樣件的制評亦完成。


2) 車輛轉向架制造。城市軌道車輛轉向架通常選用日本進口或國產的中厚合金鋼板材，同時多選用熔化極氣體保護焊。用于長直縫焊接的機械人手臂，已被各廠商所引進，來改善焊接穩定性；而開具有不同規格的坡口，通常留較小鈍邊，以確保熔透。激光-電弧復合焊優化焊接效率，顯示了激光和電弧的特點；同時減少了設備和人員投入，降低了焊接成本，并且可選較大鈍邊。


車輛激光切割

激光切割技術特性城市軌道車輛制造廠商已大量使用激光切割技術，其加工的產品有很多，如車體、內裝板材、轉向架，常選用二維平面切割。激光可以加工出高精度、高切割斷面質量的零件外形、輪廓和孔。

固體(或CO2)激光切割機通常適用于碳合金鋼、不銹鋼，同時也適用于鋁合金板，可達到理想斷面加工質量和切割速度。以某企業為例，軌道車輛車體為不銹鋼，選用6 k W激光和剪板機對6 mm以下板材下料。車輛轉向架選用激光切割機對14 mm以下板材進行下料，其材料為Q345C低合金結構鋼。

下料環節激光切割

城市地鐵機車制造首先要準備相關材料，這個階段激光切割技術尤為重要。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、節料省錢、經濟適用[16]，因此激光切割技術已被廣泛用于軌道車輛制造中。以某企業為例，其高速動車組車體選用激光和剪板機對6 mm以下板材下料，材料為鋁合金板材及型材。車輛轉向架選用6 k W激光切割機對12 mm以下板材下料[17]。

 

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Application-specific products 9323-1003ENE RSTUNE

Operator Interface 2711-B5A5L2 PV550 MONO KEY&TOUCH, RS232 (DH485)

Support 9303-3CS0E40S SUPP RENEWAL CNTRCT FOR 9303-3CS0E40

Support 9371-WIREBLDS SUPT RENEWAL CONTRACT FOR 9371WIREBLDE

ControlNet Products 2706-PCNETP CONTROLNET COMMUNICATION MODULE FOR 2706-P22R

RSI Software Products 9301-2SE2500JPU3 RSVIEW32 WORKS 300-100K UPGRADE IN-SUPT (JP)

RSI Software Products 9358-BBKEY60U1R UPGRADE: OUT-SUPT: RSBW BACK-UP KEY 03 TO 60

Motion Control MPL-A4530K-SJ22AA MOTOR,SERVO,8.36 NM,4000RPM,SINGL,230V,8.2KG

Motion Control 2090-XXNFMP-S03 CABLE,NON-FLEX,MOTOR FEEDBACK,MP/1326AB,3M

CBL-H1IC-06 Serial Cable, S2K, IMC & Target ARS RS-232 Communication, 6 Ft.

IC641LIC306 LM 90-30/20/Micro Serial Software, 10-Pack + 1 InfoLink CD-ROM

IC800SLMCONKITZB Connector Kit, 30 to 750 Watt S-Series Servo Motor with Brake

OIP-73005774 Operator Interface Panel with special membrane for CTM

20B-ENC-2 PowerFlex 700 Encoder Interface Kit

20DD385A3ENNBNANE PowerFlex 700S AC Drive 20D

20SD1K0NES PowerFlex SCR Bus Supply

2711P-B6C5D8 PanelView Plus 6 Graphic Terminal

280-PWRM35B-M15 ArmorConnect 3-PH Power Media trnk cable

CPM1A-8ET 8點擴展 晶體管輸出單元.漏型

1492-MR5X8 IEC 5 x 8 mm Marker Card

1494V-RA4 Kit Connecting Rod

軟啟動器 3RW44666BC34

運行版軟件 6AV2104-4DD04-0AE0 SIMATIC WinCC Runtime Advanced V14 Upgrade ： WinCC flexible 2008 Runtime 512 PowerTags -> WinCC Runtime Advanced 512 PowerTags V14

1585J-M4TBJM-1M5 RJ45 Ethernet Media

1756-OB16IS ControlLogix 16 Point D/O Module

188-K1B630-N Miniature Circuit Breaker 63 A

194E-G3663M Metric Abs Enclosure

2090-CFBM7DF-CDAF30 MP-Series 30m Feedback Cable

2090-UCSR-P900 Shunt Resistor

BC646OEM0200 OEM Edge - CIMPLICITY HMI Kit (Approval Required)

GC647DMC003 GC DataMart 3 Reporting Clients

IC200ALG230LT ANALOG INPUT 12 BIT VOLTAGE/CURRENT 4CH (LT)

IC646CSPWR-43 Proficy Cause+ Web Report User

IC647IFPLSR00300C iFIX Plus SCADA 300 I/O Server (M1Component Part)

IC660MLD022 Label for IC660BBD022 (Qty 100)

IC697BEM713 Bus Transmitter (Also Provides Parallel Programming Port)

IC800ABK001 Panel mounted encoder battery kit for Alpha HVi amplifiers