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USM560-002W-1,

USM560-002W-1

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激光制造业亟需组建优秀的激光加工团队，大力普及激光加工技术，设立激光加工教学、科研和生产基地，加大相关技术同步研究，将机器人技术、仿真技术应用等大规模地应用到城市轨道车辆制造中，发展我国自主特色的激光加工设备以及加工工艺。激光加工技术在城市轨道车辆制造中的应用，包括焊接、切割、表面改性、打标、快速成型、打孔及微细加工等。文章以城市轨道车辆为研究对象，阐述了先进激光焊接、激光切割在城市轨道车辆制造和轮轨表面处理等的原理和特点，分析了目前激光加工技术在城市轨道车辆制造中的特点和应用前景，为缩短与国外先进技术的差距，加快轨道交通技术储备提供参考。

城市轨道交通已成为现代城市公共交通的主动脉，具有运量大、能耗低、效率高、污染小、准点率高等优势。中国如今已成为全球城市轨道交通建设投入的主力军，甚至连许多二线城市都具备了轨道交通建设的条件与需求。
随着中国政府“十三五”规划的提出，国家发改委已批复了多地轨道交通的规划，到2020年投资预计将超万亿。目前城市轨道车辆制造行业中，激光加工制造技术备受瞩目，其很大程度上提升了城市轨道车辆制造水平；轻量化与高速化的趋势，也持续为其提出新方向、新课题。

由于中国的城市轨道交通起步较晚，因此为了缩短与国外先进技术的差距，应引进、研究和消化当前最新技术及设计思路，加快轨道交通技术储备，探究激光加工技术在城市轨道车辆制造中的应用。车辆激光焊接车辆转向架以及车体是城市轨道车辆上的关键构成，材质也经历了普通合金钢、不锈钢、铝合金型材几个阶段。目前在城市轨道车辆制造中，逐步引入了激光焊接等新的加工工艺。

激光拼焊

激光拼焊是城市轨道车辆中最被看好的技术之一，属于无接触焊接，可将不同钢种、厚度、表面处理的钢板焊接成一个整体，区别于电阻滚压缝焊，通过自由组合，使得构件变轻，零件变少，不仅提高可靠性，为宽体车制造奠定基础，同时也改善了焊接质量，提高了钢材收得率，并降低了生产成本。

激光组焊

激光组焊在城市轨道车辆车身制造中举足轻重，通过双件组焊、多件组焊，将已切割成形的各类车身构件，焊接成白车身分总成，进而总装成整车车身。激光组焊因其焊接强度高，可明显改善车身强度、刚度及密闭性。焊接同时结合面小、变形小、焊接速度快、可焊材料范围广，适合于柔性化生产，投资效益好。但激光组焊技术也有明显的缺点，如对夹具、被焊件、监测精度等要求严格，焊接后检测评价和返修困难，一次性投入大等。

激光-电弧复合焊

1) 不锈钢车体制造。城市轨道车辆车体通常选用不锈钢车体，由于电弧焊接后热影响及变形等较严重，因此为改善外观，过去常常进行涂装作业，而现在则选用激光或电阻焊进行作业。

通过长期加工技术应用的实践、积累及分析，不锈钢接头焊接技术规范、疲劳曲线、硬度、抗拉强度、屈服强度、等技术指标相继被取得或检验，车体激光焊接样件的制评亦完成。


2) 车辆转向架制造。城市轨道车辆转向架通常选用日本进口或国产的中厚合金钢板材，同时多选用熔化极气体保护焊。用于长直缝焊接的机械人手臂，已被各厂商所引进，来改善焊接稳定性；而开具有不同规格的坡口，通常留较小钝边，以确保熔透。激光-电弧复合焊优化焊接效率，显示了激光和电弧的特点；同时减少了设备和人员投入，降低了焊接成本，并且可选较大钝边。


车辆激光切割

激光切割技术特性城市轨道车辆制造厂商已大量使用激光切割技术，其加工的产品有很多，如车体、内装板材、转向架，常选用二维平面切割。激光可以加工出高精度、高切割断面质量的零件外形、轮廓和孔。

固体(或CO2)激光切割机通常适用于碳合金钢、不锈钢，同时也适用于铝合金板，可达到理想断面加工质量和切割速度。以某企业为例，轨道车辆车体为不锈钢，选用6 k W激光和剪板机对6 mm以下板材下料。车辆转向架选用激光切割机对14 mm以下板材进行下料，其材料为Q345C低合金结构钢。

下料环节激光切割

城市地铁机车制造首先要准备相关材料，这个阶段激光切割技术尤为重要。激光切割与火焰切割相比，切割速度快、工件变形小、加工精度高、适用性强、节料省钱、经济适用[16]，因此激光切割技术已被广泛用于轨道车辆制造中。以某企业为例，其高速动车组车体选用激光和剪板机对6 mm以下板材下料，材料为铝合金板材及型材。车辆转向架选用6 k W激光切割机对12 mm以下板材下料[17]。

 

IC800SKCEZ100 Encoder Cable, S2K to 200-750W S-Series Servo Motors, 10 Meters

MTR-3T57-H-R-B-M-0RR Servo Motor Metric 24V Brake

ZA06B-0273-B200 Alpha 40/4000HVis servo motor with straight shaft and key

20BC3P5A0AYNANC0 PowerFlex 700 AC Drive 20B

20G14NF119JA0NNNNN PowerFlex 755 AC Packaged Drive

22B-D4P0N204 PowerFlex 40 1.5 kW (2 Hp) AC Drive

2711P-T6C5A8 PanelView Plus 6 6 Clr Touch AC RS232

29108-505-09-R SCREW,CAP,HEX,HEX,M12x1.75,44,

MPTST-VER4.0-C 支持软件

1492-MCEA215 15 A UL489 Miniature Circuit Breaker

1494V-FS30 Fuse Block

软启动器 3RW44652BC35

运行版软件 6AV2104-0DA04-0AA0 SIMATIC WinCC Runtime Advanced 512 PowerTags V14

1585J-M4EBJM-15 RJ45 Ethernet Media

1756-N2XT ControlLogix XT Empty Slot Filler

188-K1B100-N Miniature Circuit Breaker 10 A

194E-FA40EX-PE-TN 194E Load switch

2090-CFBM7DD-CEAF30 Kinetix 30m Flexible Cable

2090-U3BK-D4401 Ultra 3000 Breakout Board Kit

BC646MRC000 Logic PC and View Runtime 8000 I/O with Proficy GlobalCare Complete

GC647ASC010 GC SDK 10 Pak

IC200ACC202 Expansion terminator, quantity 2

IC646CGMV00 CIMP Viewer GM Site License (SW Key)

IC647IFPLRN00300C iFIX Plus SCADA 300 I/O Runtime (M1Component Part)

IC660MKS511 Hand-Held Monitor Spare Key (Qty 10)

IC697ADS701 CIMPLICITY 90-ADS Package (First System)

IC756XRT049 Intel x86 DV Tools Runtime 10-49, Per User

FlexLogix System 1794-TBNK CONFORMALLY COATED, NEMA TERMINAL BASE

GuardPLC Systems 1755-L1 GUARDPLC 2000 - MODULAR SAFETY PROCESSOR

Process Control 1757-UPGSIFL UPGRADE GE API LICENSE QUICKBUILDER I/F

Operator Interface 2711P-K12C6D2 PV PLUS 1250, KEYPAD, RIO/DH, DC PS, EXT MEM

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Support 1784-DP2S SUPPORT PLAN 1784-DP2 RENEWAL

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20DC011A3EYYAEANE PowerFlex 700S AC Drive 20D

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25B-D024N114 PowerFlex 525 11kW (15Hp) AC Drive

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HE693IBMOIU-57 Personal Computer Programming Utility for all Release 3.0 OIUs

IC609EXP101RR UL Listed Series One Junior Expansion 115Vac I/O

IC647HSTSC10000KM Server to Server Collector for Historian - Standard Server 10,000,000 Points (M4 Key)

IC660BBA023 Block 24/48VdcThermocouple Input 6 Channels

IC694MDL660 RX3i 24VDC Input Module 32 point. Module is supported by serial bus andis not limited to the universal base or expansion base. The module requires a terminal block (IC694TBB032 box style or IC694TBS032 spring clamp style terminal block). Terminal

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Operator Interface

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A06B-0115-B075#0008 BM0.5/4000 Servo Motor, 32K Serial Encoder

IC200UAL004 23 point PLC, (13) 12VDC In, (1) 12VDC Out, (9) Relay Out, 12VDC Power Supply, Battery (IC200ACC403) is required for long term data rentntion and Real Time Clock. Battery not included.

IC752BCL101RR Datapanel 150/160/240E to SNP (25 pin to 15 pin)

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ZA06B-0085-B203#0100 B22/2000is Servo Motor with Straight Shaft, Key and IP67 Sealing

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20G11TC540JN0NNNNN PowerFlex 755 AC Packaged Drive

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140XSM00200 Quantum 开关量输入模拟器, 用于DAI540或DAI740

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SM1000SMC Obsolete - QUICKMARQUEE CONTROLLER

TRM-21006683 Connector for Target series axis module I/O connector J1 or analog I/O module connector J1 or digital I/O module connector J1

20BD011A3AYNACC0 PowerFlex 700 AC Drive 20B

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22B-V2P3F104 PowerFlex 40 0.4 kW (0.5 Hp) AC Drive

416NHM30030A Quantum Modbus Plus PCIadapter for PCs,with Plug

284G-FVD6P0S-25-RRG-CBG-DB1-EMI ArmorStart 284 Controller

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1492-SPM1D005 MCB Supplementary Protector 0.5 A

通用型变频器 6SE6 440-2UC23-0CA1 "3.0 KW,185 x 245 x 195"

电机启动器 3VU13402NJ00

150-C25NCD SMC-3 25A Smart Motor Controller

1609-D1000N Uninterruptible Power Supply

1770-XO PLC-2 Lithium Battery

193-EC1EE E3 18-90 A Overload Relay

195-GA10 Auxiliary Contact

2090-CPBM7E7-14AF01 MP-Series 1 m Length Pwr and Brake Cable

2093-ASP06 Kinetix 2000 Shunt Module

CP8B-1WPB-0070-AZ Right angle power cable for B0.4/5000is or B0.5/5000is or B1/5000is or BM0.5 or BM1 motors. 7 m

GFA-406 Controller Solutions Catalog

IC200UEX209 28 point expansion. (16) 120VAC In, (12) Relay Out (2 @ 10 amp & 10 @ 2 amp), 120/240VAC Power Supply. (includes IC200CBL501)

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20F11NE3P9AA0NNNNN PowerFlex 753 AC Packaged Drive

22401-603-01-R INSULATOR

140CPU65150 Quantum Unity Quantum CPU with Ethernet,w 512/71

281D-F23Z-25D-CR-3FR ArmorStart Direct Online RVSG Starter

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变送器 3RS11011CK40

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IC200MDL650CA Conformal coated. Input 24VDC POS/NEG logic (4 groups of 8) 32 points

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CBL-71006243-10 Serial RTU Cable, Data Panel DP40 to S2K Controller

IC641LCN057 Runtime license for DEC ALPHA/VMS

IC800SLMCONKITVL Connector Kit, 3.5 kW to 5 kW S-Series Servo Motors without Brake

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