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激光制造業(yè)亟需組建優(yōu)秀的激光加工團隊，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(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技術(shù)的差距，應(yīng)引進、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(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，過去常常進行涂裝作業(yè)，而現(xiàn)在則選用激光或電阻焊進行作業(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、抗拉強度、屈服強度、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(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(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激光和剪板機對6 mm以下板材下料。車輛轉(zhuǎn)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(jié)構(gòu)鋼。

下料環(huán)節(jié)激光切割

城市地鐵機車制造首先要準(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、節(jié)料省錢、經(jīng)濟適用[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激光切割機對12 mm以下板材下料[17]。

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Motion Control 2090-UXBC-D1509 BREAKOUT BOARD CABLE,CN2,ULTRAX000,9M

CBL-12-MPS-10 Power Cable, MTR-1221-*-D & MTR-1231-*-D Stepping Motor with S2K, 10 Ft.

IC600KD542RR Operator Interface Terminal, 14" Color CRT

IC800SKCBV100 Power/Brake Cable, S2K to 1 - 2.5kW S-Series Servo Motors, 10 Meters

OC647IFESGRN00900M iFIX Optn: ESig & ERec 900 I/O Runtime (M4 Part)

20AD052A0AYNANC0 PowerFlex 70 AC Drive 52 A at 40 Hp 20A

20DC5P0A0EYNANANE PowerFlex 700S AC Drive 20D

20LD650N0QNNENA0EA PowerFlex 700L AC Drive 20L

2707-NC9 MICROVIEW-MLOGIX COM CBL 49 FT/15 M.

280-PWRM22E-M14 ArmorConnect 3-PH Power Media drop cable

FX2N-422-BD RS422 通信用適配器

1492-M6X5H1-50 Connection Products

1494R-N4 Disconnect Switch Shaft

軟啟動器 3RW44476BC46

ET 200SP 6ES5710-8MA31 35mm安裝導(dǎo)軌，長度：830mm

1585D-M4UBDE-2 Micro D-Code, QD Style Ethernet Media

1756-IB16IFK ControlLogix 16 Point Digital Input

1794-TB3SK Flex Terminal Base

194E-E100-TN Neutral Terminal 80 - 100 Amp

2090-CFBM4DD-CDAA15 MP-Series 15 m Length Feedback Cable

2090-K7CK-KENDAT Kinetix 7000 EnDat Converter Module

AT-8624FC-10 Proficy Process Systems Switch with no Multi-mode Fiber Modules from Allied-Telesis

GC646TDV300 Proficy GlobalCare Complete for 300 I/O Point Runtime / Development System.

HMI-AGO-201 ANTI-GLARE OVERLAY 9 inch/ 5 per pack

IC640WDB400 Cable, 9-Pin D to 3 BNC

IC647HSTSSEO500M eSignature Option for Historian - Standard Server 500 Points (M4 Key)

IC660BSM021 Bus Switching Module 24/48Vdc

IC695DEM004 Beta i Series 1-Axis Motion Demo Case for use with PACMotion or DSM324i motion controllers

IC756WRE024E-23 DataViews Runtime for Windows 1-24, Per User, English, Version 2.3

CompactLogix System 1769-STRT2IT COMPACTLOGIX STARTER KIT ITALIAN

PLC-5/1771 System D1771-6.5.44 LINEAR POSITION CONTROL MDL(1771-QB)USER'S MNL

Process Control 1757-PLXNG PLX SERVER BATCH REPORT OPTION

Operator Interface 2711P-K7C6D1 PV PLUS 700, KEYPAD, RIO/DH, DC PS, STD MEM

Support 6620-BHAS 6620-BHA SOFTWARE SUPPORT RENEWAL

Support 8100-HSMMLR SUPT REINSTATEMENT CONTRACT FOR 8100HSMML

Support F1785-L20BSERB FIRMWARE UPGRADE FOR 1785-L20B PLC5 PROCESSOR MODU

RSI Software Products 9301-2SE2204 RSVIEW32 WORKS 300 WITH RSLINX SINGLE NODE

RSI Software Products 9701-VWSB100AENE RSVIEW SE STATION 100 DISPLAY

RSI Software Products 9399-HDWAREREF HARDWARE INTERFACE CONFIGURATION USER'S GUIDE

Motion Control 2098-DSD-HV030X-DN HIGH VOLTAGE DRIVE, 7A/14A, ULTRA3000 W/DNET, INDE

BC5105KAN0000 15 Inch Panel-C Industrial Computer - Bundled - w/ WindowsNT

IC300DIQ611 8 DC Inputs (12/24vdc, pos/neg logic), 8 DC Outputs (5/12/24vdc, 0.5A, neg logic)

IC752FDEG75 ControlStaion CE / ViewStation CE Development System

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