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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(xì)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(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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ControlLogix/1756 System 1756-DPALEN CONTROLLOGIX SYSTEM DOCUMENTATION SET PRINTED

Industrial Computers 6182H-15BRH6D VVCE 1500, KEY/TOUCH, STD MEM, RIO/DH, DC

Process Control 1757-DNBEXP65 DEVICENET MODULE EXPANSION, 50-65 MAX

Operator Interface 2711P-ST7B PANELVIEW PLUS 700 KEY/TOUCH COMBO STARTER KIT

Support 9326-AD1USR SUPT REINSTATEMENT CONTRACT FOR 9326AD1USENE

Support 9371-EDES3S SUPT RENEWAL CONTRACT FOR 9371EDES3

ControlNet Products 1794-ACN15 SINGLE MEDIA ADAPTER FOR CONTROLNET

RSI Software Products 9301-2SE240JPU3R RSVIEW32 WORKS 150-32K UPGRADE OUT-SUPT (JP)

RSI Software Products 9358-BA10ENE RSBIZWARE BATCH ARCHIVER 10 UNITS

Motion Control MPL-A4520K-HK22AA MOTOR,SERVO,6.10NM,4000RPM,ENCDR,230V,6.8KG

Motion Control 2090-UXNPAMP-10S01 CABLE,NOGRF50X,MOTOR POWER,MP,10 GAUGE,1M

CBL-203 Modicon 984 Cable

IC630MDL354RR 5-12Vdc (TTL) Sink/Source Output Module (32 points)

IC800SLCIV010 Interface Cable, 1000W SL Amplifier to Terminal Block, 1 Meter

OC647IFWOPCC iFIX Optn: WorkSpace OPC Client (M1Component Part)

20AD5P0A3AYNNNC0 PowerFlex 70 AC Drive 5 A at 3 Hp 20A

20DD022A3NYNACGNE PowerFlex 700S AC Drive 20D

20P41AB700RA0NNN PowerFlex 230V AC 200 HP DC Drive

2711C-K2M PanelView Comp C200 Graphic Terminal

280-PWRM24D-M2 ArmorConnect 3-PH Power Media drop cable

SRT2-ROC16 遠(yuǎn)程I/O端子（繼電器輸出）16點

1492-MCBA280 80A Miniature Circuit Breaker

1494V-DJ622-A-E NEMA Flange Mtd Rod Switch Disconnect Sw

軟啟動器 3RW44572BC34

工程組態(tài)編程軟件 6AV2102-3AA04-0AE5 SIMATIC WinCC Advanced V14 Upgrade ：?V11..V13 -> V14

1585D-M4UBJM-70 1585D Ethernet Media Patchcord

1756-L72S Logix 5572S Automation Controller 4M/2M

1799-D10U10B 20 Point Embedded I/P/Output Comb Module

194E-FA16E-PD10 194E Load switch

2090-CFBM7DD-CEAA01 MP-Series 1m Servo Feedback Cable

2090-SCVG150-0 Kinetix 150-150m Fiber Optic Cable

BC646MPP005 Logic Developer PLC Professional 5 Pack with Proficy GlobalCare Complete

GC647APC010 GC ProductionClient 10 Pak

HMI-CCT-205 BACKLIGHT TUBE 12.1 inch Color TFT (QPL2xxxxC2P)

IC641VPP700 VersaPro Professional Edition - Windows Programming Software for Serie s 90-70, Series 90-30, and VersaMax PLCs

IC647IFGLBLSRVRM-50 iFIX WebSpace Server including iClient Dev and 2 Web Users(M4 Key)

IC660EBR101RR Electronic Assembly Normally Open

IC697ACC715 Kit, VME Integrator, J2 Backplane Mounting

IC756WRE499J-23 DataViews Runtime for Windows 100+, Per User, Japanese, Version 2.3

FlexLogix System 1794-IR8 RTD INPUT MODULE, 8 POINT

PLC-5/1771 System D6200-6.4.18DE PLC-5 STRUCTURED TEXT REL 1.0 USER MANUAL (GERMAN)

Process Control 1757-SRM SYSTEM REDUNDANCY MODULE

Operator Interface 2711P-T10C6D1 PV PLUS 1000, TOUCH, ENET, DC PS, STD MEM

Support 6001-A1DCS SUPT RENEWAL CONTRACT FOR 6001A1DC

Support 2711-END1UR UPGRADE: OUT-SUPT: PB 1200/1200E TO PB 1400E

Support F1785-L60BSERA FIRMWARE UPGRADE FOR 1785-L60B PLC5 PROCESSOR MODU

RSI Software Products 9301-2SE230ESU1R RSVIEW32 WORKS 300-1500 UPGRADE OUT-SUPT (ES)

RSI Software Products 9701-VWSS000JPU3 RSVIEW SE 250 TO UNLTD UPG JAPANESE

RSI Software Products 9399-RSBPHRG RSBATCH PHASE LOGIC REF. GUIDE

Motion Control 1394C-SJT10-D MODULE,SYSTEM,10KW,SERVO,W/SERCOS INTF,NO HIM

BC646MPC001 Logic Developer - PLC Configuration Tools

IC300OCS063 OCS with 2x20 LCD Display and with 16-keypad. Built in I/O no expansion. High Speed Counter and PWM/PT. 8 DC Inputs (12/24vdc), 8 DC Outputs (5/12/24vdc, 0.5A pos. logic) With CAN network.

IC752WFB254 Display Station 2020 Series - w/ touch - 12.1" SVGA (800x600), Pentium 350 MHz, 128 MB RAM, 6.4 GB HD, expansion slots, Ethernet, floppy drive, CD ROM front access, built-in keypad, HMI for CNC, HSSB card, Win NT

MTR-3T22-G-R-0-M-SRR Servo Motor Metric, Seal

ZA06B-6150-H030 Alpha 30kW PSM-30HVi Power Supply

20D-P2-CKS1 PowerFlex 700S Phase II Cassette Kit

20G1AJC460JN0NNNNN PowerFlex 755 AC Packaged Drive

25B-A011N114 PowerFlex 525 2.2kW (3Hp) AC Drive

2711P-T9W21D8S PanelView Plus 7 Standard 900W

6SE6430-2UD33-7EB0 37KW