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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，設立激光加工教學、科研和生產(chǎn)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(guī)模地應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(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、準點率高等優(yōu)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(guī)劃的提出，國家發(fā)改委已批復了多地軌道交通的規(guī)劃，到2020年投資預計將超萬億。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(zhuǎn)向架以及車體是城市軌道車輛上的關鍵構(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，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。但激光組焊技術也有明顯的缺點，如對夾具、被焊件、監(jiān)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(yè)，而現(xiàn)在則選用激光或電阻焊進行作業(yè)。

通過長期加工技術應用的實踐、積累及分析，不銹鋼接頭焊接技術規(guī)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(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(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(jié)料省錢、經(jīng)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(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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FlexLogix System 1794-STRT1FR FLEXLOGIX STARTER KIT FRENCH

GuardPLC Systems 1755-PCS RSLOGIX GUARD SOFTWARE FOR GUARDPLC 2000 AND 1200

Process Control 1757-UPGSIFZD UPGRADE OPC SERV CLIENT QUICKBUILDER I/F

Operator Interface 2711P-B15C15B2 PV PLUS 1500, KEY/TOUCH, CNET, AC PS, EXT MEM

Support 9230-DNIOSDKR SUPT REINSTATEMENT CONTRACT FOR 9230DNIOSDK

Support 2760-SFTKS 2760-SFTK SOFTWARE SUPPORT RENEWAL

Support F1785-V40LSERC FIRMWARE UPGRADE FOR 1785-V40L PLC5 PROCESSOR MODU

RSI Software Products 9301-2SE2350PTE RSVIEW32 WORKS 5K (PORTUGUESE)

RSI Software Products 9701-VWSTMJPE RSVIEW STUDIO FOR MACHINE EDITION (JAPANESE)

RSI Software Products 9399-WABOUGFR RSLINX OEM USER GUIDE (FRENCH)

Motion Control 8720MC-CN1 CONTROL MODULE MATING CONNECTOR KIT

BC646MRC150 Logic PC & View Runtime 150 I/O

IC300RCS063 8 DC Inputs (0-24vdc), 8 Positive Logic DC Outputs (5/12/24vdc, 0.5A with ESCP). 2 Inputs configurable as High Speed Counters, 500KHz each. 2 Outputs configurable as PWM/Pulse Train. Built-in network interface for CsCAN or DeviceNet slav

IC754GEN001 GE Fanuc Genius Comm for QP View & Control

MTR-3T54-H-R-0-M-0RR Servo Motor Metric

20AC8P7A3AYNNEC0 PowerFlex 70 AC Drive 8.7 A at 4 kW 20A

20DC022A3NYNACGNE PowerFlex 700S AC Drive 20D

20G1ANC140JA0NNNNN PowerFlex 755 AC Packaged Drive

25B-E019N104 PowerFlex 525 11kW (15Hp) AC Drive

2715-T19CD PanelView 5500 19 in. Graphic Terminal

FR-A740-30K 43.4KVA 57A 30KW

1492-LDG3 IEC Term Blck 5.1x72.5x47.9mm Spr Clp

1494F-M2 Disconnect Switch Handle

軟啟動器 3RW44356BC44

ET 200SP 6ES7131-6BH00-0BA0 DI 16x24VDC 標準型，基座單元類型 A0

1585D-E4TBDE-10 Micro D-Code, QD Style Ethernet Media

1752-L24BBBE SmartGuard 600 Safety Controller

1794-IB16 Flex 16 Point Digital Input Module

194E-AA20E-TN-PE 194E Load switch

2080-LC20-20QBB Micro820 20 I/O ENet/IP Controller

2090-CSWM1DF-14AA21 Kinetix Cable Single DSL 2090-Series

20AC3P5A0AYNANC0 PowerFlex 70 AC Drive 20A

GC646MPP101 Proficy GlobalCare Complete for Logic Developer - PLC Professional w/Programming Cable

HE693OIU357 Full-sized VF OIU powered by 80-240VAC

IC610CCM111RR I/O Link Remote Module

IC647HSTSC250KM Server to Server Collector for Historian - Standard Server 250000 Points (M4 Key)

IC660BBA103RR Thermocouple Input Block, 115Vac/125Vdc Power

IC694MDL754 12/24VDC Output (0.75 amps/point)Module 32 point. Requires terminal block IC694TBBx32 box style or IC694TBSx32 spring clamp. Terminal block is sold seperaby. Output response Time is 0.5ms.

IC756WDJ009J-99 DV Development Sys VB and Java, Japanese, Version 9.9

MicroLogix 1500/1769 System 9399-RL50GRPT RSLOGIX 500 GETTING RESULTS GUIDE (PORTUGUESE)

PLC-5/1771 System 1771-P10 POWER SUPPLY,2-SLOT (125V DC, 8 AMPS)

Distributed I/O 1797-PS2N2 24 VDC IN QUAD-EX OUT POWER SUPPLY, NPT CONDUIT

Operator Interface 2711P-B6C5D PV PLUS 600 COLOR, KEY/TOUCH, RS232, DC PS

Support 9323-PA2ER SUPT REINSTATEMENT CONTRACT FOR 9323PA2E

Support 9358-MTRCK01S SUPT RENEWAL CONTRACT FOR 9358MTRCK01ENE

Support F1772-LXSERB FIRMWARE UPGRADE FOR 1772-LX PLC2 PROCESSOR MODULE

RSI Software Products 9324-RLD600ENE RSLOGIX 5000 FULL EDITION, ENGLISH

RSI Software Products 9305-RSVADDCPTE RSVIEW32 ACTIVE DISPLAY DED. CLIENT (PORTUGUESE)

RSI Software Products 9358-SCHSTDENE FINITE-CAPACITY SCHEDULING MODULE OF RSBIZWARE