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激光制造業(yè)亟需組建優(yōu)秀的激光加工團(tuán)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(jī)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(jìn)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(diǎn)，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(diǎn)和應(yīng)用前景，為縮短與國外先進(jìn)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(yùn)量大、能耗低、效率高、污染小、準(zhǔn)點(diǎn)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(jìn)技術(shù)的差距，應(yīng)引進(jìn)、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(jìn)而總裝成整車車身。激光組焊因其焊接強(qiáng)度高，可明顯改善車身強(qiáng)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(diǎn)，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(jìn)行涂裝作業(yè)，而現(xiàn)在則選用激光或電阻焊進(jìn)行作業(yè)。

通過長期加工技術(shù)應(yīng)用的實(shí)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(qiáng)度、屈服強(qiáng)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(jìn)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(hù)焊。用于長直縫焊接的機(jī)械人手臂，已被各廠商所引進(jìn)，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(diǎn)；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(jī)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(jī)對6 mm以下板材下料。車輛轉(zhuǎn)向架選用激光切割機(jī)對14 mm以下板材進(jìn)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(jī)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(qiáng)、節(jié)料省錢、經(jīng)濟(jì)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(jī)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(jī)對12 mm以下板材下料[17]。

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RSI Software Products 9399-WABOUG RSLINX OEM USER GUIDE

Motion Control 8720MC- -HASP STANDARD PROGRAMING ONLY HIM

BC646MRB300 Logic PC Runtime 300 I/O

IC300OSW005 Cscape PDA Software with Palm V Series Cable

IC754CBL06CTD 6" TFT QuickPanel Control, Loaded, 24Vdc, Blank

MTR-3T45-I-R-0-M-0RR Servo Motor Metric

20AC8P7A3AYNANC0 PowerFlex 70 AC Drive 8.7 A at 4 kW 20A

20DC022A0EYNANCNK PowerFlex 700S AC Drive 20D

20G1ALF500AN0NNNNN PowerFlex 755 AC Packaged Drive

25B-D4P0N114 PowerFlex 525 1.5kW (2Hp) AC Drive

2715-T12WD PanelView 5500 12.1 in. Graphic Terminal

FR-A740-11K 17.5KVA 23A 11KW

1492-LD4RB201 2-Ckt Resistor Blk,Metal Oxide Film,4mm

1494F-L3 Door Hardware Kit

軟啟動器 3RW44352BC45

ET 200SP 6ES7193-6AG40-0AA0 BA 1× LC 玻璃光纖/1×FC快連式，光纖最遠(yuǎn)距離 2KM

1585D-D4UBJM-5 Micro D-Code, QD Style Ethernet Media

1747-UIC SLC USB to DH-485 Converter

1794-IA8 Flex 8 Point Digital Input Module

194E-AA20E 194E Load switch

2080-LC10-12QBB Micro810 12 I/O Smart Relay Controller

2090-CSWM1DF-14AA17 Kinetix Cable Single DSL 2090-Series

20AC2P1C3AYNANC0 PowerFlex 70 AC Drive 20A

GC646MPP001 Proficy GlobalCare Complete for Logic Developer - PLC Professional

HE693OIU197 Compact VF Genius OIU w/numeric keypad, powered by 24VDC

IC609TCU100RR Timer/Counter Setpoint Unit (for S1 Jr & CPU 104, 105, 106)

IC647HSTSC1KM Server to Server Collector for Historian - Standard Server 1000 Points (M4 Key)

IC660BBA100RR Analog I/O Block, 115Vac Power, 4 In/2 Out, Ph B

IC694MDL752 Output module 5/24VDC (TTL) 0.5 amp 32 point negative logic.

IC756WDJ009E-27 DataViews Development System Visual Basic & Java English v2.7

MicroLogix 1500/1769 System 9399-RL50GRDE RSLOGIX 500 GETTING RESULTS GUIDE (GERMAN)

PLC-5/1771 System 1771-CP1 1771 I/O CHASSIS CABLE FOR 1771-P7 POWER SUPPLY

Distributed I/O 1797-TB3S 3-WIRE EX TERMINAL BASE - SPRING CLAMP

Operator Interface 2711P-B6C20D PV PLUS 600 COLOR, KEY/TOUCH, ETHERNET, DC PS

Support 9323-PA1IR SUPT REINSTATEMENT CONTRACT FOR 9323PA1I

Support 9358-HSTS2500S SUPT RENEWAL CONTRACT FOR 9358HSTS2500

Support F1772-LXPSERB FIRMWARE UPGRADE FOR 1772-LXP PLC2 PROCESSOR MODUL

RSI Software Products 9324-RLD3U7FRE RSLOGIX 5000 STD. TO PRO UPGRADE, FRENCH

RSI Software Products 9305-RSVADDCESE RSVIEW32 ACTIVE DISPLAY DEDICATED CLIENT (SPANISH)

RSI Software Products 9358-RTI03E RTI DATA COLLECTOR (3 CONFIGURATION)

Motion Control 2092-DA4 DRIVE, 10.7A/24.8A, ULTRA1500 DIGITAL SERVO DRIVE

A06B-0143-B075#7008 A12/3000 Servo Motor, 64K Serial Encoder

IC200UDD110 28 point; (16) 24VDC In, (12) 24VDC Out (6) 1.0 A, (6) 0.5A, 24VDC Power Supply. Battery (IC200ACC403) is required for data retention. Battery not included.

IC752BUU014 VT100 Upgrade for Datapanel K

MTR-1454-E-A-E-SRR Stepping Motor Nema42 Encoder Splashproof

ZA06B-0114-B503 B0.4/5000is servo motor with 24 VDC brake and 64k serial encoder

20BD3P4A3AYNACD0 PowerFlex 700 AC Drive 3.4 A at 2 Hp 20B

20G11TD545AN0NNNNN PowerFlex 755 AC Packaged Drive