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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，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(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(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，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；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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Support F1784-CPCIDS FIRMWARE UPGRADE FOR 1784-CPCIDS COMMUNICATION MOD

RSI Software Products 9301-2SE2200DEU1 RSVIEW32 WORKS 150-300 UPGRADE IN-SUPT (DE)

RSI Software Products 9701-VWSB000AJPE RSVIEW SE STATION UNLIMITED DISPLAY (JAPANESE)

RSI Software Products 9399-APSIE SLC 500 APS IMPORT/EXPORT UTILITY USER MANUAL

Motion Control 2098-DSD-HV220 HIGH VOLTAGE DRIVE, 47A/94A, ULTRA3000

ABK3D200C2P/DVN QUICKPANEL 6" TFT W/DVN

IC220TBK123 I/O TERMINAL STRIP, 12 POSITION SPRING STYLE W/COLOR, OUTPUT, QTY 10

IC752DPH000RR Datapanel H, 640x200 LCD with CCFT backlight. Text, bitmaps, bar graphs, real time clock. Includes integrated keypad. No touch capability.

MTR-3S33-G-R-B-E-S MTR series servo motor with resolver and brake and shaft seal

ZA06B-6050-K120 Motor encoder connector kit for B0.5/3000 motor

20BE052A3AYNAND0 PowerFlex 700 AC Drive 52 A 50 Hp 20B

20G14NF050JA0NNNNN PowerFlex 755 AC Packaged Drive

25-RF011-AL PowerFlex 520 10.7A 230V EMC Filter Kit

2711P-RTBAC3 PanelView Plus Accessory

FRN75G11S-4CX 114KVA 150A 75KW 3相AC380V/50Hz/60Hz

1492-J6FB124 Fuse Terminal Block with LED

1492-TP28 IEC Term Blck Test Plug

軟啟動器 3RW40742BB34

CPU 模塊 6ES7 677-2AA40-0AA0 CPU 1515SP PC，4GB 備件 *

153H-C317XBD-56 SMC-3 ENCLOSED COMBINATION 317A

1746-A10 SLC 10 Slots Chassis

1786-BNCJ CNet Media Jack-to-Jack TNC Connector

193-T1AA40 0.25-0.4 A IEC Bibllic Overload Relay

20-COMM-Q PowerFlex ControlNet Fiber Media Adapter

2090-CSBM1DF-10AF09 Kinetix Cable Single DSL 2090-Series

20AC011A3AYNANC0 PowerFlex 70 AC Drive 20A

GA647IFSTRNUNLMT GCA iFIX Std HMI Unlmt Run

GP647IFPLSR00150 GCP iFIX Plus SCADA 150 I/O Srv

IC600BF942RR -10Vdc to +10Vdc Analog Output Module (4 channels)

IC647HSTCR50KM Collector Redundancy Option for Historian - Standard Server 50000 Points (M4 Key)

IC647TPR935 CIMPLICITY HMI ProServer 35,000 I/O Runtime System

IC693PTM100CA Conbal Coated Power Transducer Module

IC756MDV001J-97 DV Development - Alpha OpenVMS Addt'l User, Japanese, Version 9.7

MicroLogix 1000/1761 System 1761-NET-DNI DEVICENET INTERFACE (DNI)

PLC-5/1771 System 1771-NBV1 HIGH RESOLUTION ISOLATED ANALOG MODULE

Distributed I/O 1792D-CB18JP MAXUM ROUND MEDIA 18MM BASE, PASSTHRU FOR DNET

Communications 9351-HPUSRT INTERCHANGE FOR HP-UX RUNTIME

Operator Interface D6190-6.5.25 CONTROLVIEW AND CONTROLVIEW 300 INSTALLATION MNL

Support 9358-B03R SUPT REINSTATEMENT CONTRACT FOR 9358B03ENE

Support 9392-CDRSFRU UPGRADE TO ENGLISH/FRENCH BUNDLE

RSI Software Products 9323-L2300DU UPGRADE: IN-SUPT: 6200-2 BOTH TO AI-2 BOTH

RSI Software Products 9301-2SE3500KOU5 RSVIEW32 RUNTIME 5K-100K UPGRADE IN-SUPT (KO)

RSI Software Products 9356-SQLSAPADENE RSSQL FOR SAP SOLUTIONS ADDITIONAL SAP MODULE