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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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PLC-5/1771 System 1771-M3 SERVO CONTROLLER MODULE,(1) INCLUDED W/ 1771-QC

Distributed I/O 1794-OB16 24V DC SOURCE OUTPUT MODULE, 16 POINT

Communications 9399-INTDCUUG INTERCHANGE DEVICE CONFIG. UTILITY USER'S GUIDE

Operator Interface D6195-6.5.6 CONTROLVIEW BUILDER SPC CONFIG. USER MANUAL

Support 9358-BERP03S SUPT RENEWAL CONTRACT FOR 9358BERP03ENE

Support F1771-ACNSERB FIRMWARE UPGRADE FOR 1771-ACN I/O MODULE

RSI Software Products 9324-RL0LDRENE RSLADDER VIEWER FOR SLC500

RSI Software Products 9301-2SE350ESU2R RSVIEW32 RUNTIME 1500-100K UPGRADE OUT-SUPT (ES)

RSI Software Products 9358-HSTS2350U2R UPGRADE: OUT-SUPT: HISTORIAN 300 TO 5K TAG

Motion Control 0041-5072 TEFLON SHAFT SEAL KIT FOR USE ABOVE FOOD LINES

6216A-SI Mini Workstation. 6 (.43") Chars, Red LED Display. Sourcing Outputs. NEMA 4

IC200MDD845 MIXED OUTPUT RELAY 2.0A PER PT ISO 8PT / INPUT 24VDC POS LOG GRP 16PT

IC697ACC624 230VAC SLIM fan tray for the Series 90 70 or RX7i slim racks.

MTR-1221-E-D-E-0 MTR series NEMA 23 stepping motor with encoder. Winding connection type is determined by cable

Z44A730464-G18 Motor power right angle connector for B2/3000 or B6/2000 or A6/3000 or B8/3000is or B12/3000is servo motor

20BD077A3ANNADA0 PowerFlex 700 AC Drive 77 A 60 Hp 20B

20G11NC030JA0NNNNN PowerFlex 755 AC Packaged Drive

22F-B2P5N103 PowerFlex 4M- 0.4 kW (0.5 HP) AC Drive

990NAD23021 Quantum Modbus Plus Super Tap

294D-FD1P5P-G1 Variable Frequency Drive

PFP-50N 導(dǎo)軌 0.5米

1492-SPM3B005-N MCB Supplementary Protector 0.5 A

軟啟動器 3RW40242BB14

電機(jī)啟動器 3VU16402CJ00

150-F361NZD SMC Flex Smart Motor Controller

1734-485ASC POINT I/O RS-485/422 ASCII Interface

1771-WN 1771 Field Wiring Arm

193-EEVF E1 Plus 55-110 A Overload Relay

20-750-BUS3-F10 PF755 FR10, IP00, OUTPUT TERMINATION KIT

2090-CPWM7DF-10AA25 MP-Series 25m Servo Power Cable

2097-V33PR3 Kinetix 300 Servo Drive

ET-GT-5ES-3SC 4 RJ45 Ports, 1 Singlemode Fiber Port Ethernet Switch

GFK-2028 Datapanel Models 150/160 and 240E Operator's Manual

IC220MDL641 INPUT, 24VDC POSITIVE LOGIC, 2PT (REQUIRES 1 IC220TBK082)

IC647DMB001 DataMart BI Connector

IC647PWR001 Proficy Power SCADA for Small Substation

IC693MDL241CA Conbal Coated Input 24 VAC 16 points.

IC756CDV001E-98 DV Development - Compaq True64 Op Sys Addt'l User, English, Version 9. 8

MSI-PROD Product Management Clients (Additional)

PLC-5/1771 System 1785-L80B PLC-5/80 CONTROLLER, 100K WORD SRAM

Distributed I/O 1738-EXT1 ARMORPOINT 1 M BUS EXTENSION

Communications 1784-PCC CONTROLNET PCMCIA COMMUNICATION CARD

Operator Interface 2711E-NA2 COMM CARD ADAPTER FOR PANELVIEW 1000E TERMINAL

Support 9304-WVPR300S SUPT RENEWAL CONTRACT FOR 9304WVPR300

Support 9324-RLD25U7ESE RSLOGIX 5000 LITE SPANISH TO PRO UPGRADE

DeviceNet Products 2711-K6C10 PV600 COLOR KEY, DNET & RS232 PRINT

RSI Software Products 9301-2SE3400 RSVIEW32 RUNTIME 32K

RSI Software Products 9371-EDETIAC RSWIRE DETAILER/IEC FOR AUTOCAD 14-14.01

Motion Control MPG-B025-091S24 MOTOR,SERVO,GEAR RATIO 91,100NM,65RPM,SINGL,BRK

Silver Series 2711-T14C3 PV1400 COLOR TOUCH, DH485 & RS232 PRINT

HE693STP310 Three Axis (multiplexed) indexer module w/1 axis incr. encoder feedback

IC670MDL641 48VDC Pos./Neg. Logic Input 16 Pt. Grouped

QPJ2D101L2P QUICKPANEL 5" MONO LCD WITH CE MARK

ST-7641 STXi Expansion Field Power Distribution module, 5, 24, 48, AC 10 Amp no LED status with module ID.

20BC2P1A3AYNADA0 PowerFlex 700 AC Drive 20B

20F1ANC367JN0NNNNN PowerFlex 753 AC Packaged Drive

22B-B5P0C104 PowerFlex 40- 0.75 kW (1 HP) AC Drive

140DDO15310 Quantum 開關(guān)量DC輸出,32點,5VDC,4組隔離,0.5A/點

284D-FVD7P6D-25-CR-EMI DeviceNet Variable Frequency Drive

E3F3-D12 30cm,擴(kuò)散反射式 晶體管輸出100mA電源：10-30VDC直徑18mm

1492-SPM1B080 MCB Supplementary Protector 8 A

6ED1056-5CA00-0BA0 LOGO! 程序存儲模塊

6ES78220AA000YM0

1497D-A11-M21-0-2 1EN PURPOSE TRANSFORMER