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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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IC697MEM719 Expansion RAM, 512K Bytes, CMOS (Used w/77X CPUs and PCM)

IC800SSD407RS1RR 7.2A, 480V, S2K Servo Drive for MTR Series Motors

ControlLogix/1756 System D1775-6.5.5 I/O SCANNER-COMMUNICATION ADPT.MOD.(1775S5,SR5)MNL

Industrial Computers 6182H-15TEH15B VVCE 1500, TOUCH, EXT MEM, CNET, AC

Process Control 1757-DNBUPG01 DEVICENET LIC UPG 1 DNB

Operator Interface 2711-START300U START KIT PV300U PV300, PB32,CABLES

Support 9326-AD5US SUPT RENEWAL CONTRACT FOR 9326AD5UENE

Support 9371-EDETJSAR SUPT REINSTATEMENT CONTRACT FOR 9371EDETJSA

ControlNet Products 1797-TPYS CONTROLNET EX Y-TAP STRAIGHT

RSI Software Products 9301-2SE240ZHU5R RSVIEW32 WORKS 5K-32K UPGRADE OUT-SUPT (ZH)

RSI Software Products 9358-BA60U3 UPGRADE: IN-SUPT: RSBIZWARE ARCHIVER 30 TO 60

Motion Control MPL-A4520P-HK24AA MOTOR,SERVO,6.10NM,5000RPM,ENCRD,230V,BRK,9.5KG

Motion Control 2090-UXNPAN-16R15 CABLE,NON-FLEX, MOTOR POWER, N,R/A,16AWG,15M

CBL-34-MP-30 Power Cable, MTR-3N(All), MTR-3S3x & MTR-3S43H Series Servo Motors, 30 Ft.

IC640VPS002 VersaPro programming software and documentation for VersaMax Micro and Nano Only. Programming cable (IC200CBL500) included. CD bat

IC800SLM005N3BE25 50W, 115/230 VAC SL Servo Motor, Holding Brake, 2.5K Quad Encoder

OC647IPWRPLDVUNLMTM iPower Option - Nwk Unlmt I/O Dev

20AD8P0A3AYNANC0 PowerFlex 70 AC Drive 8 A at 5 Hp 20A

20DD052A3EYNACCNK PowerFlex 700S AC Drive 52 A 40 Hp 20D

20P41AD100RA0NNN PowerFlex 460V AC 60 HP DC Drive

2711P-B10C22A9P-B PanelView Plus 7 Graphic Terminal

280-PWRM24F-M6 ArmorConnect 3-PH Power Media drop cable

MPT5-MG00(B) 單色STN LCD 分辨率: 320×240點,4.7英寸

1492-MCBA345 45 A UL489 Miniature Circuit Breaker

1494V-DR622 NEMA Flange Mtd Rod Switch Disconnect Sw

軟啟動器 3RW44582BC44

運行版軟件 6AV2103-4RX04-0AE5 SIMATIC WinCC V7.0..V7.3 RC 153600 ->WinCC 專業(yè)版 max. PowerTags V14 Combo 和 WinCC RT 專業(yè)版 153600 PowerTags

1585D-M8UGJM-10 Gigabit Ethernet Media

1756-L7SPK Logix L7SP SIL 3 PLe Safety Partner

1799-MP20 Distributed I/O Mounting Plate

194E-FA32E-P22 194E Load switch

2090-CFBM7DD-CEAA60 MP-Series 60m Servo Feedback Cable

2090-SR120-09 Kinetix 120 Ohm Shunt Resistor

BC646MPSS99 Logic Developer PLC Standard Unlimited Seat Site License with Proficy GlobalCare Complete

GC647AQC999 GC Quality Client - UNL

HMI-JBX-201 JUNCTION BOX HAND HELD

IC641VPSCAM VersaPro Cam Editor

IC647IFPLDV00300M iFIX Plus SCADA 300 I/O Development (M4 Part)

IC660ELB921 Single-slot PCIM (XT/AT Interface Board) 1-channel

IC697ACC744 Rack Cooling Fan, 24 VDC

IC756XDV000CS-925 DataViews Development on Solarisx86 Op Sys, Simplified Chinese v9.25

FlexLogix System 1794-TB3 TERMINAL BASE, 3-WIRE

PLC-5/1771 System D6300-6.5.1 PLC2 TP PLC5 CONVERSION SW(62002CV5)USER'S MANUAL

Process Control 1757-UPGRT10 UPGRADE 10 USER OI EXTENSION

Operator Interface 2711P-B12C6D2 PV PLUS 1250, KEY/TOUCH, RIO/DH, DC PS, EXT MEM

Support 6006-A1DBR SUPT REINSTATEMENT CONTRACT FOR 6006A1DB

Support 2711-ND3ESR SUPT REINSTATEMENT CONTRACT FOR 2711ND3ES

Support F1785-L66LSERB FIRMWARE UPGRADE FOR 1785-L66L PLC5 PROCESSOR MODU

RSI Software Products 9301-2SE230ZHU2R RSVIEW32 WORKS 150-1500 UPGRADE OUT-SUPT (ZH)

RSI Software Products 9701-VWSS100FRU1 RSVIEW SE 25 TO 100 DISPLAY UPGRADE (FRENCH)

RSI Software Products 9399-SLIDERUG RSSLIDER USERS GUIDE

Motion Control 8720MC -B021-AA- 21 AMP B CHASSIS DRIVE, ENCLOSURE, LESS OPTIONS

BC646MPS001 Logic Developer - PLC Standard

IC300OCS087 MiniOCS with 2x20 LCD & 16 keypad & onboard IO (no expansion) 8 DC Inputs (pos/neg) with CsCAN, 8 DC Outputs (pos), 4 ISO analog in (20mA), 2 ISO analog out (20mA)

IC752WPB204 Same as IC752WFB204 without touch

MTR-3T42-H-R-B-M-0 MTR series metric servo motor with resolver and brake

ZA66L-6001-0026#L50R03 A22/3000HVi & A12/4000HVis & A22/4000HVis, Fiber Optic Cable (Sheathed) 50M