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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(duì)，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(chǔ)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(dòng)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(jì)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(jì)思路，加快軌道交通技術(shù)儲(chǔ)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(gè)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(gè)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(shí)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(shí)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(jià)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(yàn)，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(shí)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(shí)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(shí)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(gè)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(dòng)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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1494H-CN3H6 Heavy Duty Fusible Safety Discon Switch

軟啟動(dòng)器 3RW44452BC45

ET 200SP 3RK7136-6SC00-0BC1 F-CM AS-i Safety 主站模塊，標(biāo)準(zhǔn)型，基座單元類型C0、C1

1585D-M4TBDM-3 Micro D-Code, QD Style Ethernet Media

1756-EN2F ControlLogix Enet/IP Fiber Optic Module

1794-OB32P Flex 32 Point Digital Output Module

194E-CA40EX-PE-TN 194E Load switch

2085-IRT4 Micro800 4 Channel TC/RTD Input Module

2090-DANFCT-S02 TL-Series 2m Feedback Cable

20AC5P0F0AYNNNC0 PowerFlex 70 AC Drive 5 A at 2.2 kW 20A

GC646PCM005 GlobalCare Complete for Change Management 5 user pack

HE693THM884 8 ch. J, K, N, T, E, R, S, B, C 0.1degC res., degC/F units, 8 temp + ope n circ. alarms

IC630MDL325RR 115Vac Input Module (16 points)

IC647HSTSS500KM Historian Standard Server 500,000 Points (M4 Key)

IC660BLA101 Cover w/Label for IC660BBA101

IC695ALG628RS Refurbished Analog Input HART module, 8 channels single ended, 4 channels differential,channels are configurable for voltage,current and current/ HART. Supports Current: 0 to 20mA, 4 to 20mA, +/- 20mA; Voltage: +/- 10V, 0 to 10V, +/- 5V, 0 to 5V, 1 t

IC756WDV009J-22 DV Development Sys Visual Basic, Japanese, Version 2.2

CompactLogix System 1761-NET-ENI ETHERNET INTERFACE FOR MICROLOGIX AND COMPACTLOGIX

PLC-5/1771 System 9399-PLC5IO PLC 5, 6200 SERIES I/O CONFIGURATION USER MANUAL

Distributed I/O D1791-6.5.8 BLOCK I/O (1791-IOBA, IOBB SERIES B) USER MANUAL

Operator Interface 2711P-T6M1D PV PLUS 600 GRAYSCALE, TOUCH, SRIO, DC PS

Support 6401-SDSCR 6401-SDSC SOFTWARE SUPPORT REINSTATEMENT

Support 9358-PBPC60S SUPT RENEWAL CONTRACT FOR 9358PBPC60ENE

Support F1779-KP5RSERA FIRMWARE UPGRADE FOR 1779-KP5R COMMUNICATION MODUL

RSI Software Products 9301-2SE2103PTE RSVIEW32 WORKS 150 WITH RSLINX (PORTUGESE)

RSI Software Products 9701-VWMR075JPU1 RSV ME STATION RT 15 TO 75 DISP UPGRADE(JAPANESE)

RSI Software Products 9399-2SE32RUG RSVIEW32 RUNTIME USER GUIDE

Motion Control 2098-DSD-HV050X HIGH VOLTAGE DRIVE, 11A/22A, ULTRA3000 W/INDEXING

ABI3D200C2P/DVN QUICKPANEL 10.5" TFT W/DVN 24VDC

IC220PWR002 POWER TERMINAL, FUSED 24VDC (REQIRES 1 IC220TBK087)

IC752DPA260 Mature, order QuickPanel instead. DataPanel 1060IR with infrared touch. 10.4" VGA (640x480) active matrix TFT color display. No bezel - mounts from inside panel. Supports all WinCfg functionality.

MTR-3S32-H-E-0-E-0-MODRR Servo Motor, Encoder FSI MOD=SPINNER

ZA06B-0286-B010 A100/2.5KHVis Motor w/ Fan Tpr Shaft

20BE027A0AYNAND0 PowerFlex 700 AC Drive 27 A at 25 Hp 20B

20G14ND415AN0NNNNN PowerFlex 755 AC Packaged Drive

25-PTG1-FA PowerFlex 520 Fr A Power Terminal Guard

2711P-RP9DK PanelView Plus 6 700-1500 Logic Module

FRN22G11S-4CX 34 KVA 45 A 22KW 3相AC380V/50Hz/60Hz

1492-J6-G 6 square mm Feed-Through Terminal Block

1492-TA40L Test Plug Adaptor

軟啟動(dòng)器 3RW40732BB45

CPU 模塊 6ES7 516-2PN00-0AB0 CPU 1516PRO-2 PN，1MB 程序，5 MB 數(shù)據(jù)；10 ns；集成 X1: 3x PN 接口，X2: 1x PN 接口

153H-C108XBD-49 SMC-3 ENCLOSED COMBINATION 108A

1738-OV4EM12 ArmorPoint 4 Point Output Module

1785-L80C15 PLC-5 ControlNet 1.5 Processor

193-NREENZ E1 Plus Replacement Overload Relay

20-COMM-H PowerFlex HVAC Comm Adapter