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激光制造業亟需組建優秀的激光加工團隊，大力普及激光加工技術，設立激光加工教學、科研和生產基地，加大相關技術同步研究，將機器人技術、仿真技術應用等大規模地應用到城市軌道車輛制造中，發展我國自主特色的激光加工設備以及加工工藝。激光加工技術在城市軌道車輛制造中的應用，包括焊接、切割、表面改性、打標、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在城市軌道車輛制造中的特點和應用前景，為縮短與國外先進技術的差距，加快軌道交通技術儲備提供參考。

城市軌道交通已成為現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、準點率高等優勢。中國如今已成為全球城市軌道交通建設投入的主力軍，甚至連許多二線城市都具備了軌道交通建設的條件與需求。
隨著中國政府“十三五”規劃的提出，國家發改委已批復了多地軌道交通的規劃，到2020年投資預計將超萬億。目前城市軌道車輛制造行業中，激光加工制造技術備受矚目，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的差距，應引進、研究和消化當前最新技術及設計思路，加快軌道交通技術儲備，探究激光加工技術在城市軌道車輛制造中的應用。車輛激光焊接車輛轉向架以及車體是城市軌道車輛上的關鍵構成，材質也經歷了普通合金鋼、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，區別于電阻滾壓縫焊，通過自由組合，使得構件變輕，零件變少，不僅提高可靠性，為寬體車制造奠定基礎，同時也改善了焊接質量，提高了鋼材收得率，并降低了生產成本。

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，投資效益好。但激光組焊技術也有明顯的缺點，如對夾具、被焊件、監測精度等要求嚴格，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，而現在則選用激光或電阻焊進行作業。

通過長期加工技術應用的實踐、積累及分析，不銹鋼接頭焊接技術規范、疲勞曲線、硬度、抗拉強度、屈服強度、等技術指標相繼被取得或檢驗，車體激光焊接樣件的制評亦完成。


2) 車輛轉向架制造。城市軌道車輛轉向架通常選用日本進口或國產的中厚合金鋼板材，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，來改善焊接穩定性；而開具有不同規格的坡口，通常留較小鈍邊，以確保熔透。激光-電弧復合焊優化焊接效率，顯示了激光和電弧的特點；同時減少了設備和人員投入，降低了焊接成本，并且可選較大鈍邊。


車輛激光切割

激光切割技術特性城市軌道車輛制造廠商已大量使用激光切割技術，其加工的產品有很多，如車體、內裝板材、轉向架，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量和切割速度。以某企業為例，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低合金結構鋼。

下料環節激光切割

城市地鐵機車制造首先要準備相關材料，這個階段激光切割技術尤為重要。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、節料省錢、經濟適用[16]，因此激光切割技術已被廣泛用于軌道車輛制造中。以某企業為例，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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Motion Control MPL-A430P-HJ22AA MOTOR,SERVO,5.42NM,5000RPM,ENCDR,230V,6.4KG

Motion Control 2090-UXNFDN-R03 CABLE,ULTRA,NON-FLEX, MOTOR FEEDBACK,N,R/A,3M

CBL-14-MP-10 Power Cable, MTR-1235, 13xx, 14xx Series Splashproof Stepping Motors, 10 Ft.

IC610MDL153RR 24Vdc Sink Output, 2 Amp (4 points)

IC800SLCBV050 Power/Brake Cable, 1000 W SL Servo Motor with Brake, 5 Meters

OC647IFGLBLENBLRM-51 iFIX WebSpace Enabler v 5.1

20AD3P4A3AYNAEC0 PowerFlex 70 AC Drive 3.4 A at 2 Hp 20A

20DD014A0EYNANGNE PowerFlex 700S AC Drive 20D

20P41AB029RA0NNN PowerFlex DC Drive 230V AC 7.5 HP

2711-NR5T PanelView Accessory

280-PWRM24A-M10 ArmorStart Three-Phase Power Media

3G3MV-A4022 NEW 5.9KVA 5.5A 2.2KW 三相AC380-460V/50HZ/60HZ

1492-MCAA260 60 A UL489 Miniature Circuit Breaker

1494U-NOLV 1494U N.O. L.V. Auxiliary Contact

軟啟動器 3RW44556BC36

工程組態編程軟件 6AV2102-0AA04-0AA5 SIMATIC WinCC Advanced V14

1585D-M4UBJM-0M6 1585D Ethernet Media Patchcord

1756-L62 ControlLogix 4 MB Memory Controller

1797-TB3 FlexEx Terminal Base

194E-E63-PE 194E Earthing-Grounding Terminal

2090-CFBM6DD-CCAA25 TL-Series 25m Feedback Cable

2090-SCEP3-0 Kinetix 3-3m Fiber Optic Cable

BC646MODEV10PK Motion Developer 10 pack for the S2K Series Amplifiers/Controllers with Proficy GlobalCare Complete

GC647ADC100 GC Dashboard Client 100 Pak

HMI-CAB-C76 CABLE SIEMENS S5

IC641SWP080 Windows 95/NT Driver (Ethernet SRTP)

IC647IFCLNTSRO010M iFIX iClientTS Read Only 10 PK (M4 Part)

IC660EBD021RR Ph B 24/48Vdc and 24Vdc 16 CKT Sk Electronic Asm

IC695RMX128CA Conformal coated. RX3i Redundant Memory Xchange Module for High Availability. 2Megbytes of user shared memory.

IC756WRE099E-99 DataViews Runtime for Windows 50-99, Per User, English, Version 9.9

FlexLogix System 1794-OB32P 24 VDC OUTPUT MODULE, 32 POINTS

PLC-5/1771 System D1785-6.5.9 PLC-V5 VMEBUS PROGRAM. CONTROLLERS USER MANUAL

Process Control 1757-PLXSIFZA PLX APPLICON QUICKBUILDER INTERFACE

Operator Interface 2711P-K10C4D2 PV PLUS 1000, KEYPAD, ENET, DC PS, EXT MEM

Support 9324-FW5PCOENR SUPT REINSTATEMENT CONTRACT FOR 9324FW5PCOEN

Support 2706-NP3S SUPT RENEWAL CONTRACT FOR 2706NP3

Support F1785-L40CSERE FIRMWARE UPGRADE FOR 1785-L40C PLC5 PROCESSOR MODU

RSI Software Products 9301-2SE2300ZHE RSVIEW32 WORKS 1500 (CHINESE)

RSI Software Products 9701-VWSS000ADEE RSVIEW SE SERVER UNLIMITED DISPLAY (GERMAN)

RSI Software Products 9399-RL50GRIT RSLOGIX 500 GETTING RESULTS GUIDE (ITALIAN)

Motion Control 1394C-AM50 MODULE,AXIS,10KW,23.3A CONT,33.2A PEAK