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激光制造业亟需组建优秀的激光加工团队，大力普及激光加工技术，设立激光加工教学、科研和生产基地，加大相关技术同步研究，将机器人技术、仿真技术应用等大规模地应用到城市轨道车辆制造中，发展我国自主特色的激光加工设备以及加工工艺。激光加工技术在城市轨道车辆制造中的应用，包括焊接、切割、表面改性、打标、快速成型、打孔及微细加工等。文章以城市轨道车辆为研究对象，阐述了先进激光焊接、激光切割在城市轨道车辆制造和轮轨表面处理等的原理和特点，分析了目前激光加工技术在城市轨道车辆制造中的特点和应用前景，为缩短与国外先进技术的差距，加快轨道交通技术储备提供参考。

城市轨道交通已成为现代城市公共交通的主动脉，具有运量大、能耗低、效率高、污染小、准点率高等优势。中国如今已成为全球城市轨道交通建设投入的主力军，甚至连许多二线城市都具备了轨道交通建设的条件与需求。
随着中国政府“十三五”规划的提出，国家发改委已批复了多地轨道交通的规划，到2020年投资预计将超万亿。目前城市轨道车辆制造行业中，激光加工制造技术备受瞩目，其很大程度上提升了城市轨道车辆制造水平；轻量化与高速化的趋势，也持续为其提出新方向、新课题。

由于中国的城市轨道交通起步较晚，因此为了缩短与国外先进技术的差距，应引进、研究和消化当前最新技术及设计思路，加快轨道交通技术储备，探究激光加工技术在城市轨道车辆制造中的应用。车辆激光焊接车辆转向架以及车体是城市轨道车辆上的关键构成，材质也经历了普通合金钢、不锈钢、铝合金型材几个阶段。目前在城市轨道车辆制造中，逐步引入了激光焊接等新的加工工艺。

激光拼焊

激光拼焊是城市轨道车辆中最被看好的技术之一，属于无接触焊接，可将不同钢种、厚度、表面处理的钢板焊接成一个整体，区别于电阻滚压缝焊，通过自由组合，使得构件变轻，零件变少，不仅提高可靠性，为宽体车制造奠定基础，同时也改善了焊接质量，提高了钢材收得率，并降低了生产成本。

激光组焊

激光组焊在城市轨道车辆车身制造中举足轻重，通过双件组焊、多件组焊，将已切割成形的各类车身构件，焊接成白车身分总成，进而总装成整车车身。激光组焊因其焊接强度高，可明显改善车身强度、刚度及密闭性。焊接同时结合面小、变形小、焊接速度快、可焊材料范围广，适合于柔性化生产，投资效益好。但激光组焊技术也有明显的缺点，如对夹具、被焊件、监测精度等要求严格，焊接后检测评价和返修困难，一次性投入大等。

激光-电弧复合焊

1) 不锈钢车体制造。城市轨道车辆车体通常选用不锈钢车体，由于电弧焊接后热影响及变形等较严重，因此为改善外观，过去常常进行涂装作业，而现在则选用激光或电阻焊进行作业。

通过长期加工技术应用的实践、积累及分析，不锈钢接头焊接技术规范、疲劳曲线、硬度、抗拉强度、屈服强度、等技术指标相继被取得或检验，车体激光焊接样件的制评亦完成。


2) 车辆转向架制造。城市轨道车辆转向架通常选用日本进口或国产的中厚合金钢板材，同时多选用熔化极气体保护焊。用于长直缝焊接的机械人手臂，已被各厂商所引进，来改善焊接稳定性；而开具有不同规格的坡口，通常留较小钝边，以确保熔透。激光-电弧复合焊优化焊接效率，显示了激光和电弧的特点；同时减少了设备和人员投入，降低了焊接成本，并且可选较大钝边。


车辆激光切割

激光切割技术特性城市轨道车辆制造厂商已大量使用激光切割技术，其加工的产品有很多，如车体、内装板材、转向架，常选用二维平面切割。激光可以加工出高精度、高切割断面质量的零件外形、轮廓和孔。

固体(或CO2)激光切割机通常适用于碳合金钢、不锈钢，同时也适用于铝合金板，可达到理想断面加工质量和切割速度。以某企业为例，轨道车辆车体为不锈钢，选用6 k W激光和剪板机对6 mm以下板材下料。车辆转向架选用激光切割机对14 mm以下板材进行下料，其材料为Q345C低合金结构钢。

下料环节激光切割

城市地铁机车制造首先要准备相关材料，这个阶段激光切割技术尤为重要。激光切割与火焰切割相比，切割速度快、工件变形小、加工精度高、适用性强、节料省钱、经济适用[16]，因此激光切割技术已被广泛用于轨道车辆制造中。以某企业为例，其高速动车组车体选用激光和剪板机对6 mm以下板材下料，材料为铝合金板材及型材。车辆转向架选用6 k W激光切割机对12 mm以下板材下料[17]。

 

1492-PBC1 Power Distribution Block Accessory

中央处理单元 6ES7414-4HJ04-0AB0 CPU414-4H,1.4MB RAM，60ns，电源 24VDC，MPI/PROFIBUS-DP 主站接口

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1734-APB POINT I/O Profibus-DP Network Adapter

1756-L73XT ControlLogix 8MB Controller L7XT

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193-ESM-IG-30A-T E300/E200 30 Amp Sensing Module

194E-Y80-1753-6N 80 A 194E Load switch

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2090-UXPC-D0909 Ultra Series 9m Interface Cable

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GC647IFPRRNUNLMT GCC iFIX Profsnl SCADA Unlmt Run

IC200CHS014 I/O interposing box style Thermocouple cold junction compensation

IC646MRA300 View Runtime 300 I/O

IC647IFSTDV00900M iFIX Standard HMI 900 I/O Development (M4 Part)

IC670CBL002 21 inch I/O Expansion Cable

IC697CPX935 CPU, 96 MHz, 12K Discrete I/O, 1M byte fixed user memory

IC800SKCEZ050 Encoder cable to connect an S2K to any 30 Watt to 750 Watt S-series servo motor. 5 meters

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Industrial Computers 6182H-10TRH15D VVCE 1000, TOUCH, STD MEM, CNET, DC

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IC600KD512RR Color Operator Interface Terminal, 12" CRT

IC800SGM450M2KE25 4500W, 230V S-Series Servo Motor, 322 in-lb (36.4 Nm)

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280-PWRM22E-M025 ArmorStart Three-Phase Power Media

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1492-M6X12VR1-20 Connection Products

1494R-N19 200 A/400 A Multi-Tap Lug Adaptor Kit

软启动器 3RW44476BC44

ET 200SP 6ES7193-6SC00-1AM0 基座单元屏蔽组件

1585D-M4UBDE-0M3 1585D Ethernet Media Patchcord

1756-IB16D ControlLogix 16 Point D/I Module

1794-TB3GS Flex Terminal Base

194E-E100-1753-6N 100 A 194E Load switch

2090-CFBM4DD-CDAA03 MP-Series 3 m Length Feedback Cable

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IC756WET200K-23 Custom Datasource Toolkit, Korean, Version 2.3

CompactLogix System 1769-STRT2DE COMPACTLOGIX STARTER KIT GERMAN

PLC-5/1771 System D1771-6.5.27 DIRECT COMMUNICATION MODULE(1771-DCM)USER'S MNL

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IC752ECD550 Display Station 1493 - 14" XGA (1024x768) resistive touch screen, Pentium 133, 32MB, 2 Gig hard drive, expansion slots, Ethernet, with CIMPLICITY HMI and Win NT

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2711P-T10C4D9 PanelView Plus Terminal

FRN280P11S-4CX 400KVA 520A 280KW 3相AC380V/50Hz/60Hz

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156-B30BV1 30 A Contactor

1746-IB8 SLC 8 Point DC Input Module

1786-TNCL10 ControlNet Media TNC Connector Plug

193-T1BC30 24.5-30.0 A IEC Bibllic Ovld Relay

20-HIM-A5 PowerFlex Architecture Class HIM

2090-CSBM1DF-14AA20 Kinetix 20m Smartb Single Cable

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GA647TPR915 Proficy GlobalCare Assist for CIMPLICITY HMI ProServer 1500 I/O Runtime System

GP647IFSTDVUNLMT GCP iFIX Std HMI Unlmt Dev

IC600CB524RR Arithmetic Control Module

IC647HSTCSCCP25M Historian Enterprise Corporate Client Enterprise Connection Pack 25 Users (M4 Key)

IC647UDCC UDC:Honeywell UDC Controllers

IC693UAA007RR 28 pt AC In/AC Out, AC Power Supply

IC756RDV000K-99 DV Development - Irix Op Sys, Korean, Version 9.9

MicroLogix 1200 System 1762-L24BWA MICROLOGIX 1200, 24 PT.

PLC-5/1771 System 1771-CFMK CONFORMALLY COATED, CONFIGURABLE FLOW METER

Distributed I/O 1794-IB10XOB6 10/6 24VDC COMBO

Communications 9355-WABGWFRE RSLINX GATEWAY - FRENCH

Operator Interface D6190-6.5.9 CONTROLVIEW NETWORKER(CAT.NO.6190-NET)USER'S MNL

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Motion Control Y-2012-2-H00AA MOTOR,SERVO,1.35 NM,4500RPM,ENCDR,230V,2.31KG

5401 Greyline Micro MC. 2 Lines, (20) 5MM Chars. LCD. Quick Connect. NEMA 4

IC200DTX450 Operator Interface with up to 200 stored messages. 2 x 16 character LCD backlight display and 6 function keys

IC695CHS016 RX3i BASE 16 SLOTS

MSI-WEB-UNL-43 Unltd Site Clients - Web or Excel Rep-43

VSPCSE-OPC10 Secure Edition OPC Client Option includes VisualSPC Importer (licensin g is per client PC), Support for up to 10 Points/Tags.

20BD065A0AYNAND0 PowerFlex 700 AC Drive 65 A 50 Hp 20B

20G11LE825JN0NNNNN PowerFlex 755 AC Packaged Drive

22F-A011N113 PowerFlex 4M- 2.2 kW (3 HP) AC Drive

490NRP25300 Quantum 光纤中极器,MBPL

291E-FAP-G1 Direct Online Reversing Starte

P2CF-08 导轨安装型，

1492-SPM2D070 MCB Supplementary Protector 7 A

软启动器 3RW30382BB14

电机启动器 3VU16400CQ00

150-F317NBDB SMC Flex Smart Motor Controller

1732E-IB16M12DR ArmorBlock 16 Point Input

1771-RTP3 1771 Remote Terminal Panel

193-EEGF E1 Plus 18-90 A Overload Relay

20-750-1132C-2R PowerFlex 750 Series 24V DC EIO Kit

2090-CPWM7DF-08AF25 MP-Series 25m Continuous-Flex PWR Cable

2097-R6 Kinetix 300/350 75 Ohm Shunt Resistor

ENP2115M010 Male Industrial/Male Industrial, 1 meter

GFK-1687 User Manual-Mini OCS Hardware Manual

IC220BEM485 RS-485 Communications Module interfaces serial I/O devices to a VersaPoint I/O Station. Requires a NIU that supports PCP services, not compatible with IC220EBI002 Ethernet NIU. Supports the following protocols Transparent, End-to-end, Dual buffer,

IC647CSPC005 Proficy Cause+ for Inbligent HMI/SCADA Client Enabler - 5X CALs

IC647PSC000 Proficy Process Systems 5000+ I/O with CIMPLICITY

IC693MCD001 Beta series servo demo case

IC756ADV010J-99 DV Draw Development on AIX Op Sys, Japanese, Version 9.9

MSI-MGMT-100 Production Management Clients 100 Pack

PLC-5/1771 System 1771-DXPS CONTROL COPROCESSOR - SERIAL EXPANDER MODULE

Distributed I/O 1738-IR2M12 24VDC 2 INPUT RTD WITH M12 CONNECTORS

Communications 1784-PCD DEVICENET PCMCIA COMM CARD

Operator Interface 2711-NV6T ANTIGLARE OVERLAY PV1000 TOUCH

Support 9304-WRM300R 9304-WRM300 SOFTWRE SUPPORT CONTRACT REINSTATEMENT

Support 9393-EGLX500R SUPT REINSTATEMENT CONTRACT FOR 9393EGLX500

DeviceNet Products 2706-PDNETK DEVICENET COMMUNICATION MODULE FOR 2706-P7X & P9X

RSI Software Products 9301-2SE335ITU1R RSVIEW32 RUNTIME 150-5K UPGRADE OUT-SUPT (IT)

RSI Software Products 9371-EDES2 RSWIRE DESIGNER/JIC FOR AUTOCAD 14-14.01

Motion Control MPG-B010-031M22 MOTOR,SERVO,GEAR RATIO 31,25NM,208RPM,MULTI,460V

Silver Series 2711-K14C12 PV1400 COLOR KEY, PBUS & RS232 PRINT

HE693SER300 Slot One Sequential Event Recorder

IC670ALG620 RTD 4 Channel Isolated 3 wire

QPI-DEM-L02 QUICKPANEL DEMO 10.5" MONO LCD

ST-5651 STXi 1 Channels, Pulse Out module, 0.5A/5V (RS422), 20Khz

20BC260A0ANNAED0 PowerFlex 700 AC Drive 20B

20F1ANC205AN0NNNNN PowerFlex 753 AC Packaged Drive

22B-B012N104 PowerFlex 40- 2.2 kW (3 HP) AC Drive

140DII33000C Quantum 开关量输入, 8点, 本安型,CC

284D-FVD6P0B-25-RR-3-DB-SB-EMI DeviceNet Variable Frequency Drive

E3S-VS1E4 色标检测型 1.2CM晶体管输出NPN最大80MA电源12-24VDC

1492-SPM1B010 MCB Supplementary Protector 1 A

人机界面 6AV6545-0DB10-0AX0 MP370 触摸面板，256 色，15.1 英寸，800? 600

6ES73317KF024AB2

1497B-A6-M13-0-N Control Power Transber

1606-XLS480G-3 36-42V Dc 480 Watt Power Supply

1769-IG16 CompactLogix 16 Pt TTL DC D/I Module

189-ASCR3 MCB Accessory Signal Contact

194R-HM4E 194R 100-400-625 A Operating Handle

2090-CPBM7DF-14AA07 MP-Series 7m Standard Cable

2090-XXNPMP-8S05 MP-Series 5 m Length Power Cable

CBL-3C-L1D-FLY-10 S2K flying lead feedback cable for special for 3rd party motors with hall commutating encoders. 10 feet

GF-0304 Connecting FlashCable to Edmunds Trendsetter (for use with the Combo G agePort). Contact Dave Chapman X5472 for additional electrical testing.

IC200TBX340 Tool box, Micro 40, operator interface and software. Includes (IC200UDR140) 24VDC In/Relay Out, requires 120/240VAC power, (IC200USB001) RS-232 option board with (2) 0 -10VDC analog in with VersaMax DataPanel DP 45 (IC200DTX450) with Proficy Logic

IC646TBSPMPW025 Smart Process Monitoring Process+ Web Clients 25 Pack

IC647NST000 CIMPLICITY HMI Stratus High Availability Server License

IC693ACC350 Redundant Power Supply Adapter (RPSA) Module. The RPSA replaces the p ower supply on a CPU base or expansion base and connects to a Redundan t Power Supply Base.

IC752CBT050RR Datapanel 320T CB (Color Base): 320x240 1/4 VGA Passive Color with 803 86SX/40 PC processor. Analog touch screen with text, bitmaps, bar gra phs, real time clock.

IC800VMCP3030 Power cable for 3 kW VersaMotion servo motors- 3 meter

SLC/1746 System 1746-NI8 (8) ANALOG INPUT FOR PROGRAMMABLE CONTROLLER

Industrial Computers 6189V-CPUSTD2 STANDARD SBC (W/CPU AND COOLER) (1400R)

Application-specific products 1403-CF010 10 M F LINK FOR POWERMONITOR

Operator Interface 2711-K6C1 PV600 COLOR KEY, RIO & RS232 PRINT

Support 9301-2SE2400PTR SUPT REINSTATEMENT CONTRACT FOR 93012SE2400PT

Support 9323-1003ENS SUPT RENEWAL CONTRACT FOR 93231003EN

DeviceNet Products 1734-OB2EP 24V DC 2 AMP 2 CHANNEL SOURCE OUTPUT MODULE

RSI Software Products 9301-2SE3100ITE RSVIEW32 RUNTIME 150 (ITALIAN)

RSI Software Products 9358-BNTK30U1R UPGRADE: OUT-SUPT: RSBATCH BACK-UP KEY 03 TO 30

Motion Control MPL-B420P-MJ22AA MOTOR,SERVO,4.74 NM,5000RPM,MULTI,460V,5.0KG

Motion Control 2090-UXBB-DM09 BREAKOUT BOARD, CN3, ULTRAX000 DRIVE MOUNTED

GFK-0771 C Programmer's Toolkit for Series 90 PCM User's Manual

IC646MDA075 View 75 Tag Runtime & Development System

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PSPC-MONITOR10 Prof Shop Floor SPC Monitor 10 User

20BC022A0AYNACB0 PowerFlex 700 AC Drive 22 A at 11 kW 20B

20F11GC011JA0NNNNN PowerFlex 753 AC Packaged Drive

2198-P070 Kinetix 5700 DC Bus Supply

2711P-RCH PanelView Plus Accessory

280D-F12B-10A-CR ArmorStart Direct Online Starter

CQM1-OA221 输出 8点.可控硅 100-240V AC 0.4A

1492-N49 TERM BLCK 10 Pole Side Jumper

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变送器 3RS18001BP00

TIA 博途 WinCC 选件 6AV2107-0LH00-0BB0 SIMATIC WinCC DataMonitor for Runtime Professional 25 Clients

1585J-M8PBJM-1 RJ45 Ethernet Media

1760-L12BWB-ND Pico 12 Point DC Controller

188-K2C130 Miniature Circuit Breaker 13 A

194L-A25-1753-6N 25 A 194L Load Switch

2090-CNSRPRS-AA07 Kinetix 6000M Network Cable

2090-XB120-03 107 Amp 3 Ohm Resistive Brake Module

BC647MRA075 View Runtime 75 I/O with Proficy GlobalCare Complete with USB Hardware key

GC647IFSTRN00900 GCC iFIX Std HMI 900 I/O Run

IC200CPU005 CPU 128K user configurable user memory, 0.8MSEC/K Boolean one RS232 and one RS485 serial ports

IC646NAP000 Applicom Communications

IC647IFSTRN00900C iFIX Standard HMI 900 I/O Runtime (M1Component Part)

IC670GBI102RR 120Vac/125Vdc Powered Genius Bus Interface Unit

IC697MCS704 This part is obsolete

IC800SLCAPM010 Control cable to connect the SL servo amplifier terminal block to an APM300 motion controller module. 1 meter

ControlLogix/1756 System 1756-M03SE 1756 3 AXIS SERCOS INTERFACE SERVO MODULE

Industrial Computers 6182H-12BRH4B VVCE 1250, KEY/TOUCH, STD MEM, ENET, AC

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Operator Interface 2711P-RN15S CONTROLNET COMMUNICATIONS MODULE

Support 9355-WABSNS SUPT RENEWAL CONTRACT FOR 9355WABSNEN

Support 9361-CHARTR SUPT REINSTATEMENT CONTRACT FOR 9361CHART

ControlNet Products 1734-IV2 24V DC 2 CHANNEL SOURCE INPUT MODULE

RSI Software Products 9301-2SE2400U2R UPGRADE: OUT-SUPT: RSVIEW WORKS 300 TO 32K

RSI Software Products 9357-DNETL3U UPGRADE: IN-SUPT: DNET MGR TO RSNETWORX FOR DNET

Motion Control MPL-A330P-SK24AA MOTOR,SERVO,4.18 NM,5000RPM,SINGL,230V,BRK,6.1KG

Motion Control 2090-UXNFBMP-S03 CABLE,ULGRF50ON-FLEX,MOTOR FEEDBACK,MP,3M

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IC600WD025 I/O Cable, 25 feet (7.5m)

IC800SKCI030 Interface Cable, S2K Aux. I/O Connector to 44A726268-001 Terminal Block, 3 Meter

OC647IFESGSR00900M iFIX Optn: ESig & ERec 900 I/O Server (M4 Part)

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