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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]。

 

IC200CPUE05 CPU WITH CONFIGURABLE USER MEMORY 0.8 MSEC/K BOOLEAN ONE RS232 SERIAL PORT ONE RS485 SERIAL PORT AND ONE 10/100 MBIT BASE T ETHERNET PORT

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IC752CTD550 Display Station - 10.4" active matrix VGA (640x480) resistive touch screen, Pentium 133, 32M, 2 Gig hard drive, expansion slots, Ethernet, with CIMPLCITY HMI and Win NT

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ZA06B-0239-B500 Alpha 12/4000HVis servo motor with straight shaft with key and brake

20BD8P0A3AYNAND0 PowerFlex 700 AC Drive 8 A 5 Hp 20B

20G14ND077AA0NNNNN PowerFlex 755 AC Packaged Drive

25-PM2-D024 PowerFlex 520 11kW (15Hp) Power Module

Safety Quantum系统

FRN1.5C1S-7C 3. 0KVA 8.0A 1.5KW 单相AC220V/50Hz/60Hz

1492-J4-RE 4 square mm Feed-Through Terminal Block

1492-SPM3D300-N MCB Supplementary Protector 30 A

软启动器 3RW40556BB45

配件 6ES7 297-0AX30-0XA0 S7-1200 电池板

150-TC3 SMC-50 IEC Line Or Load Terminal Covers

1738-IV8M12 ArmorPoint 8 Point Digital Input Module

1784-PKTX Data Highway Plus PC Card

193-NCRID E1 Plus Remote Indication Display

20-750-PUB-IN1-EN PowerFlex 750 Series Install Publication

2090-CSBM1DE-14AF01 Kinetix Cable Single DSL 2090-Series

20AB6P8A0AYNNEC0 PowerFlex 70 AC Drive 6.8 A at 2 Hp 20A

GA647IFPRRN00300 GCA iFIX Profsnl SCADA 300 I/O Run

GP647IFESGRNUNLMT GCP iFIX Optn: ESig & ERec Unl I/O Run

IC600BF907RR 12Vdc Source Output Module (8 points)

IC647HSTCR1250KM Collector Redundancy Option for Historian - Standard Server 1,250,000 Points (M4 Key)

IC647TMS001 CIMPLCTY UPGRADE INTEL- NO COST

IC693PCM300LT Prog. Coproc. Mdl., 160 KB (35 KB Basic Prgm), w/Port Exp. Cbl. (LT)

IC756LDV010J-99 DV Draw Development on Inb/Linux RedHat Op Sys, Japanese, Version 9. 9

MicroLogix 1000/1761 System 1761-L16NWA MICROLOGIX 1000 16PT. WITH 24V AC INPUTS AC POWER

PLC-5/1771 System 1771-SIM 8 POINT DISCRETE INPUT/OUTPUT SIMULATOR MODULE

Distributed I/O 1792D-12BVT4D 12 SINK/SOURCE INPUTS, 4 SOURCING 0.5 AMP OUTPUTS

Communications 1788-MCHKR NETWORK MEDIACHECKER (ENET, CNET, DNET, DH+/RIO)

Operator Interface D1784-6.5.6 T35 PLANT FLOOR TERMINAL (1784-T35) USER'S MANUAL

Support 9356-PRO2500S SUPT RENEWAL CONTRACT FOR 9356PRO2500