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SCC-ICP01

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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]。

 

AIMB-750

FSP460-60GLN

SOL2MEVCLB

HY-6220

1492-MC6X10 IEC 6 x 10 mm Marker Card

1492-WMG3 IEC Term Blck 8x47.6x41mm Screw

通用型变频器 6SE6 420-2UC15-5AA1 0.55 KW，73 x 173 x 149

数字量输出信号板 6ES7 222-1BD30-0XB0 SB 1222 DQ 4 x 24 V DC，200 kHz

TIA 博途 WinCC 选件 6AV2107-2KG00-0BD0 SIMATIC WinCC WebNavigator for Runtime Professional Powerpack 5 -> 10 Clients

1585J-M8HBJM-50 RJ45 Ethernet Media

1760-IB12XOW6I Pico DC Expansion Input/Output Module

188-K2C005 Miniature Circuit Breaker 0.5 A

194L-A12-1754 12A 194L Load Switch

2090-CHBP8S8-12AA12 Kinetix 6000M IDM Hybrid Cable

2090-UXTBMP-18S12 MP-Series 12 m Length Brake Cable

BC647MPP101 Logic Developer PLC Professional with Programming Cable with Proficy GlobalCare Complete with USB Hardware key

GC647IFSTDV00075 GCC iFIX Std HMI 75 I/O Dev

IC200CHS102 I/O interposing disconnect style, 16 point expansion

IC646MSP005 Logic Developer State Professional 5 Pack

IC647IFSTRN00075K iFIX Standard HMI 75 I/O Runtime (M1 Kit Part)

IC670CHS003 I/O Base, Connector Style

IC697CSE925 State Logic CPU, 64MHz, 80486DX2

IC800SKCI030 Interface cable to connect an S2K auxiliary I/O connector to the 44A726268-001 terminal block. 3 meter

ControlLogix/1756 System 1756-OG16 0-5 VDC TTL OUTPUT (LOW TRUE) 16 PTS (20 PIN)

Industrial Computers 6182H-12BEH15B VVCE 1250, KEY/TOUCH, EXT MEM, CNET, AC

Process Control 1757-FIMUPG080 FIELDBUS LICENSE UPGRADE, 80 FIMS

Operator Interface 2711P-RGT12 PV PLUS/VVCE PROTECTIVE ANTIGLARE OVERLAYS QTY 3

Support 9355-WABOEMENS SUPT RENEWAL CONTRACT FOR 9355WABOEMEN

Support 9354-SS100R 9354-SS100 SOFTWARE SUPPORT CONTRACT REINSTATEMENT

ControlNet Products 1788-CNF CONTROLNET LOGIX DAUGHTER CARD

RSI Software Products 9301-2SE2400PTE RSVIEW32 WORKS 32K (PORTUGUESE)

RSI Software Products 9355-WABSNEU3R UPGRADE: OUT-SUPT RSLINX SINGLE NODE TO RSLINX GW

Motion Control MPL-A330P-HK24AA MOTOR,SERVO,4.18NM,5000RPM,ENCDR,230V,BRK,6.1KG

Motion Control 2090-UXNBMP-18S01 CABLE,ULTRA,NON-FLEX,MOTOR BRAKE,MP 1 MTR.

CBL-12-MPS-30 Power Cable, MTR-1221-*-D & MTR-1231-*-D Stepping Motor with S2K, 30 Ft.

IC600PB552RR PDT Prom Board

IC800SKCBVL100 Power/Brake Cable, S2K to 4.5 - 5kW S-Series Servo Motors, 10 Meters

OC647IFESGRNUNLMTM iFIX Optn: ESig & ERec Unl I/O Runtime (M4 Part)

PXI-2206

eTX-Lx15

FSC-1611VD4N

N55-PAC-750W

PCISA-3716EV-R3

PCIe-RTV24

1492-M6X5V1-50 Connection Products

1494U-AC 1494U 30A-100A Crossbar Adapter

软启动器 3RW44532BC44

SIMATIC STEP 7 V14 6ES7822-0AA04-0YA7 SIMATIC STEP 7 基本版 V14 试用授权

1585D-M4UBDE-3 Ethernet Media M12, Patchord

1756-IB16K ControlLogix 16 Pt 12/24V DC D/I Module

1794-TB3TK Flex Terminal Base

194E-E16-1753-4A 16 A 194E Load switch

2090-CFBM4DF-CDAF02 MP-Series 2m Feedback Cable

2090-KFBE7-CAAA MP-Series Feedback Connector Kit

AT-8624FC-10_2 Proficy Process Systems Switch with Two Multi-mode Fiber Modules from Allied-Telesis

GC646TDV915 Proficy GlobalCare Complete for 1500 Point I/O Development / Runtime System.

HMI-AGO-203 ANTI-GLARE OVERLAY 5 inch/ 5 per pack

IC640WMI310RR Series 90 XT/AT Serial Interface Card

IC647HSTSSEO750KM eSignature Option for Historian - Standard Server 750,000 Points (M4 Key)

IC660BSM120RR Bus Switching Module, 24/48 Vdc

IC695ETM001 Ethernet module 10/100 Mbits 2 RJ45 connections one IP address occupies one slot on system base

IC756WRE024E-275 "Runtime License for Windows 1-24 Users, Per User, English v2.7.5"

FlexLogix System 1794-L34 FLEX LOGIX PROCESSOR, 512KBYTES USER MEMORY

PLC-5/1771 System D1771-6.5.7 ANALOG INPUT MODULE(8-BIT)(1771-IE)USER'S MANUAL

Process Control 1757-PLXNU OPEN DATA ACCESS - 1 USER

Operator Interface 2711P-RDT7C PV PLUS 700, TOUCH SCREEN DISPLAY MODULE

Support 6626-NMU2R 6626-NMU2 SOFTWARE SUPPORT REINSTATEMENT

Support 8100-HSRASS SUPT RENEWAL CONTRACT FOR 8100HSRAS

Support F1785-L20C15SERC FIRMWARE UPGRADE FOR 1785-L20C15 PLC5 PROCESSOR MO

RSI Software Products 9301-2SE220FRU1R RSVIEW32 WORKS 150-300 UPGRADE OUT-SUPT (FR)

RSI Software Products 9701-VWSB100DEU1 RSV SE STATION 25 - 100 DISPLAY UPGRADE (GERMAN)

RSI Software Products 9399-HDWAREREFFR HARDWARE INTERFACE CONFIG. USER GUIDE (FRENCH)

Motion Control 2098-DSD-HV100-DN HIGH VOLTAGE DRIVE, 23A/46A, ULTRA3000 W/DNET

BC641VPN950 VersaPro Nano/Micro Edition 50 Seat Site License - Windows Programming Software for VersaMax Nano/Micro PLCs

IC300DIQ622 8 AC Inputs (120 vac), 6 Isolated Relay Outputs (4.0Aper point)

IC752GEIU11 GEF 9030 I/O Master/Scanner for ControlStation CE Iix

MTR-3S46-G-R-B-E-SRR Servo Motor 24V Brake, Seal

PCI-4462

SBC84500/510

COM-840-R-12

BPA-R350-21N

MMC-BDPV81

GV-N610D3-1GI

1492-JG10 10 square mm Ground Terminal Block

1492-WD6 IEC Term Blck 8x47.6x41mm Screw

软启动器 3RW44221BC46

性能信号模块 6ES7 522-5HH00-0AB0 DQ 16：数字量输出模块，继电器 DQ 16x 230 VAC/ 2A ST (RELAY), 35mm 模块，不含前连接器

156-B32CA3 32 A Contactor

1746-IV32 SLC 32 Point Digital Input Module

1786-TPST2T ControlNet Coaxial IP67 TNC T-Tap

193-T1DC47 35-47 A IEC Bibllic Overload Relay

20-HIM-H10 PowerFlex 20 HIM Remote Cable Kit

2090-CSBM1DF-14AF05 Kinetix Cable Single DSL 2090-Series

20AC022A3AYNAEC0 PowerFlex 70 AC Drive 22 A at 11 kW 20A

GA647TRT300 Proficy GlobalCare Assist for CIMPLICITY HMI Server 300 I/O Runtime System

GP647IFUBSTS GCP iFIX iClientTS User Base Support

IC600CM542RR 2K CMOS Logic Memory Module

IC647HSTCSEO100KM eSignature Option for Historian - Enterprise Corporate Server 100000 Points (M4 Key)

IC647WDEM WDE:Woodword Modbus Ethernet

IC693UEX011RR 14pt DC In/Relay Out, AC Pwr. Sup.

IC756RDV001J-99 DV Development - Irix Op Sys Addt'l User, Japanese, Version 9.9

MicroLogix 1200 System 1762-L40BWA MICROLOGIX 1200, 40 PT.

PLC-5/1771 System 1771-IJ ENCODER/COUNTER MODULE ASSEMBLY TTL, 5V DC

Distributed I/O 1794-IB32 24 VDC INPUT MODULE, 32 POINTS

Communications 9355-WABOEMDEE RSLINX OEM - GERMAN

Operator Interface D6195-6.5.2FR CONTROLVIEW 300 USER MANUAL (FRENCH)

Support 9358-BEPB10S SUPT RENEWAL CONTRACT FOR 9358BEPBNT10ENE

Support F1756-DNB FIRMWARE UPGRADE FOR 1756-DNB/A MODULE

RSI Software Products 9324-RL0300ESE RSLOGIX 500 STANDARD SPANISH CD

RSI Software Products 9301-2SE3503KOE RSVIEW32 RUNTIME 100K WITH RSLINX (KOREAN)

RSI Software Products 9358-HSTS2300 RSBIZWARE HISTORIAN SERVER - 1500 TAG LIMIT

Motion Control W-3016-N-H00AB MOTOR,SERVO,WASHDOWN,BF,1.7 NM,3000RPM,6.4KG

5601 Greyline Micro MC. 2 Lines, (20) 5MM Chars. LCD. ASCII/Serial Interface. NEMA 4

IC200ETM001 EXPANSION TRANSMITTER

IC695DEM003 RX3i type 3 demo stand. Demo includes, CPU, power supply, Ethernet, b simulator, output, high speed counter, comination analog, Universal analog, and digital servo module, QuickPanel control/View, and S2K amplifier and motor

MTR-1220-0-A-E-0RR Stepping Motor Nema23 Double Shaft

cRIO-9073

PCA-6277VE

MOXA CP-118U

EC0-1815V2NAR

ACE-916A

VPM-8120X-5060

ROBO-8111VG2AR-Q77

1492-SPM2D160 MCB Supplementary Protector 16 A

软启动器 3RW30471BB04

电机启动器 3VU16401CK00

150-F317NZD SMC Flex Smart Motor Controller

1732E-IF4M12R ARMORBLOCK 4 POINT ANALOG INPUT

1771-WA FIELD WIRING ARM 10 TRMLS TIN PLATED

193-EEKG E1 Plus 60-300 A IEC Overload Relay

20-750-2262D-2R PowerFlex 750 115V AC IO Option module

2090-CPWM7DF-10AA02 MP-Series 2m Servo Power Cable

2097-V31PR2-LM Kinetix 350 800W Servo Drive

ENQAM315 Attachable Connector, Stranded Cable

GFK-1868 CIMPLICITY Machine Edition Getting Started

IC220EBI001 Ethernet Network Interface Unit (REQUIRES 1 IC220TBK087)

IC647CSPR005 Proficy Cause+ for Inbligent HMI/SCADA Runtime Server - 5X monitored KPIs

IC647PSC500 Proficy Process Systems 5000 I/O with CIMPLICITY

IC693MDL230RR 120 Vac Isolated Input (8 Points)

IC756CDV000E-98 DV Development - Compaq True64 Op Sys, English, Version 9.8

MSI-MGMT-43 Production Mang Clients-43

PLC-5/1771 System 1785-L30B PLC-5/30 CONTROLLER, 32K WORD SRAM

Distributed I/O 1738-SSIM23 SSI ABSOLUTE ENCODER INTERFACE

Communications 1787-PLUG10R DEVICENET 10 POSITION CONNECTOR WITH JACK SCREWS

Operator Interface 2711-NM14 4 MBYTE PC FLASH MEMORY CARD FOR PANELVIEW E TERMS

Support 9304-WVD128R SUPT REINSTATEMENT CONTRACT FOR 9304WVD128

Support 9324-RLD250DEE RSLOGIX 5000 LITE EDITION GERMAN

DeviceNet Products 2711-B5A10L2 PV550 MONO KEY&TOUCH, DNET & RS232 PRINT

RSI Software Products 9301-2SE335KOU1R RSVIEW32 RUNTIME 150-5K UPGRADE OUT-SUPT (KO)

RSI Software Products 9371-EDESI1U4 UPGRADE: IN-SUPT: RSWIRE DET IEC STD TO DES IEC

Motion Control MPG-B010-091S22 MOTOR,SERVO,GEAR RATIO 91,35NM,71RPM,SINGL,460V

Silver Series 2711-K14C8 PV1400 COLOR KEY, DH+ & RS232 PRINT

HE693STG884 8-ch. +/-25mV, +/-50mV, +/-100mV with 16-bit resolution + weighing func.

IC670CHS004 TC Cold Junction Compensation Base

QPI-PBS-201 MODULE PROFIBUS DP SLAVE W/O MEMORY RETENTION

ST-7118 STXi Potential Distribution module module, 24VDC, 8 points, 10A

USB-9472

C79458-L9006-B

P4SGA+

DELL Studio XPS 9000

EC7-1814

GALIL ICM-20100

1492-SPM1B040 MCB Supplementary Protector 4 A

6ED1052-1FB00-0BA5 "LOGO!230RC 8DI/4DO,230V,10A 继电器输出"

6ES73317PF114AB2

1497B-A9-M14-0-N 500VA 240x480-120x240V 60Hz CPT

1606-XLS960F-3 380 to 480VAC In 48 to 54VDC Out 960W PS

1769-IQ6XOW4 CMPLX 10 Pt 24VDC D/I Relay D/O Module

190-HM4 Circuit-Breaker Accessory

194R-J30-1753 194R Disconnect Switch

2090-CPBM7DF-14AA30 MP-Series 30m Standard Cable

2090-XXNPMP-8S30 MP-Series 30 m Length Power Cable

CBL-3C-RD-10 Resolver cable for MTR-3S or MTR-3N series servo motors. 10 feet

GF-0800-1 Connecting FlashCable to Generic Torque (bare-ended cable).

IC200TBX540 Tool box, Micro 40, QuickPanel color touch screen and software. Includes (IC200UDR140) 24VDC In/Relay Out, requires 120/240VAC power, (IC200UEM001) Ethernet option board, QuickPanel Display (IC754VSI06STD) with Proficy software, manuals and cables (

IC646TBSPMSW001 Smart Process Monitoring SPC+ Web Client

IC647NTS050 CIMPLICITY HMI Terminal Services 50 User Pack

IC693ALG220LT Analog Input, Voltage/Current, 4 Channels (LT)

IC752CGE101 SNP 485 cable for DataPanel 30/50

IC800VMM02LBKSE25 200 W VersaMotion servo motor with 24 VDC holding brake (0.64 Nm)

SLC/1746 System 1746-NO8V 8 CHANNEL ANALOG VOLTAGE OUTPUT FOR SLC 500

Industrial Computers 6189V-DIMM512 DIMM MEMORY 512MB

Application-specific products 1403-DMB DISPLAY UNIT FOR POWERMONITOR

Operator Interface 2711-K6C15 PV600 COLOR KEY, CNET & RS232 PRINT

Support 9301-2SE2500DER SUPT REINSTATEMENT CONTRACT FOR 93012SE2500DE

Support 9323-P1003ENS SUPT RENEWAL CONTRACT FOR 9323P1003EN

DeviceNet Products 1734-OW4 24V DC COIL N.O. DPST 4 RELAY MODULE

RSI Software Products 9301-2SE3103DEE RSVIEW32 RUNTIME 150 WITH RSLINX (GERMAN)

RSI Software Products 9358-BNTK60U3R UPGRADE: OUT-SUPT: RSBATCH BACK-UP KEY 30 TO 60

Motion Control MPL-B420P-RJ24AA MOTOR,SERVO,4.74 NM,5000RPM,RSLVR,460V,BRK,7.7KG

Motion Control 2090-UXBK-D1515 BREAKOUT BOARD KIT,MTR FDBK,CN2,ULTRA X000,15M

GFK-0825 Field Control Distributed I/O and Control System Genius Field Processor User's Manual

IC646MDB000 Logic Developer PC w/Runtime 8,000 I/O

MSDIS-1200 Marathon 12" Display, Touch

PSPC-MONITOR25/E Prof Shop Floor SPC Monitor 25 User eSig

PXIe-2575

OMRON XM2C-0912

C79040-A6420-C849-03-85

PCLTA-20

MATROX METEOR2/4 750-03

PCM-9371

1492-NM16 TERM BLCK End Barrier

前连接器 6ES7392-1AJ00-0AA0 20 针前连接器，螺钉型

变送器 3RS18001HP00

TIA 博途 WinCC 选件 6AV2107-2LK00-0BD0 SIMATIC WinCC DataMonitor for Runtime Professional Powerpack 25 -> 50 Clients

1585J-M8PBJM-1X 1585J Ethernet Media Cables

1760-L18AWA-EXND Pico 18 Point AC Controller

188-K2C400 Miniature Circuit Breaker 40 A

194L-E12-1752 12A 194L Load Switch

2090-CNSRPRS-AAP5 Kinetix 6000M Network Cable

2090-XNRBM-2 RBM CONN SPARE PARTS KIT (75A)

BC647MRC000 Logic PC and View Runtime 8000 I/O with Proficy GlobalCare Complete with USB Hardware key

GC647IPWRPLDV00300M iPower Option - Nwk 300 I/O Dev Globalcare Complete part

IC200DEM004 VersaMax MicroMotion and VersaMotion Simulator is prewired and ready to use. The simulator includes a IC200UMM102 MicroMotion Module, Serial Port on VersaMotion Motor, Amplifier, communications cable (1meter)from VersaMotion to Micro, programming ca

IC646NDF000 Allen-Bradley DF1 Communications

IC647IFUBSTSC iFIX iClientTS User Base Support (M1Component Part)

IC670MDL241 240VAC Input, 16 Point, 2 Groups of 8

IC697MDL250RR 120 Vac Input (32 Points)

IC800SLCBZ050 Brake cable for any 30 Watt to 750 Watt S-series servo motor with brake. 5 meters

ControlLogix/1756 System 1756-DMCF010 10 M DUPLEX FIBER OPTIC CABLE FOR DRIVE MODULE

Industrial Computers 6182H-12KEH4B VVCE 1250, KEYPAD, EXT MEM, ENET, AC

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