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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]。

 

E5CZ-Q2 NEW 外型：48×48mm開孔；45×45電源：100V-240VAC

1494F-M1 Disconnect Switch Handle

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軟啟動器 3RW44472BC46

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1497-M-BASX-0-N Control Circuit Transformer

1608N-BP025A240V2 MiniDySC 25 Amp Bypass

1783-US16T Stratix 2000 16 port unmanaged switch

188-K2C200 Miniature Circuit Breaker 20 A

194L-A40-1752 40 A 194L Load Switch

2090-CNSRPRS-AA12 Kinetix 6000M Network Cable

2090-XB33-16 RESISTIVE BRAKE MODULE 33A 16 OHM

BC647MRA159 View Runtime 1500 I/O with Proficy GlobalCare Complete with USB Hardware key

GC647IFUBSTS GCC iFIX iClientTS User Base Support

IC200CPUE05CA Conformal coated CPU with built-in Ethernet 10Mbits, one RS 232 and one RS 485 port.

IC646NCN010 HMI for CNC Option

IC647IFSTRNUNLMTC iFIX Standard HMI Unlimited Runtime (M1Component Part)

IC670MDL233RR 120VAC 8 pt. Isolated Input

IC697MDL241 240 Vac Isolated Input (16 Points)

IC800SLCBV100 Power/brake cable for SLM100 or SLM250 S-series servo motor with brake. 10 meters

ControlLogix/1756 System 1756-DMAF 2-RE PMI FIBER OPTIC CABLE ADAPTERS

Industrial Computers 6182H-12BRH6D VVCE 1250, KEY/TOUCH, STD MEM, RIO/DH, DC

Process Control 1757-PFBEXP035 PROFIBUS INTERFACE MODULE EXPANSION

Operator Interface 2711P-RN6 PV PLUS DH+/RIO/DH-485 COMMUNICATION MODULE

Support 9357-ANETMD3R SUPT REINSTATEMENT CONTRACT FOR 9357ANETMD3E

Support 9361-DATAOCXS SUPT RENEWAL CONTRACT FOR 9361DATAOCX

ControlNet Products 1734-OB2E 24V DC 2 CHANNEL SOURCE OUTPUT MODULE

RSI Software Products 9301-2SE2400U4 UPGRADE: IN-SUPT: WINVIEW TO RSVIEW32 WORKS 32K

RSI Software Products 9357-DNETMDAD3E RSNETWORX MD FOR DEVICENET ADD-ON

Motion Control MPL-A420P-HK22AA MOTOR,SERVO,4.74NM,5000RPM,ENCDR,230V,5.0KG

Motion Control 2090-UXNFBMP-S30 CABLE,ULGRF50ON-FLEX,MOTOR FEEDBACK,MP,30M

CBL-13-ED-30 Encoder Cable, MTR-1235, 13xx, 14xx & 1N Series Stepping Motors to IMC-D or S2K, 30 Ft.

IC600WD200 I/O Cable, 200 feet (60m)

IC800SKCPVL050 Power Cable, S2K to 4.5 - 5kW S-Series Servo Motors, 5 Meters

OC647IFFDTPC iFIX Optn: Fix Desktop (M1Component Part)

20AD1P1A0AYNANC0 PowerFlex 70 AC Drive 20A

20DC820ACENNBNANE PowerFlex 700S AC Drive 820 A 450 kW 20D

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2711-ND3DEM PanelView ND3DE MED Accessory

280-PWRM22G-M05 ArmorStart Three-Phase Power Media

35 FX-EEPROM-8 EEPROM存儲卡8K/步,適用FX2N 620.-

1492-MC6X5 IEC 6 x 5 mm Marker Card

1494U-F60 1494U 60A Fuse Block

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SIMATIC STEP 7 V14 6ES7822-1AA00-0YL5 SIMATIC STEP 7 專業版 TIA Portal SUS

1585D-M4UBDF-5 1585D Ethernet Media Patchcord

1756-IF8I ControlLogix 8 Point Analog Input

1797-BIC FlexEx Accessories

194E-E25-1753-6N 25 A 194E Load switch

2090-CFBM4DF-CDAF40 MP-Series 40m Feedback Cable

2090-KPBM7-06AA MP-Series Power and Brake Connector Kit

BC646EXM365 Solution Provider additional ME License

GC646TRT915 Proficy GlobalCare Complete for Server 1500 I/O Runtime System

HMI-CAB-C101 CABLE SIMATIC TI 500 SERIES 9 PIN PROGRAM PORT

IC641GBE671 PCIM Driver Software Source Code (Microsoft C)

IC647IFCLNTCDVM iFIX iClient Development (M4 Part)

IC660EBA024 Electronic Assembly for IC660BBA024

IC695MDL664 Smart Digital 24VDC Input module, 16 input channels in two groups of eight. Module does not ship with terminal block. IC694TBB032 or IC694TBSx032 terminal block is required.

IC756WRE024K-99 DataViews Runtime for Windows 1-24, Per User, Korean, Version 9.9

FlexLogix System 1794-IA8 85-132 VAC INPUT MODULE, 8 POINT

PLC-5/1771 System D1771-6.5.91 ISOLATED ANALOG INPUT MODULE USER MANUAL

Process Control 1757-PLXSIFC AB RSLINX QUICKBUILDER INTERFACE

Operator Interface 2711P-T7C6D1 PV PLUS 700, TOUCH, RIO/DH, DC PS, STD MEM

Support 9307-RSP32RENS SUPT RENEWAL CONTRACT FOR 9307RSP32REN

Support GML-DSR SUPT REINSTATEMENT CONTRACT FOR GMLDS

Support F1785-L26BSERC FIRMWARE UPGRADE FOR 1785-L26B PLC5 PROCESSOR MODU

RSI Software Products 9301-2SE2300ESU1 RSVIEW32 WORKS 300-1500 UPGRADE IN-SUPT (ES)

RSI Software Products 9701-VWSB250AJPE RSVIEW SE STATION 250 DISPLAY (JAPANESE)

RSI Software Products 9399-INTWINEUG INTERCHANGE FOR WINDOWS (ETHERNET) USER GUIDE

Motion Control 2098-IPD-150-DN DRIVE, 65A/150A, ULTRA5000, DEVICENET

BC646MBW001 Machine Edition View for Quick Panel, Professional Dev Suite with R/T

IC300DQM406 32 DC Outputs (5/12/24vdc, 0.5A pos logic with ESCP)

IC752PBMU01 Profibus Master/Scanner for ControlStation CE II 6"

MTR-3S65-G-R-B-E-S MTR series servo motor with resolver and brake and shaft seal

ZA06B-6114-K220#S Motor power and brake power straight connector for B2/4000is or B4/4000is motor

20C-316051-C01 MOV ASSY, 460V, 700A, 40J, M6 LUGS

20G1ABC750AN0NNNNN PowerFlex 755 AC Packaged Drive

25A-CTMFC1 PowerFlex 523 Control Module Front Cover

2711P-T15C22D9P PanelView Plus 7 Graphic Terminal

6SE6440-2UC13-7AA1 0.37KW

1492-JG50 IEC 1-Ckt Feed-Through Grd Blk 50mm

1492-WM3-B IEC Term Blck 8x47.6x41mm Screw

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性能信號模塊 6ES7 532-5HD00-0AB0 AQ 4：模擬量輸出模塊，AQ 4x U/I ST, 35mm 模塊，不含前連接器

156-B90CB1 90 A Contactor

1746-NO8V SLC 8 Point Analog Output Module

1788-EN2DN EtherNet/IP to DeviceNet Linking Device

193S-EERB E1 Plus 3.2-16.0 A IEC Overload Relay

20-PP00066 PRECHARGING RESISTORS

2090-CSBM1DF-14AF15 Kinetix Cable Single DSL 2090-Series

20AC022F0AYNANC0 PowerFlex 70 AC Drive 22 A at 11 kW 20A

GC-8450-SW-CF CONFIG SW WITH CABLE

GPA-602-H LVDT Expansion Unit (Half Bridge), includes G-0602 connecting cable.

IC600CP625RR 19 inch Series Six Plus CPU 125Vdc Power Supply (11 Slots)

IC647HSTCSEO40KM eSignature Option for Historian - Enterprise Corporate Server 40000 Points (M4 Key)

IC647WFLCWSP Proficy Workflow - Cityworks Service Provider

IC694ALG222CA Conformal Coated Analog Voltage Input module 16 channels single ended/ 8channels differential

IC756RDV010K-97 DV Draw Development on IRIX Op Sys, Korean, Version 9.7

MicroLogix 1200 System 1762-OB16 16 POINT 24 VDC SOURCE OUTPUT MODULE

PLC-5/1771 System 1771-PD PID CONTROL MODULE, 2 LOOPS

Distributed I/O 1794-OB16P 24V DC SOURCE OUTPUT MODULE (PROTECTED), 16 POINT

Communications 9399-INTHPUG INTERCHANGE FOR HP-UX USERS GUIDE

Support

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Support F1771-ASBSERB FIRMWARE UPGRADE FOR 1771-ASB I/O MODULE

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78004653 Target Empty Rack Assembly

IC200MDD846LT MIXED OUTPUT RELAY 2.0A PER PT ISOLATED 8PT / INPUT 120VAC GRP 8PT (LT)

IC697ACC720 Blank Slot Filler (qty. 6)

MTR-1231-E-D-E-0 MTR series NEMA 23 stepping motor with encoder. Winding connection type is determined by cable

Z44A730464-G20 Motor power right angle connector for AC12/2000 or AC12/3000 or A12/3000 or A22/2000 or B22/2000is motor

20BD077A3ANNANC0 PowerFlex 700 AC Drive 77 A 60 Hp 20B

20G11NC037JA0NNNNN PowerFlex 755 AC Packaged Drive

22F-B8P0N103 PowerFlex 4M- 1.5 kW (2 HP) AC Drive

990NAA21510 Quantum RUGGEDIZED MBUS+ TAP PROG

294D-FD1P5Z-G1 Variable Frequency Drive

S82Y-05N 電源安裝支架，（導軌用）適用S82J

1492-SPM3B010-N MCB Supplementary Protector 1 A

軟啟動器 3RW40241BB05

電機啟動器 3VU16402CL00

150-F43NBD SMC Flex Smart Motor Controller

1734-8CFG POINT I/O 8 Point Combination Module

1774-XD 2 (3POS) PROCESSOR KEYS

193-EF1BKP EF 160-400 A IEC Overload Relay

20-750-BUS3-F9 PF755 FR9, IP00, OUTPUT TERMINATION KIT

2090-CPWM7DF-10AA40 MP-Series 40m Servo Power Cable

2097-V33PR5 Kinetix 300 Servo Drive

ET-GT-5ES-4SC 3 RJ45 Ports, 2 Multimode Fiber Port Ethernet Switch

GFK-2055 VMIC

IC220MDL643 INPUT, 24VDC POSITIVE LOGIC, 8PT (REQUIRES 4 IC220TBK082)

IC647DMC003 DataMart 3 Reporting Clients

IC647PWR003 Proficy Power SCADA for Large Control Room

IC693MDL241RR 24 Vac/Vdc Input (16 Points)

IC756CDV001J-97 DV Development - Compaq True64 Op Sys Addt'l User, Japanese, Version 9 .7

MSI-PROD-10-43 Product Mang Clients 10 Pack-43

PLC-5/1771 System 1785-L80E ETHERNET/IP PLC-5/80 CONTROLLER, 100K WORD SRAM

Distributed I/O 1738-EP24DC 24 V DC POWER EXTENSION

Communications 1784-PCIC CONTROLNET PCI BUS MESSAGING CARD WITH

Operator Interface 2711E-NF1 FUNCTION KEY LEGEND INSERTS, PV1000E KEYPAD

Support 9304-WVR128S SUPT RENEWAL CONTRACT FOR 9304WVR128

Support 9324-RLD25U7ITE RSLOGIX 5000 LITE ITALIAN TO PRO UPGRADE

DeviceNet Products 2711-T6C10L1 PV600 COLOR TOUCH, DNET & RS232 PRINT

RSI Software Products 9301-2SE3400DEU1 RSVIEW32 RUNTIME 1500-32K UPGRADE IN-SUPT (DE)

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2024 Greyline OS, 2 Line, (20) 5MM Chars, LCD, Quick Connect, NEMA 4

HE693THM166 16 ch. J, K, N, T, E, R, S, B, C 0.5 癈 resolution, 癈/癋 units, 16 alarms

IC670MDL644 24VDC Pos./Neg. Logic Fast Input 16pt Grouped

QPJ-ABR-201 MODULE AB REMOTE I/O

STXPBS016 STXi Profibus with relay output, 16 points, expandable to 8 additional modules.

20BC2P1A3AYNANC0 PowerFlex 700 AC Drive 20B

20F1ANC456JA0NNNNN PowerFlex 753 AC Packaged Drive

22B-B5P0N104 PowerFlex 40- 0.75 kW (1 HP) AC Drive

140DDO35300C Quantum 開關量DC輸出,32點,24VDC,4組隔離,0.5A/點,

284D-FVD7P6Z-25-CR-3-DB-SB-EMI DeviceNet Variable Frequency Drive

E3X-A11 光纖放大器, 晶體管輸出 NPN 80mA, 電源:12-30VDC

1492-SPM1B100-N MCB Supplementary Protector 10 A

直流電源 6EP1322-1SH02 100/240VAC 輸入，12VDC/4.5A 輸出

6ES78221AA000YM5

1497D-A12-M10-0-N Gen Purpose Transformer

1606-XLSBATBR2 1606 Power Supply

1769-L24ER-QBFC1B CompactLogix 750KB DI/O AI/O Controller

190E-AND2-CB40X 2.5-4.0 A Economy Starter W/Ckt-Bkr

194R-J60-1753-PYS1 194R Disconnect Switch

2090-CPBM7DF-14AF12 MP-Series 12m Continuous-Flex Cable

2090-XXNPT-16S09 Kinetix Drives 09m Standard Cable

CBL-3T-MP-20 Power cable for MTR-3T50 or MTR-3T60 series servo motors. 20 feet

GF-0912R/FOW Connecting FlashCable to Fowler Sylvac, Metronics, Mettler, Omega, Tol edo (FOW).

IC200UAL006-24 Qty of 24, 23 point PLC< (13) 24VDC In, (9) Relay Out, (1) 24VDC Out, (2) Analog In & (1) Analog Out, 120V/240AC Power Supply. Battery (IC2 00ACC403) is required for dtat retention. Battery not included.

IC646TDV300 300 I/O Point Development System

IC647NWV050 CIMPLICITY HMI WebView 50 User

IC693ALG223 Analog Input, Current, 16 Single Channels

IC752CTD400RR Display Station - 9.5 inch active matrix VGA (640x480) infrared touch scre en/ 16 color support/ Pentium 133/ 32M/ 1.2 Gig hard driv e/ expansion slots/ Ethernet/ with CIMPLCITY HMI and Win 95

IC800VMM20LBKSE25 2 kW VersaMotion servo motor with 24 VDC holding brake (6.37 Nm)

SLC/1746 System 1746-HSRV SLC SERVO

Industrial Computers 6189V-RACKSLIDES 1400R RACKSLIDES

Application-specific products 1403-NDNET COMMUNICATION MODULE (DEVICENET)

Operator Interface 2711-K6C3L1 PV600 COLOR KEY, DH485 & RS232 PRINT

Support 9301-2SE2500PTR SUPT REINSTATEMENT CONTRACT FOR 93012SE2500PT

Support 9380-RSB5000S SUPT RENEWAL CONTRACT FOR 9380RSB5000

DeviceNet Products 1734-IJ 5 VDC INCREMENTAL ENCODER MODULE

RSI Software Products 9301-2SE3200DEE RSVIEW32 RUNTIME 300 (GERMAN)

RSI Software Products 9358-BPC60U1 UPGRADE: IN-SUPT: RSBIZWARE PC PHASES 03 TO 60

Motion Control MPL-B430P-RJ22AA MOTOR,SERVO,6.55 NM,5000RPM,RSLVR,460V,7.3KG

Motion Control 2090-SCEP3-0 SERCOS FBR CABL,CONN,ENCLOSURE ONLY PLASTIC,3.0M

GFK-1055 Plug & Play PC Coprocessor for Series 90-70 PLC User's Manual

IC646MDC700 Logic Developer - PC & View 700 Tag Runtime & Development System

MSP-CUR-IN2 Obsolete - 0-20 mA in / Pulse out

QPI-ABD-201 Communication Module for 7 inch/ 9 inch/ 10 inch & 12 inch: AB DataHighway Plus/ UL/ c UL/ CE/ UL1604

20BC022A3AYNANC0 PowerFlex 700 AC Drive 22 A at 11 kW 20B

20F11GC8P7JA0NNNNN PowerFlex 753 AC Packaged Drive

21G14PC770JN2NNNNN-ND-P20 PowerFlex Air Cooled 755 Packaged Drive

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