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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]。

 

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44C742238-004 Cable, Alpha and Beta Series Motor Holding Brake, 14 Meters

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C200H-OD411 输出单元, 8点, 晶体管 1A 12-48VDC

1492-PPSL3 IEC Term Blck 2x56x39 mm Partition Plt

接口模块 6ES7460-3AA01-0AB0 IM460-3 发送器模块，用于分布式连接最大 102m

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1497-D-CXJK-0-N Control Circuit Transformer

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194L-G3393 194L Padlocking Metal Shaft Extension

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2090-XXNFY-S05 Y-Series 5 m Length Feedback Cable

BC647SPK1M4 Solution Provider Additional M4 Key includes 1 physical M4 key.

GC647PPSEWF "Global Care, #### iFIX#Proficy########"

IC200MDL636 Input 48VDC POS/NEG logic (4 groups of 8) 32 points

IC646PCM010 Proficy Change Management 10 user pack

IC647MPP001 Logic Developer PLC Professional with USB Hardware key

IC676CBLPWF020 IP67 Power Cordset - 2 Meters - Female Connector w/Leads

IC697PCM711WMP Programmable Coprocessor Modified for use by OEMs

IC800SSI107P2 7.2 amp 115/230 VAC Profibus S2K servo controller for S-series motors

SoftLogix System 1789-DPALEN SOFTLOGIX DOCUMENTATION SET

Industrial Computers 6189-RDK15C VVCE 1500, KEYPAD DISPLAY MODULE

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IC641CTL991 Distributor Demo 10 Pack

IC800SLM250M2KE25 2500W, 230 VAC SL Servo Motor, 2.5K Quad Encoder

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MTR-1362-0-A-E-0RR Stepping Motor Nema34 Dbl Shft

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20BD011A3NYNACD0 PowerFlex 700 AC Drive 20B

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22B-V6P0C104 PowerFlex 40 1.1 kW (1.5 Hp) AC Drive

140XBP00300 Quantum 背板, 3槽

284R-360P500-M05 360 Ohm Dynamic Brake Resistor

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20BC072A3AYNACC0 PowerFlex 700 AC Drive 72 A 37 kW 20B

20F11RC015AA0NNNNN PowerFlex 753 AC Packaged Drive

22A-A1P4N113 PowerFlex 4- 0.2 kW (0.25 HP) AC Drive

140CPU65150C Quantum CC QUANTUM PROCESS- UNITY W/ 1024/7

281E-F23Z-25D-CR-3FR ArmorStart Direct Online RVSG Starter

C200H-DA001 模出单元,2路12位?D/A 4-20mA/1-5V/0-10V 可选

1492-RCDA2A40 Residual Current Device 40 A

存储卡 6ES7952-0KF00-0AA0 FEPROM 存储卡， 64K

变送器 3RS11202DD20

1497-F-M4-0-N Control Circuit Transformer

1606-XL960E-3S Power Supply XL 960 W Power Supply

1762-MM1RTC MicroLogix 1200 with RTC Memory Module

188-K3D020-N Miniature Circuit Breaker 2 A

194L-HC4A-825 Actuator For Control Switch

2090-CPBM7DF-06AA15 MP-Series 15m Power and Brake Cable

2090-XXNPMF-10S25 Kinetix Drives 25m Standard Cable

BC647TPD075 CIMPLICITY HMI ProServer 75 I/O Development and Runtime System with Proficy GlobalCare

GC647PRTHE010 GlobalCare Complete - Proficy Portal Historian Edition Client Pack 10 Users Ver 3.0

IC200MDL740LT OUTPUT 12/24VDC POS LOGIC 0.5A PER PT (1 GROUP OF 16) 16PT (LT)

IC646PCN110 OpenProcess Operator Console (700 I/O)

IC647MRA150 View Runtime 150 I/O with USB Hardware key

IC677CBLY006 IP67 Sensor/actuator cable, 3-pos., PUR halogen-free black, straight M12 Y-socket, on 2x angled M12 connector, cable length: 0.6 meters

IC697PWR732RR Replacement Power Supply, 125 Vdc, 60 Watts

IC800SSI216RD2 16 amp 230 VAC Devicenet S2K servo controller for MTR series motors

SLC/1746 System 1747-L511 SLC 5/01 CONTROLLER, 1K MEMORY - DH 485

Industrial Computers 6189-RW2 VVCE COMPACT FLASH 128MB W/ME

Application-specific products 9358-PB30ENE RSBIZWARE BATCH FOR PROCESSLOGIX 30 UNITS

Operator Interface 2711-B5A8L1 PV550 MONO KEY&TOUCH, DH+ & RS232 PRINT

Support 9303-3CS0E80S SUPP RENEWAL CNTRCT FOR 9303-3CS0E80