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00N1254003

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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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PEAK8920VL2

1494V-DJ622-D-E-FF NEMA Flange Mtd Rod Switch Disconnect Sw

软启动器 3RW44233BC46

变送器 3RS17022CD00

1497D-A11-M14-0-N Gen Purpose Transformer

1715-IB16D 1715 16 Point Digital Input Module

1786-TNCJ4 CNet Media Jack-to-Jack TNC Connector

188-K3C400-N Miniature Circuit Breaker 40 A

194L-G3573 194L IP66 ABS Thermoplastic Enclosure

2090-CPBM7DF-04AA50 MP-Series 50 m Length Cable

2090-XXNFY-S20 Y-Series 20 m Length Feedback Cable

BC647SPPSK01 Solution Provider Process M4 Key includes 1 physcial M4 key that authorizes Proficy Process System as well as all core products

GC647PRTADO GlobalCare Complete - Proficy Portal ADO Connector Ver 3.0

IC200MDL643 Input 5/12VDC POS/NEG logic (2 groups of 8) 16 points

IC646PCMKIT Proficy Change Management Starter Kit (1 user, Scheduler)

IC647MPP101 Logic Developer PLC Professional with Programming Cable with USB Hardware key

IC676CBLPWM050 IP67 Power Cordset - 5 Meters - Male Connector w/Leads

IC697PWR711 Power Supply, 120/240 Vac,125VDC, 100 Watts

IC800SSI107RP2 7.2 amp 115/230 VAC Profibus S2K servo controller for MTR series motors

SLC/1746 System 1747-L20C 20 I/O FIXED HARDWARE STYLE

Industrial Computers 6189-RDT15C VVCE 1500, TOUCH SCREEN DISPLAY MODULE

Process Control 9399-RSBVWUG RSBATCH VIEW USER'S GUIDE

Operator Interface 2711-B5A2L3 PV550 MONO KEY&TOUCH, DH485

Support 9303-3CS0E10UR UPGRADE: OUT-SUPT: DRIVEMANAGER TO DRIVEMANAGER32

Support 9371-RSWD2R SUPT REINSTATEMENT CONTRACT FOR 9371RSWD2

ControlNet Products 2706-P72CN2 INVIEW MESSAGE DISPLAY. 1 TO 4 LINE

RSI Software Products 9301-2SE2500ITU2 RSVIEW32 WORKS 1500-100K UPGRADE IN-SUPT (IT)

RSI Software Products 9358-BBKEY03ENE RSBIZWARE BATCH BACK-UP KEY 03 UNITS

Motion Control MPL-A4530K-HJ24AA MOTOR,SERVO,8.36NM,4000RPM,ENCDR,230V,BRK,11KG

Motion Control 2090-UXNPBMP-8S30 CABLE,460V,NON-FLEX,MOTOR POWER,MP,8 GAUGE,30M

CBL-3T-MP-30 Power Cable, MTR-3T4x, MTR-3T5x & MTR-3T6x Series Servo Motors, 30 Ft.

IC641CTL995 Media Kit

IC800SLM350M2XE25 3500W, 230 VAC SL Servo Motor, Holding Brake, 2.5K Quad Encoder

OC647TSSOPCC000 Proficy Troubleshooter Connector: OPC Client Read & Write (including OPC HDA)

PXI-5152

PX-10S-RS-R30

LAMBDA UAZ1EP 400W UAZXEXPX0000 9940

AC6650

ICPMB-8650GR-R12

METEOR2-DIG/4/L

1492-MCGAT230 Ground Fault Circuit Breaker

1494V-L2 Door Hardware Kit

软启动器 3RW44656BC36

运行版软件 6AV2104-2HK04-0BD0 SIMATIC WinCC Runtime Advanced Powerpack 4096 PowerTags -> 8192 PowerTags V14

1585J-M4TBJM-0M15 RJ45 Ethernet Media

1756-OB16D ControlLogix 16 Pt 24V DC D/O Module

188-K1B250-N Miniature Circuit Breaker 25 A

194E-FA80 194E Load switch

2090-CFBM7DF-CDAF04 MP-Series 4m Feedback Cable

2090-U5EK-DN Ultra 5000 Breakout Board Kit

BC646MVD000 ME View View OPC Driver License w/Global Care and Software Key

GC647AUR002 GC Universal Reporting Client 2 Pak

IC200ACC403 Battery for 23 and 28 point Micro for data retention

IC646CSPR001 Proficy Cause+ for Intelligent HMI/SCADA Runtime Server - 1X monitored KPI

IC647IFPLRNUNLMTM iFIX Plus SCADA Unlimited Runtime (M4 Part)

IC660MLA101 Label for IC660BBA101 (Qty 100)

IC697ALG440RR Analog Input Expander, Current, 16 Channels

IC758WMM010 iGlobalCare Complete 6-10 Users (same site): DataViews for Windows

FlexLogix System 1794-CE1 EXTENDER CABLE FOR TERMINAL BASES, 1FT/.3M

GuardPLC Systems 1755-OF8 GUARDPLC 2000 - ANALOG OUTPUT MODULE

Process Control 1757-UPGSIFW UPGRADE MA500 QUICKBUILDER I/F

Operator Interface 2711P-T12C6B1 PV PLUS 1250, TOUCH, RIO/DH, AC PS, STD MEM

Support 9220-TAS SUPT RENEWAL CONTRACT FOR 9220TA

Support 2755-ASNR SUPT REINSTATEMENT CONTRACT FOR 2755ASN

Support F1785-V30BSERC FIRMWARE UPGRADE FOR 1785-V30B PLC5 PROCESSOR MODU

RSI Software Products 9301-2SE2350JPU3 RSVIEW32 WORKS 1500-5K UPGRADE IN-SUPT (JP)

RSI Software Products 9701-VWSTJPE RSVIEW STUDIO FOR RSVIEW ENTERPRISE (JAPANESE)

RSI Software Products 9399-WABCPG RSLINX C SDK PROGRAMMER'S GUIDE

Motion Control 8720MC- -HAS1 ANALOG DIAL HIM

BC646MRB159 Logic PC Runtime 1,500 I/O

IC300OSW003 Cscape PDA Software with Palm III Series Cable

IC754ACC12MNT Mounting Clips (10) & PWR Conn, 12 QuickPanel View & Control"

MTR-3T45-H-R-B-M-0RR Servo Motor Metric 24V Brake

PCI-6703

FB2504

NORCO-740 NORCO-740AE

PSB-810EAV-J

EW-NET811N4

SMC-3(PC)

1492-LD4DFX2 IEC Term Blck 6.1x76x52.2mm Spr Clp

1494F-L2 Door Hardware Kit

软启动器 3RW44352BC35

ET 200SP 6ES7193-6AG20-0AA0 BA 1× LC 玻璃光纤/1×RJ45， 光纤最远距离 2KM

1585D-D4UBJM-3 Micro D-Code, QD Style Ethernet Media

1747-SN SLC Remote I/O Scanner Module

1794-IA16 Flex 16 Point Digital Input Module

194E-AA20-TN 194E Load switch

2080-LC10-12DWD Micro810 12 I/O Smart Relay Controller

2090-CSWM1DF-14AA16 Kinetix Cable Single DSL 2090-Series

20AC2P1C0NYNANC0 PowerFlex 70 AC Drive 20A

GC646MPM101 Proficy GlobalCare Complete for Logic Developer - PLC Nano/Micro w/Programming Cable

HE693OIU187 Compact LCD Genius OIU w/numeric keypad, powered by 24VDC

IC609SJR124RR Series One Junior 24Vdc Sk In/Rly Out, 24Vdc Power

IC647HSTSC1750KM Server to Server Collector for Historian - Standard Server 1,750,000 Points (M4 Key)

IC660BBA100 Block 115Vac Analog 4 Inputs / 2 Outputs

IC694MDL742 Output module 12/24VDC, 1 amp 16 point positive logic ESCP protection.

IC756WDJ009E-26 DV Dev Sys VB and Java, Eng v2.6

MicroLogix 1500/1769 System 9399-RL50GR RSLOGIX 500 GETTING RESULTS GUIDE

PLC-5/1771 System 1771-CL2 1771 I/O CHASSIS CABLE FOR 1771-P1 POWER SUPPLY

Distributed I/O 1797-TB3 3-WIRE EX TERMINAL BASE - SCREW CLAMP

Operator Interface 2711P-B6C20A PV PLUS 600 COLOR, KEY/TOUCH, ETHERNET, AC PS

Support 9323-PA1GS SUPT RENEWAL CONTRACT FOR 9323PA1G

Support 9358-HSTS2500R SUPT REINSTATEMENT CONTRACT FOR 9358HSTS2500

Support F1772-LXPSERA FIRMWARE UPGRADE FOR 1772-LXP PLC2 PROCESSOR MODUL

RSI Software Products 9324-RLD3U7ESE RSLOGIX 5000 STD. TO PRO UPGRADE, SPANISH

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A06B-0141-B175#7008 AC12/2000 Servo Motor, Holding Brake, 32K Serial Encoder

IC200UDD104 14 point (8) 24VDC In, (6) 24VDC Out (2) 1.0 A, (4) 0.5A, 24VDC Power Supply

IC752BUU000 WinCfg & Datapanel Software Upgrade

MTR-1362-N-D-E-S-MODRR Stepping Motor Nema34 w/Sng 1 7/8 inch Shaft

NI 9219

ROCKY-3703E1V

CBP-6405R

WAFER-6612-R10-BULK

PBP-10P7 NORCO-840AE

MATROX 906-01

NORCO-740AE

1492-SPM3C320-N MCB Supplementary Protector 32 A

软启动器 3RW40462BB14

热电偶模拟量输入信号板 6ES7 231-5QA30-0XB0 SB 1231 AI 1 x 16 位 热电偶

150-SC2NBR SMC-50 SOLID STATE MOTOR CONTROLLER 260A

1734-TOP3S POINT I/O Terminal Base

1783-SFP100LX 100LX SFP Fiber Transceiver

193-ESM-VIG-30A-CT E300/E200 30 Amp Sensing Module

20-750-I2B-C770D740 PowerFlex 750 Inverter Assembly

2090-CPWM7DF-16AA12 MP-Series 12m Servo Power Cable

2099-BM11-S Kinetix 7000 Servo Drive

GA647IFESGCLNTS GCA iFIX Optn: ESig & ERec iClientTS

GP-2102NT/OBG GagePort Digital NT 2-port input (Owens Brockway OEM)

IC5007TAX0110 PanelPC 17 inch Standard Unit with Windows XP and Stainless Steel Bezel

IC647HSTCC10000KM Calculation Collector for Historian - Standard Server 10,000,000 Points (M4 Key)

IC647SST001 Scheduler SAP Toolkit

IC693MDL742LT 12/24 Vdc Output, 1 Amp, Positive Logic (16 Points), Fused (LT)

IC756LDV000E-97 DV Development - Intel/Linux RedHat Op Sys, English, Version 9.7

Pico Controllers 1760-IB12XOB8 18 I/O EXPANSION MODULE, DC

PLC-5/1771 System 1771-OB 12-24V DC OUTPUT MODULE, 8 OUTPUTS

Distributed I/O 1791P-4B4P PROFIBUS 24 VDC CBLOCK I/O, 4 IN SINK 4 OUT SOURCE

Communications 6001-F1E SOFTWARE DRIVER FOR 1784-KT

Operator Interface 2706-PDHPK DH+ COMMUNICATION MODULE FOR 2706-P7X & P9X

Support 9701-VWSB000AS SUPT RENEWAL CONTRACT FOR 9701VWSB000AENE

Support 9515-RSNHS500R SUPT REINSTATEMENT CONTRACT FOR 9515RSNHS500ENE

EtherNet/IP Products 2711P-K7C4D1 PV PLUS 700, KEYPAD, ENET, DC PS, STD MEM

RSI Software Products 9301-2SE340ITU3R RSVIEW32 RUNTIME 150-32K UPGRADE OUT-SUPT (IT)

RSI Software Products 9356-PRO2350 RSSQL PRF VER WTH 5000 TG

Motion Control 1326AB-B740E-M2K7L MOTOR,SERVO,460V,50.0NM,3400RPM,MULTI,BRK,IP67

4162-L-8 4162 Continuous Lens Kit. For (8) 4162s

HMI-KPN-302/B QUICKPANEL KEYPAD FOR 10.5" BLANK

IC693CPU363 CPU 363 Module (240K Bytes configurable user memory)

SPS-50W Discontinue - POWER SUPPY 24VDC 2.1AMP UL, CUL, CE

AKD-P00607-NBEC-0000

AIMB-542VE-00A1E

PCM-3730

ElanVital EVM-3507-00

BTX-400P4

MC8041A

VPM-54416-32M

1492-SPM1D040-N MCB Supplementary Protector 4 A

通用型变频器 6SE6 440-2UC33-7FA1 "37 KW,350 x 850 x 320"

电机启动器 3VU13403MH00

150-C37FBD Encl. SMC-3 37 A Smart Motor Controller

1609-P10000E Uninterruptible Power Supply P UPS Acces

1771-CE 1771 I/O CHASSIS CBL FOR 1771-P2 P/S

193-EC1ZZ E3 9-5000 A Overload Relay

198-F3 IEC Mounting Foot Enclosure Accessory

2090-CPBM7E7-14AF20 MP-Series 20 m Length Cable

2094-AC05-M01-S Kinetix 6000 Integrated Axis Module

CP9I-0MEB-0140-AZ "A50HVis Sh Motor Power Cable, Straight Connector, 14 M"

GFK-0265 Series 90-70 PLC CPU Instruction Set Reference Manual

IC200UEX214 28 point expansion. (16) 24VDC In, (12) 24VDC Out, 24VDC Power Supply (includes IC200CBL501)

IC647APC001 PA Production Client

IC647PDCH050 Ruggedized PDC Historian Base with 5000 Tags

IC693CHS393 Base, Remote Expansion, 10 Slots (700 ft.)

IC754CSL06MTD Ctrl Loaded 6 In Mono Touch DC

KIT-GFS-356 RX3i Workshop Student Kit

SLC/1746 System D1746-UM026AENP SLC 500 8 CHANNEL ANALOG OUTPUT MANUAL

Distributed I/O 1734D-IA16 120 VAC 16 IN, DNET COMMS, SCREW

Application-specific products 1405-M620-400 MINI POWERMONITOR M620 400V

Operator Interface 2711-T10C20L1 PV1000 COLOR TOUCH, ENET & RS232 PRINT

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Support 9381-PA250ENR SUPT REINSTATEMENT CONTRACT FOR 9381PA250EN

DeviceNet Products 1790D-8BV8V DNET LDX, 24VDC,8 UNIV IN/8 SINK OUT BASE, D-SHELL

RSI Software Products 9301-2SE3303KOE RSVIEW32 RUNTME 1500 WITH RSLINX (KOREAN)

RSI Software Products 9358-PBANT60ENE RSBATCH NT FOR PROCESSLOGIX ARCHIVER 60 UNITS

Motion Control MPL-B540K-SK24AA MOTOR,SERVO,19.4 NM,4000RPM,SINGL,460V,BRK,19.1KG

Motion Control 2090-UXLF-106 AC LINE FILTER,ULTRA,6 AMPS,1 PHASE

GQPL-DEM-C02 QUICKPANEL DEMO COLOR 12.1" GE LABEL

IC646MSP101 Logic Developer - State Professional w/Programming Cable

MTR-3T45-H-R-0-M-0 MTR-Series Servo Motor, Resolver, Metric

ST-121F STXi input module 16 points, Positive Logic, 12V/ 24VDC (connector type)

SCXI-1122

PCI-1750

超微 X7DWE

GA-X48-DS5

CANON SC-01A AG9-0498-02

AT-COM/V53A2 C24B1000-0A

1492-RCDA2C40 Residual Current Device 40 A

存储卡 6ES7952-1KM00-0AA0 FEPROM 存储卡， 4M

变送器 3RS11211DW30

1497-G-AXSX-3-N Control Circuit Transformer

1606-XLBUFFER 1606 1606-XL Buffer Module Power Supply

1762-OB32T MicroLogix 32 Point D/O Module

188-K3D040 Miniature Circuit Breaker 4 A

194L-HC4L-175I 194L Control and Load Switch Actuator

2090-CPBM7DF-06AA30 MP-Series 30m Power and Brake Cable

2090-XXNPMF-10S60 Kinetix Drives 60m Standard Cable

BC647TPD700 CIMPLICITY HMI ProServer 700 I/O Development and Runtime System with Proficy GlobalCare

GC647PRTHE100 GlobalCare Complete - Proficy Portal Historian Edition Client Pack 100 Users Ver 3.0

IC200MDL741LT OUTPUT 24VDC POS LOGIC 0.5A PER PT (1 GROUP OF 16) W/ESCP 16PT (LT)

IC646PEW100 OpenProcess Engineering Workstation

IC647MRA700 View Runtime 700 I/O with USB Hardware key

IC677DBO085 Profibus VersaMax IP Modular slave with (8) 24VDC outputs

IC697RCM711 Hot Standby Redundancy Communications Module

IC800SSI216RP2RR 16A, 230V, Profibus S2K Servo Controller for MTR Series Motors

SLC/1746 System 1747-L531 SLC 5/03,WITH 8K USER INSTRUCTION CAPACITY

Industrial Computers 6181H-15TS2KH VERSAVIEW 15" DISPLAY COMPUTER HAZARDOUS LOCATIONS

Application-specific products 9358-PBA10ENE RSBIZWARE BATCH FOR PROCESSLOGIX ARCHIVER 10 UNITS

Operator Interface 2711-B5A9 PV550 MONO KEY&TOUCH, RS232 (DH485) & RS232 PRINT

Support 9303-3CS0EFFS SUPP RENEWAL CNTRCT FOR 9303-3CS0EFF

Support 9391-SDVEKS 9391-SDVEK SOFTWARE SUPPORT CONTRACT RENEWAL

ControlNet Products 2711-K5A15L2 PV550 MONOCHROME KEY, CNET & RS232 PRINT

RSI Software Products 9301-2SE2500KOU3 RSVIEW32 WORKS 300-100K UPGRADE IN-SUPT (KO)

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