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A16B-1310-002

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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IC200TBX123 Tool box, 23 point (IC200UAL006) 24VDCIn/Relay Out, 2 Analog In/1 Analog out, 24 P/S, VersaMax DataPanel DP45 with Programming software and cables, (IC640VPS00, IC752DDZ000, IC200CBL555)

IC800SLCIV010 Interface Cable, 1000W SL Amplifier to Terminal Block, 1 Meter

MTR-3S46-H-R-0-E-SRR Servo Motor with Seal

ST-1114 STXi input module 4 points, Positive Logic, 5VDC

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

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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

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Support 9391-SDHEHR 9391-SDHEH SOFTWARE SUPPORT CONTRACT REINSTATEMENT

ControlNet Products 2711-B5A15L2 PV550 MONO KEY&TOUCH, CNET & RS232 PRINT

RSI Software Products 9301-2SE2500KOE RSVIEW32 WORKS 100K (KOREAN)

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Motion Control 2090-XXNFMP-S07 CABLE,NON-FLEX,MOTOR FEEDBACK,MP/1326AB,7M

CBL-HSLK-06-RA Serial Cable, Operator Interface Panel (OIP) to IMC or Target, Rt. Ang, 6 Ft.

IC641PCC002 Complete Development System - 128 Points

IC800SLR003 Ext. Regen Resistor, 20 Ohm 300W for 1000W 230VAC SL Amplifier

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20B-STD-A0 PowerFlex 700 std Control Cassette Kit

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20SF1K0NEM PowerFlex 1000 A SCR Bus Supply

2711P-B6M5A8 PanelView Plus 6 6 Gray/Touch AC RS232

280-PWRM35B-M30 ArmorConnect 3-PH Power Media trnk cable

输出:0～10V,-10～+10V,4～20毫安

1492-MR5X8H11-20 Connection Products

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运行版软件 6AV2104-4KK04-0AE0 SIMATIC WinCC Runtime Advanced V14 Upgrade ： WinCC flexible 2008 Runtime 8192 PowerTags -> WinCC Runtime Advanced 8192 PowerTags V14

1585J-M4TBJM-25 RJ45 Ethernet Media

1756-OB8 ControlLogix 8 Pt 12/24V DC D/O Module

188-K1C010 Miniature Circuit Breaker 1 A

194E-G3673 Terminals For Load Switch

2090-CFBM7DF-CDAF60 MP-Series 60m Feedback Cable

2090-UXBC-D1501 Ultra Series 1m Breakout Board Cable

BC646OEM0301 OEM Edge Renewal - Machine Edition

GC647DMC020 GC DataMart 20 Reporting Clients

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IC646IFCLNTCRO005C iFIX iClient Read Only 5 PK Keyless (M1Component Part)

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Operator Interface 2711P-B15C4D1 PV PLUS 1500, KEY/TOUCH, ENET, DC PS, STD MEM

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25B-E1P7N104 PowerFlex 525 0.75kW (1Hp) AC Drive

280-BRCAP-M25 Cap, Sealing for M25 Source Brake

FR-F740-1.5K 2.7KVA 3.5A 1.5KW 3相AC380V/50Hz/60Hz

1492-LG2Q IEC Term Blck 3.5x75x29.5mm Spr Clp

1494F-P2 Disconnect Switch Handle

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ET 200SP 6ES7131-6TF00-0CA0 DI 8xNAMUR 高性能型，基座单元类型 A0

1585D-E4UBDE-0M3 1585D Ethernet Media Patchcord

1753-IB8XOB8 GuardPLC Digital Combo Module

1794-IB8 Flex 8 Point Digital Input Module

194E-AA32E-PE-TN 194E Load switch

2080-LC30-10QWB Micro830 10 I/O Controller

2090-CSWM1DF-14AA50 Kinetix Cable Single DSL 2090-Series

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HE693PIF104 PC Interface to Series 90-30 I/O in PC104 form factor.

IC610CHS130RR Rack, 115/230Vac Power Supply (10 Slots)

IC647HSTSC5000KM Server to Server Collector for Historian - Standard Server 5,000,000 Points (M4 Key)

IC660BBA106 Block 115Vac/125Vdc Analog Current Source 6 Inputs

IC694MDL931 Output module, relay 3 amp form B and C; 8 point isolated

IC756WDN009E-22 DV Development Sys VB, Java, C++, C, English, Version 2.2

MicroLogix 1500/1769 System D1764-UM001AUSP MICROLOGIX 1500 PROG. CONTROLLER USER MANUAL

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IC200UDR005 28 point; (16) 24VDC In, (11) Relay Out, (1) 24VDC Out, AC Power Supply. Battery (IC200ACC403) is required for data retention. Battery not included.

IC752CBT013RR Datapanel 320T ME (Mono Expansion)w/ Advanced software: 320x240 1/4 VGA Mono LCD with 386SX/40. Analog touch screen w/ text, bitmaps, bar graphs, real time clock. With 2M memory & PC/104. With Real Time Trends & Host Communications.

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25-PM1-D024 PowerFlex 520 11kW (15Hp) Power Module

372SPU78001PDEV Quantum PROWORX 32 ONLINE OFFLINE SGL USER PKG

FRN0.1E1S-2J 0.3KVA 0.8A 0.1KW 3相AC220V/50Hz/60Hz

K8AB-PM2 三相相序、电压及缺相保护，额定输入380、400、415或480VAC

1492-SPM3D020 MCB Supplementary Protector 2 A

软启动器 3RW40282BB04

SIMATIC 存储卡 6ES7 954-8LE02-0AA0 12 MB

150-SD1NUR SMC-50 SOLID STATE MOTOR CONTROLLER 361A

1738-8CFGM8 ArmorPoint 8 Point Combination Module

1783-US6T2H Stratix 2000 6+2 port unmanaged switch

193-EXP-DIO-42-240 E300 240V AC Digital Expansion Module

20-750-NEMA1-F2 PowerFlex 750 Frame 2 Conduit Box Kit

2090-CPWM7DF-16AF04 MP-Series 4 m Length Power Cable

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GA647IFESGSR00075 GCA iFIX Optn: ESig & ERec 75 I/O Srv

GP646IFCLNTCRO025 GCP iFIX iClient Read Only 50 PK Keyless Runtime Version

IC600BF804RR 115Vac/dc Input Module (8 points)

IC647HSTCC20000KM Calculation Collector for Historian - Standard Server 20,000,000 Points (M4 Key)

IC647TBLCPVC002 Virtual Campus for Proficy Troubleshooter and Cause+ - 2 Users

IC693MDL753LT 12/24 Vdc Output, Pos Logic (32 Pts) (LT)

IC756LDV000K-97 DV Development - Intel/Linux RedHat Op Sys, Korean, Version 9.7

Pico Controllers 1760-SIM INPUT SIMULATOR FOR 12 I/O DC PICO CONTROLLER

PLC-5/1771 System 1771-OD16K CONFORMALLY COATED, 120V AC ISOLATED OUTPUT MODULE

Distributed I/O 1791-0A32 BLOCK I/O, 120V AC, 32 POINT MODULE (32 OUTPUT)

Communications 1786-RPA CONTROLNET MODULAR REPEATER ADAPTER

Operator Interface 2706-PRIOK REMOTE I/O COMMUNICATION MODULE FOR 2706-P7X & P9X

Support 9701-VWSCWAS SUPT RENEWAL CONTRACT FOR 9701VWSCWAENE

Support 9324-RL0100ESR SUPT REINSTATEMENT CONTRACT FOR 9324RL0100ES

EtherNet/IP Products 2711P-K15C4B1 PV PLUS 1500, KEYPAD, ENET, AC PS, STD MEM

RSI Software Products 9301-2SE340PTU1R RSVIEW32 RUNTIME 1500-32K UPGRADE OUT-SUPT (PT)

RSI Software Products 9356-PRO2350U6R UPGRADE: OUT-SUPT: RSSQL PROF.300 TO PROF.5000 TAG

Motion Control F-4050-Q-H04AA MOTOR/ENCODER/BRAKE

4360-N 4360 WITH NEMA 4

IC200ACC303 I/O SHORTING BAR QTY 2

IC693DNM200 DeviceNet Master

TGT-E000-0-0 Target Rack Expansion Module, 10' Rack Linker Cable

VDOCS-ADM VisualDocs Administration (includes integrated viewer)

20BD014A3AYYANC0 PowerFlex 700 AC Drive 14 A at 10 Hp 20B

20G11BF710JN0NNNNN PowerFlex 755 AC Packaged Drive

22C-B145A103 PowerFlex 400- 37 kW (50 HP) AC Drive

140XCA71709 Quantum 背板扩展电缆, 3M

285-BRC25-M10 Cable,ArmorStart Source Brake Cable

H7ET-NFV 7位液晶显示累积计时器,电压（24-240AC）输入、外部/手动复位、999999.9h-3999d23.9h可切换

1492-SPM1D100-N MCB Supplementary Protector 10 A

通用型变频器 6SE6 440-2UD25-5CA1 5.5 KW,185 x 245 x 195

电机启动器 3VU13403NL00

150-C43NCR SMC-3 43A Smart Motor Controller

1609-SBAT Bul 1609 UPS Standard 12VDC Battery

1771-IAD 1771 16 Point Digital Input Module

193-EC2PB E3 Plus 0.4-2.0 A Overload Relay

198-MS24 Start/Stop, On/Off Push Button Kit

2090-CPBM7E7-16AF15 MP-Series 15 m Length Cable

2094-AM01-S Kinetix 6000 Axis Module

CW0DT1005 Industrial Key Board for DuraTouch, QWERTY Keyboard, Elastomer Type

GFK-0487 Series 90 PCM Development Software (PCOP) User's Manual

IC200UEX636-24 Qty of 24, 6 channel Analog expansion. (4) Analog inputs & (2) Analog outputs. 120/240

IC647APXM APX:Moore APACS

IC647PFL300 Proficy Process Systems Standard Edition 3000 I/O with iFIX

IC693CHS398LT Base, Expansion, 5 Slots (LT)

IC754UEX001 VersaMax Micro Expansion I/O Interface for QP Control

MA15/D/2/SI AC15AMP PWR SRG PROTECT (240AC)

SLC/1746 System D1761-6.4 AIC + ADVANCED INTERFACE CONVERTER USER MANUAL

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Application-specific products 1803-EEM02 EEM,16 ANALOG, 4 TO 20 MA

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DeviceNet Products 1790D-N0C2 DNET LDX, 2 OUTPUT ANALOG CURRENT BSE,D-SHELL CONN

RSI Software Products 9301-2SE330ITU1R RSVIEW32 RUNTIME 300-1500 UPGRADE OUT-SUPT (IT)

RSI Software Products 9358-PBEPB30ENE RSBIZWARE BATCH & EPROCEDURE BNDLE PLX 30 UNITS

Motion Control MPL-B640F-MJ24AA MOTOR,SERVO,36.0NM,3000RPM,MULTI,460V,BRK

Motion Control 2090-UXLF-HV350 AC LINE FILTER,ULTRA,50 AMPS, 460V, 3 PHASE

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ST-2124 STXi output module 4 points, TTL, 5VDC/20mA Non inverting

20BC085A0AYNANC1 PowerFlex 700 AC Drive 85 A 45 kW 20B

20F11RD5P0AA0NNNNN PowerFlex 753 AC Packaged Drive

22A-A4P5H204 PowerFlex 4 0.75 kW (1 Hp) AC Drive

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284-MTRS22-M14 ArmorConnect Brake and Motor Cable

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1492-RCDA4C25 Residual Current Device 25 A

6ES7153-2BA01-0XB0 IM153-2 高性能型，支持冗余，时间标签

变送器 3RS11 40-1GD60

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

1606-XLE240EE Power Supply XLE 240 W Power Supply

1763-BA MicroLogix 1100 Battery

188-K3D160-N Miniature Circuit Breaker 16 A

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