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cDAQ-9188

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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]。

 

IC647IFSTDV00075M iFIX Standard HMI 75 I/O Development (M4 Part)

IC660EBD120RR High Speed Counter Electronic Assembly

IC693TCM302 Temperature Control Module

IC697MEM735 Expansion RAM, 512K Bytes, CMOS, 32 Bit (Used w/78X CPUs)

IC800SLR002 External regeneration resistor rated 100 ohm 225 Watt SL series and S2K series

ControlLogix/1756 System 1756-IF6CIS ISOLATED ANALOG IN-CURRENT SOURCING 6 PTS (20 PIN)

PLC-5/1771 System D6200-6.4.18FR PLC5 PROG.SOFTWR STRUCTURED TEXT USER MNL.(FRENCH)

Distributed I/O 1794-OA16 85-132V AC OUTPUT MODULE, 16 POINT

Application-specific products 9358-PBA03ENE RSBIZWARE BATCH FOR PROCESSLOGIX ARCHIVER 03 UNITS

Operator Interface 2711-B5A8L3 PV550 MONO KEY&TOUCH, DH+ & RS232 PRINT

Support 9303-3CS0EFFR SUPP REINSTATEMENT CNTRCT FOR 9303-3CS0EFF

Support 9391-SDVEKR 9391-SDVEK SOFTWARE SUPPORT CONTRACT REINSTATEMENT

ControlNet Products 2711-K5A15L1 PV550 MONOCHROME KEY, CNET & RS232 PRINT

RSI Software Products 9301-2SE2500KOU2 RSVIEW32 WORKS 1500-100K UPGRADE IN-SUPT (KO)

RSI Software Products 9358-BEBNT10ENE RSBATCH / EPROCEDURE FOR NT BUNDLE 10 UNITS

Motion Control MPL-A4540C-HJ24AA MOTOR,SERVO,10.2NM,1500RPM,ENCDR,230V,BRK,13KG(PIN

Motion Control 2090-XXNFMP-S12 CABLE,NON-FLEX,MOTOR FEEDBACK,MP/1326AB,12M

CBL-OIJR-06-RA Serial Cable, Operator Interface Panel (OIP) to S2K, Rt. Ang, 6 Ft.

IC641PCC006 Complete Development System - Unlimited Points

IC800SLT001 SL Amplifier Terminal Block for APM/DSM Interface

PPS-DEMO-01 Proficy Process Systems Demo Kit containing PACSystems RX3i Controller w ith 12-slot base, 24VDC Multipurpose Power Supply, 300Mhz CPU, Ethernet module, RX3i Profibus Master module, Analog Input HART module, 16 Point Input Simulator module and Unive

PXI-6040E

GPC-0511

RICOH PWB:FB9 No.R0226003 R0207500

CONTEC PIO-16/16B(LPCI)H

BPS-550SP

316022360036 r1mo 386

1492-MR6X12 IEC 6 x 12 mm Marker Card

1494V-W1 Disconnect Swi tch Handle

软启动器 3RW44666BC46

运行版软件 6AV2105-0DA04-0AA0 SIMATIC WinCC Runtime 专业版 512 PowerTags V14

1585J-M4TBJM-2X RJ45 Ethernet Media

1756-OC8 ControlLogix 8 Point D/O Module

188-K1C020 Miniature Circuit Breaker 2 A

194E-G3688 194E 34 mm Metal Load Switch Shaft

2090-CFBM7DF-CDAF90 MP-Series 90 m Length Feedback Cable

2090-UXBC-D1509 Kinetix 9 m Length Breakout Board Cable

BC646OEM0400 OEM Edge - Historian Kit (Approval Required)

GC647DMC200 GC DataMart 200 Reporting Clients

IC200ALG261 Analog input 15 bit differential voltage 8 channel

IC646IFCLNTCRO010C iFIX iClient Read Only 10 PK Keyless (M1Component Part)

IC647IFPLSRUNLMTC iFIX Plus SCADA Unlimited Server (M1Component Part)

IC660MLD120 Label for IC660BBD120 (Qty 100)

IC697BEM731RR Series 90-70 Genius I/O Bus Controller

IC800APK080 SVU1-80 Alpha series 80 amp amplifier kit

ControlLogix/1756 System 1756-L55M13 LOGIX5555 PROCESSOR WITH 1.5MBYTE MEMORY

Industrial Computers 6182H-7BEH4B VVCE 700, KEY/TOUCH, EXT MEM, ENET, AC

Process Control 9358-BHIST01ENE RSBIZWARE BATCHHISTORIAN - 3 UNITS

Operator Interface 2711P-B15C6B2 PV PLUS 1500, KEY/TOUCH, RIO/DH, AC PS, EXT MEM

Support 9240-MON16R SUPT REINSTATEMENT CONTRACT FOR 9240MON16

Support 6310-MSS 6310-MS SOFTWARE SUPPORT RENEWAL

Support F1794-ACNR15SERB FIRMWARE UPGRADE FOR 1794-ACNR15 I/O MODULE

RSI Software Products 9301-2SE2350U3 UPGRADE: IN-SUPT: RSVIEW32 WORKS 1500 TO 5000

RSI Software Products 9351-DKTSRT INTERCHANGE SOFTWARE FOR MS-DOS RUNTIME

RSI Software Products 9399-WGGUG RSSERVER FOR GE FANUC GENIUS I/O USER GUIDE

Motion Control 8720MC-MCM SPARE MAIN CONTROL MODULE KIT

BC646MRD300 Logic PC Runtime (HRT) 300 I/O

IC300RCS210 Remote Control Station (OCS without Keypad and display) Supports up to 4 SmartStack I/O Boards, full ladder instruction set, and CsCAN Networking.

IC754VKB06MTD Starter Kit - 6" Monochrome QuickPanel View Basic, Touch, 24VDC

MTR-3T55-I-R-B-M-0RR Servo Motor Metric 24V Brake

PCI-8430/2

WG-7462

PCA-6114P7-OD1

HITACHI SAS柜 RS-1220

IP-3VLP2B

P8R8DIO

1492-LG3 IEC Term Blck 5.1x59.5x31.3mm Spr Clp

1494F-S2 Disconnect Switch Handle

软启动器 3RW44362BC35

ET 200SP 6ES7131-6FD00-0BB1 DI 4x120..230VAC 标准型，基座单元类型 B1

1585D-E4UBDE-1 Micro D-Code, QD Style Ethernet Media

1753-L28BBBM GuardPLC 1600 Safety Controller

1794-ID2 Flex 2 Point Distributed I/O Comb Module

194E-AA40 194E Load switch

2080-LC30-16QVB Micro830 16 I/O Controller

2090-CSWM1DF-18AA02 Kinetix Cable Single DSL 2090-Series

20AC3P5A3AYNAEC1 PowerFlex 70 AC Drive 20A

GC646MPS101 Proficy GlobalCare Complete for Logic Developer - PLC Standard - w/Programming Cable

HE693RLY100 8 point unfused relay module for Series 90-30, rated to 8A, 2 NO/NC, 6 NO.

IC610CPU104RR Series One CPU, 700 Words, Expandable to 1.7K Words

IC647HSTSC500M Server to Server Collector for Historian - Standard Server 500 Points (M4 Key)

IC660BBD020 Block 24/48Vdc Source I/O 16 Circuits, 3 Wire Sensor Compatible

IC694MDL940CA Conformal Coated Relay Output module 2 amp, non isolated 16 points.

IC756WDN009E-26 DV Dev Sys VB, Java, C++, C, Eng v2.6

MicroLogix 1500/1769 System 1769-RD REPLACEMENT 1769 I/O TERMINAL DOORS

PLC-5/1771 System 1771-P5 POWER SUPPLY,SLOT,8A,24V DC

Distributed I/O 1798-IB4D FLEXARMOR 4 INPUT 24 VDC MODULE WITH DIAGNOSTICS

Operator Interface 2711P-B6M3A PV PLUS 600 GRAYSCALE, KEY/TOUCH, DH485, AC PS

Support 9323-PA2IS SUPT RENEWAL CONTRACT FOR 9323PA2I

Support 9358-PB10R SUPT REINSTATEMENT CONTRACT FOR 9358PB10ENE

Support F1772-LZSERA FIRMWARE UPGRADE FOR 1772-LZ PLC2 PROCESSOR MODULE

RSI Software Products 9324-RLD6U7ESE RSLOGIX 5000 FULL TO PRO UPGRADE, SPANISH

RSI Software Products 9305-RSVADFCPTE RSVIEW32 ACTIVE DISPLAY FLOAT. CLIENT (PORTUGUESE)

RSI Software Products 1771-PCB CONTROL COPROCESSOR PRGM DEVELOPMENT & CROSS CMPLR

Motion Control 2094-BL02 MODULE, LINE INTERFACE, 15KW 400/460V, 6A+3A 24VDC

A06B-0153-B175#7076 A30/3000 Servo Motor, IP67 Sealing, Holding Brake, 64K Serial Encoder

IC200UDR006 28 point PLC, (16) 12VDC In, (1) 12VDC Out, (11) Relay Out, 12VDC Power Supply. Battery (IC200ACC403) is required for long term data rentntion and Real Time Clock. Battery not included.

IC752CBT020RR Datapanel 320T MEG (Mono Expansion w/ Genius): 320x240 1/4 VGA Monochrome LCD with 80386SX/40 PC processor. Analog touch screen with text, bitmaps, bar graphs, real time clock. With 2M memory. With Genius PC/104.

MTR-1N32-I-N-D-S-0RR Stepping Motor Nema34

NI 9236

WSB-9154-R20-ZTE

SUN CP2040-TRN

TR1000+P24V8FH-T1

BP-14S

FSP250-50PLB(1U)

A20B-0005-0583

1492-SPM3D030 MCB Supplementary Protector 3 A

软启动器 3RW40281BB15

" "24 MB

150-SD2NBR SMC-50 SOLID STATE MOTOR CONTROLLER 420A

1738-ADN12 ArmorPoint DeviceNet Network Adaptor

1783-US7T1F Stratix 2000 7+1 port unmanaged switch

193-EXP-PS-AC E300 AC Expansion Power Supply

20-750-NEMA1-F4 NowerFlex 750 Frame 4 Conduit Box Kit

2090-CPWM7DF-16AF07 MP-Series 7m Length Power Cable

20AB015F0AYNANC0 PowerFlex 70 AC Drive 15.3 A at 5 Hp 20A

GA647IFESGSR00300 GCA iFIX Optn: ESig & ERec 300 I/O Srv

GP646IFCLNTCRO100 GCP iFIX iClientTS Read Only 1 PK Runtime Version

IC600BF806RR 12Vac/dc Input Module (8 points)

IC647HSTCC20KM Calculation Collector for Historian - Standard Server 20000 Points (M4 Key)

IC647TBLCPVC010 Virtual Campus for Proficy Troubleshooter and Cause+ - 10 Users

IC693MDL754 12/24VDC Output (0.75 amps per point) Module 32 point. The module requires a terminal block (IC694TBB032 box style or IC694TBS032 spring clamp style terminal block). Terminal block is sold seperately. Output response Time is 0.5ms.

IC756LDV000K-99 DV Development - Intel/Linux RedHat Op Sys, Korean, Version 9.9

Pico Controllers 1760-CBL-INT01 PICO-LINK CONNECTIVITY CABLE .3M 1 PCS/PACK

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

Distributed I/O 1791-16A0 BLOCK I/O, 120V AC, 16 POINT MODULE (16 INPUT)

Communications 1786-TCT2BD1 CONTROLNET TNC IP67 T-TAP/BNC STRAIGHT

Operator Interface 2706-PSW1 INVIEW MESSAGING SOFTWARE.

Support 9701-VWSS025AR SUPT REINSTATEMENT CONTRACT FOR 9701VWSS025AENE

Support 9324-RL0100FRS SUPT RENEWAL CONTRACT FOR 9324RL0100FR

EtherNet/IP Products 2711P-K15C4D2 PV PLUS 1500, KEYPAD, ENET, DC PS, EXT MEM

RSI Software Products 9301-2SE340PTU5R RSVIEW32 RUNTIME 5K-32K UPGRADE OUT-SUPT (PT)

RSI Software Products 9356-PRO2450 RSSQL PR0 VERS WTH 32000

Motion Control F-4075-R-H00AN MOTOR,F-,NEMA 56C,82 IN LB CONT.

4362-H 4362 WITH 0-10 OR 4-20 mA OUTPUT

IC200ACC404 Spare parts kit. Two terminal strips and four plastic doors and four covers

IC693DSM314 Series 90-30 DSM314 Motion Controller, 1-4 axis

TGT-S000-1-1 Target System Module with 2 MB RAM

CB68-LP

PCM-5825

DM/V960-4T1-PCI

kvaser PCIcanS SDA-A1011

EPIA-EX EPIA-EX15000LG

HPCI-CPD532

SOM-2353F

1492-SPM1D150 MCB Supplementary Protector 15 A

通用型变频器 6SE6 440-2UD31-5DB1 "15 KW,275 x 520 x 245"

电机启动器 3VU13403MS00

150-C480NCD SMC-3 480A Smart Motor Controller

1609-SPD UPS Surge Replacement Module

1771-IC DC INPUT 48V

193-EC3BB E3 Plus 3-15 A Overload Relay

198-MT1 IEC Selector Switch

2090-CPBM7E7-16AF25 MP-Series 25 m Length Cable

2094-AM03-S Kinetix 6000 Axis Module

CW0DT1009 Industrial Key Board for DuraTouch, QWERTY Keyboard, Oil Resistant Typ e

GFK-0582 Series 90 PLC Serial Communications Driver User's Manual

IC200UEX726 RTD expansion module for VersaMax Micro Pt 100, -100 to +600 C-150 to +1050 F 2 and 3 wire support and 2 analog output voltage and current.

IC647AQC002 PA Quality Client 2 Pak

IC647PFSM2011 Proficy for Sustainability Metrics 2011

IC693CHS399 Base, Remote Expansion, 5 Slots (700 ft.)

IC754UPGRD01VINT QP View Intermediate OS Upgrade Qty-1

MB-FB-GT Proficy Process Systems HD2-GTR-4PA Simplex Gateway MB from Pepperl+Fuchs

SLC/1746 System D1784-6.5.17 SLC500 & PLC5 I/O MONITOR USER MANUAL

Distributed I/O 1734-ACNR 24V DC CONTROLNET ADAPTER

Application-specific products 1803-EEM02E4 EEM,16 ANALOG, 4 TO 20 MA, NEMA 4 ENCLOSURE

Operator Interface 2711-T10G14 PV1000 GRAYSCALE TOUCH, MBUS & RS232 PRINT

Support 9301-2SE3500PTS SUPT RENEWAL CONTRACT FOR 93012SE3500PT

Support 9381-PEDRCPENR SUPT REINSTATEMENT CONTRACT FOR 9381PEDRCPEN

DeviceNet Products 1790D-N4C0 DNET LDX, 4 INPUT ANALOG CURRENT BSE,D-SHELL CONN

RSI Software Products 9301-2SE330JPU1R RSVIEW32 RUNTIME 300-1500 UPGRADE OUT-SUPT (JP)

RSI Software Products 9358-PBNT03ENE RSBATCH NT FOR PROCESSLOGIX 03 UNITS

Motion Control MPL-B640F-SJ24AA MOTOR,SERVO,36.0NM,3000RPM,SINGL,460V,BRK

Miscellaneous

GQSK2D100S2P QUICKSTART KIT 6" STN GE LABEL

IC646NSL001 CIMPLICITY SQL 1 Client User

MTR-3T69-G-R-B-M-0 MTR-Series Servo Motor, Resolver, Metric, 24V Brake

ST-222F STXi output module 16 points, Positive Logic, 24VDC/ 0.3A

SCXI-1175

Znyx LK6-ZX312

canopus NHX-E2

0B0KEIS80200B200

AIMB-256G2

AR-B9140

1492-RCDA4C40S Residual Current Device 40 A

有源导轨 6ES7195-1GA00-0XA0 有源导轨/480mm

变送器 3RS11 40-2GD60

1497-K-BAJK-0-N Control Circuit Transformer

1606-XLE240EP Power Supply XLE 240 W Power Supply

1763-L16BBB MicroLogix 1100 16 Point Controller

188-K3D200-N Miniature Circuit Breaker 20 A

194L-HE4A-451 IEC Control And Load Sw Actuator Type A

2090-CPBM7DF-08AA25 MP-Series 25m Power and Brake Cable

2090-XXNPMF-14S30 Kinetix Drives 30m Standard Cable

BC647TRT150 CIMPLICITY HMI Server 150 I/O Runtime System with Proficy GlobalCare

GC647PSC300 Global Care for Proficy Process Systems 3000 I/O with CIMPLICITY

IC200MDL940CA OUTPUT RELAY 2A ISO FORM A 16PT MODULE CONFORMAL COATED

IC646PME050 Proficy Change Management for ME 50 user pack

IC647MX1M MX1:Leeds and Northrup Max1

IC687BEM713 Half Slot Bus Transmitter Module

IC697VAL324 Discontinued, replacement is Embedded VME-6550. Contact GE IP Embedded for details.

IC800SSI407RS1 7.2 amp 480 VAC S2K servo controller for MTR series motors

SLC/1746 System 1747-M2 EEPROM MEMORY, 4K FOR PROGRAMMABLE CONTROLLER

Industrial Computers 6181P-15NP2KH VERSAVIEW INTEGRATED DISPLAY COMPUTER 15-INCH

Application-specific products 9358-PBEBNT60ENE RSBATCH NT & EPROCEDURE BNDLE PROCESLGIX 60 UNITS

Operator Interface 2711-K5A15L1 PV550 MONOCHROME KEY, CNET & RS232 PRINT

Support 9306-4PXP01S SUPT RENEWAL CONTRACT FOR 93064PXP01ENE

Support 9393-RSTLX500R SUPT REINSTATEMENT CONTRACT FOR 9393RSLTX500

ControlNet Products 2711P-K7C15D1 PV PLUS 700, KEYPAD, CNET, DC PS, STD MEM

RSI Software Products 9301-2SE2500U3 UPGRADE: IN-SUPT: RSVIEW32 WORKS 300 TO 100K

RSI Software Products 9358-BEPB60U1R UPGRADE: OUT-SUPT: RSBW BATCH & EPROCEDURE 03 TO60

Motion Control MPL-A4540F-HK24AA MOTOR,SERVO,10.2NM,3000RPM,ENCDR,230V,BRK,13KG

Motion Control 2090-XXNFY-S12 CABLE,NON-FLEX,MOTOR FEEDBACK,Y,12M

GABI31200C2P/AR QUICKPANEL 10.5" TFT W/AB RIO GE LABEL

IC641PCC804 Annual Maintenance for IC641PCC004

IC800SSI104RD2 4.3A, 115/230V, DeviceNet S2K Servo Controller for MTR Series Motors

PR-PAT-RX-1.2 Proficy PAT - Process Analytical Software Suite, Pharmaceutical

PXI-6229

PCI-14S3-RS-R30

YOKOGAWA LR4100E

EMACS P1U-6200P

TEKNOR T936IB

NEXCOM ICES101-C65-TY

1492-MS5X9H1-10 Connection Products

1495-N68 Protective Fuse Cover

行程开关 3SE53120SG12

运行版软件 6AV2105-0MA14-0AA0 SIMATIC WinCC Runtime 专业版 65536 PowerTags ASIA V14

1585J-M4UBJM-1 RJ45 Ethernet Media

1756-OV32E ControlLogix 32 Point D/O Module

188-K1C160 Miniature Circuit Breaker 16 A

194E-KA16E-P11 194E Load switch