臺灣博碩士論文加值系統

生產不同形式與尺寸的扣件需要可靠的製造機械。在本研究中，實驗數據與分析技術被用來分析這類製造機械在空車運轉或負載運轉的一般行為模式。分析的結果可被用來建立偵測製造機械與產品的異常情形之方法，從而設計出可靠的製造機械。偵測方法中的第一個步驟是在製造機械上安裝探測器，所得的訊號是一個加速規和定位系統的類比轉數位資料。加速規是安裝在主滑台上，由驅動器供應固定電流並將其加速度造成的電壓加以放大。定位系統是由安裝在主滑台上的齒條經由齒輪驅動固定在機台上的編碼器，編碼器所產生的Gray Code經由轉換電路變成二進位數位訊號再轉換成類比電壓。其次，將所得加速度與編碼器的電壓訊號經由運動學分析可以獲得主滑台的加速度、速度與位移的水平分量隨時間的變化關係。接著，使用加速度和位移的時間序列可產生在每一個週期內的(1)主滑台震動的均方根值、(2)主滑台震動的頻譜、以及(3)低頻震動強度隨主滑台位移的變化。速度和位移的時間序列可用來產生主滑台(1)被吸收的比動能和(2)所受水平分量的力隨位移的變化。然後，將前述所產生的曲線圖與由Qform® 軟體所模擬的曲線圖比較，或將所有的曲線圖與正常操作下的曲線圖加以比較，可以找出不同之處，依此可預測製造機械或產品早期可能發生的問題。最後，依照本偵測方法可在最少增添設備與最低成本增加的原則下，用其他任何比較的技術，例如機器學習，來分析並找出製造機械與產品的異常並生產可靠的扣件製造機械。

The manufacturing of fasteners with diverse shapes and sizes entitled with diverse specification requires credible and reliable bulk-forming machinery. In this research, both experimental data and simulation techniques are used to analyze the general behavior of the machinery that operates with or without fabricating parts. The results of the analysis are used to establish the monitoring methods that detect anomalies in the machinery and the products for building reliable and credible machineries. The methodology is firstly to equip the machinery with sensors. The data acquired are the A/D-converted signals from an accelerometer and a positioning mechanism, which consists of a set of rack and pinion and an optical encoder. Secondly, with the help of kinematics and the positioning signals, the voltage signals of acceleration were processed to obtain the horizontal components of acceleration, velocity, and displacement of the sliding block mechanism (SBM) with respect to time. Thirdly, the time series of acceleration and displacement were used to generate (1) vibration RMS value, (2) vibration spectrum, and (3) the power of low-frequency vibration with respect to displacement for each cycle. The time series of velocity and displacement were used to produce (1) the specific kinetic energy absorption of the SBM and (2) the horizontal force exerted by the SBM with respect to displacement. Fourthly, the resultant graphs and curves were compared with those resulted from simulation with Qform® software or with each other of normal and abnormal situations. The last step of the methodology is to use all kinds of comparative analysis techniques, such as machine learning, for the diagnosis or prognosis of the anomalies of the machinery or the manufactured products with the minimized additional equipment’s and costs.

Recommendation Letter from the Thesis Advisor
Thesis/Dissertation Oral Defense Committee Certification
Acknowledgements iii
中文摘要 iv
English Abstract v
Table of Contents vi
List of Figures ix
List of Tables xiii
1. Introduction - 1 -
1.1 Research background - 1 -
1.2 Research motivation - 3 -
1.3 Research objectives - 5 -
2. Methodology - 7 -
2.1 Theoretical and simulation modeling - 7 -
2.1.1. Slider crank mechanism - 8 -
2.1.2. Bulk forming analysis - 12 -
2.2 Experimental analysis - 19 -
2.2.2 Data processing - 28 -
2.2.3 Data analysis - 34 -
3. Results and Discussion - 39 -
3.1 Methods established through bulk forming simulation - 39 -
3.1.1 Signature curves for formed shapes - 39 -
3.1.2 Forming tool and formed parts analysis - 41 -
Case 1: Analysis of the punch with and without tip common to all punches. - 41 -
Case 2: Analysis to find the tolerance range, before the degradation - 43 -
Case 3: Analysis of multi-station forming parts load curve - 46 -
3.1.3 Simulation designed model and boundary condition check - 51 -
Case 1: Analysis of 2-D and 3-D parts with uncoupled and coupled - 51 -
Case 2: Analysis of 2-D and 2-D parts with uncoupled and coupled simulations - 52 -
3.1.4 Curve summation analysis for estimations of peaks and falls. - 54 -
3.2 Methods established with processed sensor data - 56 -
3.2.1 Time waveform analysis - 57 -
Case 1: RMS and mean value analysis of waveforms - 57 -
Case 2: The normalized RMS of the forged cycle w.r.t whole cycle - 59 -
3.2.2 Spectral analysis - 61 -
3.2.3 Time-Position-Amplitude-Frequency Signal Analysis - 63 -
3.2.4. Power spectrum of forging stroke - 68 -
Case 1: Lower frequencies power spectrum - 68 -
Case 2: Higher frequency power spectrum - 70 -
3.2.5 Specific kinetic energy absorbed - 72 -
3.2.6 Comparative load analysis of acquired vs simulated data - 75 -
3.2.7 Comparative study between the repaired vs general machine - 77 -
3.2.8 The analysis between healthy vs unhealty machinery - 78 -
4. Conclusions - 79 -
References - 81 -
Appendix A - 82 -
Appendix B - 88 -
Appendix C - 89 -
Appendix D - 90 -
Appendix E - 91 -

List of Figures
Figure 1-1 Industrial revolutions [1]. - 1 -
Figure 2-1 Methodology chart. - 7 -
Figure 2-2 Machinery view with its type description. - 8 -
Figure 2-3 Schematic representation of machinery (top) and CAD models (bottom). - 9 -
Figure 2-4 Crank slider mechanism. - 10 -
Figure 2-5 Graph of the ideal acceleration versus time for a slider-free slider crank mechanism. - 12 -
Figure 2-6 Top view of forging stations. - 13 -
Figure. 2-7 Drive type selection in QForm. - 17 -
Figure 2-8 Schematic view of the setup (top) and actual installed experimental setup (bottom). - 20 -
Figure 2-10 Schematics of accelerometer [8]. - 21 -
Figure 2-11 Sensitivity [8]. - 21 -
Figure 2-12 Dytran 3006A acceleration gauge. - 22 -
Figure 2-12 Dytran 4103C current supply and signal amplifier. - 22 -
Figure 2-13 Optical encoder [9]. - 23 -
Figure 2-14 Truth table [9]. - 23 -
Figure 2-15 Dimensions of A1 absolute light load shaft encoder. - 24 -
Figure 2-17 Designed circuit board (Top), Circuit diagram (Bottom). - 25 -
Figure 2-17 Advantech USB-4716 data capturing device. - 26 -
Figure 2-18 (a) Rack and pinion arrangement with, (b) prototype made in 3-D printer. - 27 -
Figure 2-20 Encoder signals. - 29 -
Figure 2-20 Conditioning of the encoder data. - 30 -
Figure 2-21 Plot of displacement and velocity. - 32 -
Figure 2-22 Force diagram. - 33 -
Figure 2-23 (a) Actual view of accelerometer and encoder signals in data logger [10], (b) Plot of data recorded by data logger. - 35 -
Figure 2-24 Comparisons of waveforms of machinery working with and without workpiece. - 36 -
Figure 2-25 Comparison of peaks by FFT [10]. - 37 -
Figure 2-26 The spectrogram of a working cycle. - 38 -
Figure 3-1 Three Hex-head process station load curves. - 39 -
Figure 3-2 Plus head process stations load curves. - 40 -
Figure 3-3 ASSY process station load curves. - 40 -
Figure 3-4 (a) Hex-head tool tip, (b) Plus head tool tip, (c) Internal ASSY head tool tip (Section view). - 42 -
Figure 3-5 Tool tip types. - 42 -
Figure 3-6 Load-time curve. - 43 -
Figure 3-7 Tolerance range curve. - 45 -
Figure 3-8 Variation in parts with tolerance. - 45 -
Figure 3-9 Hex head formed parts. - 46 -
Figure 3-10 Hex head punch and die molds - 46 -
Figure 3-11 Load-displacement curve for Hex-head screw. - 47 -
Figure 3-12 Plus head (a) Actual part, (b) CAD model, (c) CAD model (hidden lines). - 47 -
Figure 3-13 Plus head punch and die design. - 48 -
Figure 3-14 Load-displacement Plus head screw - 48 -
Figure 3-15 ASSY Head (a) and (b) actual parts and below are the simulated parts corresponding to dies. - 49 -
Figure 3-16 Load displacement curve ASSY head screw. - 50 -
Figure 3-17 Comparison of (a) 2-D and (b) 3-D curve for uncoupled conditions. - 51 -
Figure 3-18 Comparative load variation curve for coupled and uncoupled conditions of plus head screw. - 52 -
Figure 3-19 2-D Models comparison. - 52 -
Figure 3-20 Comparitive load curve for 2-D models of ASSY screw. - 53 -
Figure 3-21 Load curve of plus head screw (4-process). - 54 -
Figure 3-22 Load curve of ASSY head screw (2-process). - 55 -
Figure 3-23 RMS value for 95 cycles of plus head screw warm and cold. - 57 -
Figure 3-25 RMS value for 78 cycles of ASSY warm and cold cycles. - 58 -
Figure 3-26 Normalized RMS of warm cycle for plus screw head. - 59 -
Figure 3-27 Normalized RMS of cold cycle for plus screw head. - 60 -
Figure 3-28 FFT analysis of plus head screw. - 61 -
Figure 3-29 FFT analysis of ASSY head. - 62 -
Figure 3-30 Spectrogram (left) and Time-waveform analysis (right) of plus screw head for loaded cycle (top) and empty cycle (bottom). - 63 -
Figure 3-31 Load curve for estimating the forging station. - 64 -
Figure 3-32 Time frequency analysis (Spectrogram). - 64 -
Figure 3-33 The spectrogram for one cycle in the process of production ASSY head screws. (Left: a loaded cycle; Right: an empty cycle). - 66 -
Figure 3-34 Load curve for estimating the forging station of ASSY head screws. - 66 -
Figure 3-35 Spectrogram. - 67 -
Figure 3-36 Power spectrum of forging stroke for plus screw head. - 68 -
Figure 3-37 Load-displacement curve with preform location. - 69 -
Figure 3-38 Power Spectrum of forging stroke for ASSY head. - 69 -
Figure 3-39 Load-displacement curve. - 70 -
Figure 3-40 High frequency power spectrum of plus screw head. - 71 -
Figure 3-41 Forward cycles of plus screw head. - 72 -
Figure 3-42 Analysis of plus screw head. - 73 -
Figure 3-43 Analysis of ASSY head screw. - 74 -
Figure 3-44 (a) Experimental Data vs (b) Simulated data. - 75 -
Figure 3-45 Experimental Data vs Simulated data - 76 -
Figure 3-46 Plots for repaired (left) and general (right) machinery; (a) Time-waveform, (b) Spectrum, (c) Spectrogram. - 77 -
Figure 3-47 The comparison between the plots of (a) healthy and (b) unhealthy machine. Time waveforms are shown in the upper row; spectrogram in the lower row. - 78 -

List of Tables
Table 2-1 Parts and machinery specifications - 15 -
Table 2-2 A1 Absolute light load shaft encoder specifications - 24 -

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