臺灣博碩士論文加值系統

本論文的目的是提高航太用異形薄集油器焊接製程的生產效率，由於集油器具備複雜的結構，生產過程需要以手動調整多組夾治具，然後，再將多個圓筒型薄板件依序經TIG(Tungsten Inert-Gas)焊接成型。此方式，導致集油器的生產效率低落，且品質難以掌控。因此，本論文提出一套結合油壓驅動系統之自動化夾治具，取代現有的手動夾治具，大幅縮短集油器之製程時間，並維持穩定的品質。
本研究所開發之自動化夾治具，是以油壓系統驅動楔形塊向外擴張形成同心之圓筒狀，並緊密夾持焊接薄板件。因此，在焊接加工後，集油器能保持圓錐之圓筒狀。另外，夾治具內部設有氣體流道系統及流量調節功能，能流暢導引惰性氬氣，並有效的保護焊接位置。而開發自動化夾治具過程進行包含機構設計、有限元素分析、製造、系統整合、製程規劃與性能驗證等內容。而經由現場實際組裝自動夾治具進行性能測試，其結果顯示，集油器製程時間由目前的45分鐘縮短至30分鐘，生產效率提高33.3%，驗證所開發之自動化夾治具的性能。最後，本論文所獲得的研究成果，將可應用到其它特殊形狀之薄板件焊接設備的開發。

The thesis is aimed at improving the welding productivity of a special-shaped aircraft oil collector. Because of the complex structure of the oil collector, the manufacturing process requires manual adjustment for groups of fixtures, and then the thin circular components are welded together by TIG (Tungsten Inert-Gas) welding. This process leads to the low productivity of the oil collector, and the quality is difficult to maintain. Therefore, this thesis proposes an automatic fixture with hydraulic driving system to replace the manual fixtures for reducing process time of oil collector and maintaining stable production quality.
The developed automatic fixtures is to use a hydraulic system to drive the wedge blocks outward to form a cylindrical and conic shapes, which can firmly contact with the thin welding components. Therefore, after the welding process, the oil collector can maintain its cylindrical and conic shapes. In addition, the fixture is designed with internal gas flow channels and with a flow rate regulation function so that the inert argon gas flow can be well guided and the welding position can be effectively protected. The developing processes of the automatic fixture include mechanical design, finite element analysis, fabrication, systems integration, process planning, and performance verification. An on-site performance examination was performed by using the assembled automatic fixture. As a result, the developed automatic fixture might reduce the processing time of an oil collector from current 45 minutes to 30 minutes with productivity improvement of 33.3%. The effectiveness of the proposed automatic fixture was demonstrated. The results obtained in this these can be applied to the welding devices with thin and specially-shaped components.

中文摘要 I
ABSTRACT II
致謝 IV
目錄 V
圖目錄 VII
表目錄 IX
第1章 緒論 1
1.1前言 1
1.2集油器之加工製造現況 1
1.2.1集油器 1
1.2.2生產現況 2
1.2.3現有夾治具之問題點 6
1.3研究動機與目的 7
1.4文獻探討 7
1.5論文架構 9
第2章 設計方法 10
2.1 前言 10
2.2 設計概念 10
2.3 作動原理與機構特點 11
2.4 自動化夾治具開發流程 13
2.5 有限元素分析與驗證方法 14
2.5.1 推拔角度分析 14
2.5.2 驗證方法 15
第3章 夾治具分析與設計成果 16
3.1 前言 16
3.2 推拔錐度角 17
3.3 自動化夾治具開發成果 21
3.3.1 設計結果 21
3.3.2 夾具塊 23
3.3.3 推拔(楔形塊) 24
3.3.4 自動化夾治具 25
第4章 系統整合與驗證 28
4.1 前言 28
4.2 系統整合 28
4.3 製程規劃 32
4.4 夾治具驗證 36
第5章 結論與未來展望 40
5.1 結論 40
5.2 未來展望 41
參考文獻 42

[1]W. H. Kearns, 1982, Welding Handbook, 7th ed., Vol.4, American Welding Society, Miami, FL.
[2]CFM56-5B SAC ENGINE AIRFLOW, CFM International
[3]CFM56-5B工件製造標準，寶一科技內部資料。
[4]周長彬，蔡丕椿，郭央諶，1993，焊接學，全華出版社，台北。
[5]CFM56-5C自動化焊接型架，寶一科技內部資料。
[6]CFM56-5B焊接型架，寶一科技內部資料。
[7]http://www.mindman.com.tw/big5/products.php
[8]http://tw.misumi-ec.com/