臺灣博碩士論文加值系統

近年台灣工具機產業朝向智能化技術發展，除機械設備之性能與精度的提升外，並要求將機械智慧化技術整合，以建立高可靠度、高穩定度與系統化的製造系統。同時輕薄3C筆電、平板機殼及智慧型手機金屬外殼等產品愈來愈多利用鋁合金超薄板件製造，故鋁薄板接合技術愈形重要。摩擦攪拌銲接加工為固態銲接製程，具有銲接品質優良、低變形及高再現性等優點，屬於無汙染綠色製造及符合未來節能減碳與環保的要求，所以發展微摩擦攪拌銲接技術不僅能降低製造成本，更能增加機械微接合元件之強度與品質。本研究以實驗室自行設計之微摩擦攪拌銲接加工機作為開發平台，將控制器與周邊設備整合開發作為控制系統介面。
本研究利用微摩擦攪拌銲接加工機之GALIL控制器與夾治具感測荷重元，自行撰寫程式將機器感測訊號擷取設計於電腦之控制系統，用以提升微摩擦攪拌銲接製程的操控效率，便利操作者使用。使用Microsoft Visual C#調用GALIL控制器提供之動態連結函式庫(DLL)，利用Ethernet讀取GALIL控制器之機械參數，以及控制軸向運動功能，將RS-485連接Modbus擷取荷重元訊號並轉換成下壓力、夾持力、進給力，整合上述功能整合至微摩擦攪拌銲接控制系統，針對摩擦攪拌銲接製程設計即時監控模組、系統控制模組、數據紀錄模組、摩擦攪拌銲接模組，並且加入互動回饋控制功能，令使用者得知當前操作狀態，透過即時偵測機器狀態適時顯示提示，同時保護機台之機構與操作者的安全措施。進行摩擦攪拌銲接製程，操作者可依照介面的提示與教學，逐一將銲接參數輸入至系統之摩擦攪拌銲接模組，系統自動將銲接參數組成GALIL控制器之摩擦攪拌銲接路徑程式碼，操作者檢查銲接參數無誤後，即可執行完成摩擦攪拌銲接製程。
本研究開發出來的微摩擦攪拌銲接加工機控制系統介面，已成功提升微摩擦攪拌銲接加工機的操控性能與效率，並可應用至各型工具機或精密機械的控制系統，對產業技術提升貢獻相當大。

In recent years, Taiwan's machine tool industry towards intelligent technology development, in addition to enhance the performance of mechanical equipment and precision and demanded intelligence of the mechanical technology integration in order to establish a high reliability, high stability and systematic manufacturing systems. Meanwhile 3C thin notebook, tablet cases and metal cases products of smart phones are more and more use of aluminum alloy thin plate. Therefore, the technique of aluminum sheet joining is getting important. Friction stir welding(FSW) is a solid state welding process with high welding quality, low distortion and high reproducibility, pollution-free green manufacturing, carbon reduction and environmental protection with the requirements of the future. Therefore, the development of micro friction stir welding technology can not only reduce manufacturing costs, but also increase the strength and quality of the mechanical components of the micro-joint. This study use the micro friction stir welding machine of design ourselves as a development platform, the controller and peripheral integration and development of the control system interface.
In this study, the GALIL controllers and fixture sensing load cell of micro friction stir welding machine were employed. And the control system programs of machine sensed signal acquisition system were designed. It is in order to improve the control efficiency of micro friction stir welding machine and to facilitate operator use. Use Microsoft Visual C # to call a dynamic link library (DLL) GALIL controllers provided by Ethernet to read GALIL controllers of mechanical parameters, as well as axial movement control function. The RS-485 connection load cell signal capture by Modbus and conversion a downward pressure, clamping force, feed force, and the integration of these functions integrated into the micro friction stir welding control system. For friction stir welding process design real-time monitoring module, system control module, data recording module, friction stir welding modules, and adding interactive feedback control function, so that operators know the current operating status. Through detection prompts immediate machine state, while protecting the institution of the machine and the operator's security measures procedures. When micro friction stir welding process was in progress, the operator can follow the prompts to interface with the teaching of each welding parameter input to the system's friction stir welding modules. And the system automatically welding parameters consisting of friction stir welding path GALIL controller code, and can perform complete friction stir welding process after the operator checking the correct welding parameters.
This study developed micro friction stir welding machine control system interface, has been successfully control to enhance the micro friction stir welding machine performance and efficiency, and can be applied to various types of machine tools or precision machine control systems, industrial technology to enhance contribution considerable.

中文摘要------------------------------------------------------------- i
ABSTRACT----------------------------------------------------------- iii
誌　謝--------------------------------------------------------------- v
目錄---------------------------------------------------------------- vi
表目錄-------------------------------------------------------------- ix
圖目錄--------------------------------------------------------------- x
第一章 緒論--------------------------------------------------------- 1
1.1 前言--------------------------------------------------------- 1
1.2 摩擦攪拌銲接------------------------------------------------- 2
1.2.1 摩擦攪拌銲接原理--------------------------------------- 2
1.2.2 摩擦攪拌銲接製程--------------------------------------- 4
1.2.3 摩擦攪拌銲接之微觀組織--------------------------------- 5
1.2.4 摩擦攪拌銲接的加工參數--------------------------------- 7
1.2.5 摩擦攪拌銲接之形成缺陷--------------------------------- 8
1.3 文獻回顧---------------------------------------------------- 10
1.4 研究動機與目的---------------------------------------------- 14
1.5 論文架構---------------------------------------------------- 16
第二章 系統架構與建置設備------------------------------------------ 17
2.1 微摩擦攪拌銲接加工機------------------------------------ 17
2.1.1 夾治具設計及荷重元設置-------------------------------- 18
2.1.2 銲接中心定位------------------------------------------ 19
2.2 GALIL運動控制器--------------------------------------------- 20
2.2.1 GALIL運動控制器與PC通訊連接-------------------------- 22
2.2.2 GalilTools指令及設置---------------------------------- 26
2.3 GALIL程式應用----------------------------------------------- 28
2.4 應用ModBus擷取Load Cell荷重元訊號------------------------- 33
2.5 系統架構---------------------------------------------------- 36
第三章 微摩擦攪拌銲接加工控制系統規劃------------------------------ 38
3.1 微摩擦攪拌銲接加工控制介面規劃------------------------------ 38
3.2 微摩擦攪拌銲接加工控制系統規劃------------------------------ 39
3.3 系統初始化規劃---------------------------------------------- 41
3.4 即時監控模組規劃-------------------------------------------- 41
3.5 系統控制模組規劃-------------------------------------------- 43
3.6 摩擦攪拌銲接模組規劃---------------------------------------- 46
3.7 數據紀錄模組規劃-------------------------------------------- 48
3.8 系統連線與緊急停止規劃-------------------------------------- 49
第四章 微摩擦攪拌銲接加工控制系統建置與測試------------------------ 50
4.1 前言-------------------------------------------------------- 50
4.2 系統開發環境------------------------------------------------ 50
4.3 GalilTools 動態連結函式庫------------------------------------ 52
4.4 動態連結函式庫-ClsFSW.dll----------------------------------- 53
4.5 微摩擦攪拌銲接加工控制系統之介面設計與功能建立-------------- 57
4.5.1 GALIL控制器連線建立----------------------------------- 57
4.5.2 即時監控模組建立-------------------------------------- 58
4.5.3 RS-485連接Modbus擷取荷重元建立----------------------- 59
4.5.4系統控制模組功能建立----------------------------------- 62
4.5.5摩擦攪拌銲接模組建立----------------------------------- 64
4.5.6數據記錄模組建立--------------------------------------- 68
4.6微摩擦攪拌銲接加工控制系統測試------------------------------- 76
4.7微摩擦攪拌銲接加工測試-------------------------------------- 108
第五章 結論與建議------------------------------------------------- 110
5.1 結論------------------------------------------------------- 110
5.2 建議------------------------------------------------------- 111
參考文獻----------------------------------------------------------- 112

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