臺灣博碩士論文加值系統

自動化系統在工業 4.0 中是不可或缺的元素之一，自動化不但能取代基
本的人力作業，也提升生產線的產能，更因為標準化的生產流程，使品質以
及產量都相較於人力穩定。本論文為一個產學合作案，針對委託方需求，利
用軟體設計開發一個以 PC-Based (Personal Computer Based)為基礎的自動電
池點焊系統，將生產過程中需要的功能皆整合在系統當中。此系統一共可分
為六大功能，依照操作流程分別為「成員登入、點位設定、機台設定、產品
生產、焊接紀錄、成員權限設定」。使用者一開始登入時，會依據權限的不
同而呈現對應成員權限的使用者畫面，而點位設定介面，可設定產品的點位
路徑及布局方式，機台設定可以調整機台的焊接相關配置，主畫面可依據既
有的布局方式生產產品，且在產品生產過程中，記錄每一次焊接的電壓、電
流、阻抗及功率。
最後， 我們透過實驗比較自動化以及人力兩種生產方式，結果得到在
導入自動化系統之後，人力介入生產時間約減少了 33%，另外一方面，產量
也提升 6.6%。

An automated system is one of the indispensable elements in Industry 4.0,
because the automation not only replaces basic labor operations, but also increases
production line capacity. Due to standardized production processes, quality and
output are comparable to labor stability. Therefore, in this study, we propose a
PC-Based (Personal Computer Based) automatic battery spot welding system is
customized to integrate the functions required in the production process into the
system by the software design and development for the demands of a client.
According to the operation process, the system divided into six functions: member
login, point setting, machine setting, product production, welding record, and
member authority setting. The system shows different user interfaces based on
user permissions, and the point setting interface can be set the point path and
layout mode of the product. Besides, the machine setting can adjust the welding
related configuration of the machine. The main screen controls the products
production according to the existing layout method, and records the voltage,
current, impedance and power of each welding during the production process.
Finally, we compare the automation and labor production methods for the
labor intervention time and throughputs by the experiments. The results show that
the labor intervention time reduced by about 33% and the throughputs
increased by 6.6%.

目錄
摘要 I
Abstract II
致謝 III
目錄 IV
圖目錄 VII
表目錄 XII
第一章、 緒論 1
1.1 前言 1
1.2 研究動機與目的 2
1.3 論文章節介紹 4
第二章、 相關研究 5
2.1 工業4.0 5
2.2 工業自動化 6
第三章、 開發環境 8
3.1 伺服馬達介紹 8
3.2 數位輸入輸出模組介紹 9
3.3 點焊機介紹 10
第四章、 系統架構與功能 14
4.1 馬達運動控制方法 15
4.2 數位輸入輸出模組設計 16
4.3 點焊機通訊方法 18
4.4 軟體功能規劃 22
第五章、 實驗結果與說明 37
5.1 系統軟體 37
5.2 實驗結果 57
第六章、 結論 62
參考文獻 64

圖目錄
圖1 傳統方式點焊電池 3
圖2 伺服馬達及驅動器 8
圖3 數位輸入輸出模組 9
圖4 點焊機 10
圖5 點焊機接點 11
圖 6腳本選擇方式 12
圖 7 Visual Studio 2017 Community開發畫面 13
圖8 硬體架構圖 14
圖9 自動點焊機 15
圖10 系統操主畫面 16
圖11 點焊機接頭 19
圖12 點焊機接線圖 19
圖 13軟體架構圖 23
圖 14人員登入流程圖 24
圖 15點位新增流程 25
圖 16單點單次焊接 26
圖 17單點2次焊接 26
圖 18單點3次焊接 27
圖 18電池編號示意圖 28
圖 19電擊棒研磨裝置 29
圖20 狀態流程方塊圖 30
圖 21生產流程圖 31
圖 22設備檢查程序流程圖 32
圖 23生產程序流程圖 33
圖 24焊接程序 35
圖 25緊急停止程序流程 36
圖26系統登入畫面 37
圖27系統成員設定 38
圖28 系統主畫面－作業人員畫面 40
圖29 系統主畫面－管理人員畫面 40
圖30 系統原點復歸後 41
圖31 系統主畫面－選擇產品 42
圖 32系統主畫面－產品匯入 43
圖33 系統主畫面－輸入條碼 43
圖 34系統主畫面－產品生產 44
圖 35系統主畫面－焊接失敗 45
圖36 系統點位設定 45
圖37 系統點位設定－點位資訊 46
圖38 系統點位設定－編輯條件1 47
圖39 系統點位設定－編輯條件2 47
圖40選取點位 48
圖41選取移動單位 48
圖42點位移動 49
圖43 選取移動單位為0 49
圖44 選取欲排序之點位 50
圖45 點位變更排序後 50
圖46 系統點位設定－馬達控制 51
圖47 系統點位設定－馬達控制2 51
圖48 系統點位設定－Z軸控制 52
圖49 系統點位設定－Z軸控制2 52
圖50 系統點位設定－產品新增 53
圖51 系統點位設定－產品匯入 54
圖52 系統機台設定 55
圖53 系統點位狀態 56
圖54 系統焊接紀錄 57
圖 55人員介入生產時間 59
圖 56自動化與人力產量 60
圖 57焊接結果 61

表目錄
表 1數位輸入輸出模組-輸入部分 17
表 2數位輸入輸出模組-輸出部分 18
表 3點焊機訊息格式 20
表 4 字串拆解步驟1 21
表 5字串拆解步驟2 21
表 6字串拆解步驟3 22
表 7訊息結果 22
表 8 頁面操作權限 39
表 9人員生產時間(單位:分鐘) 58
表 10人員與自動化產量數據(單位: 次) 59
表 11電流峰值數據 61

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