臺灣博碩士論文加值系統

工業上常見的溶劑式噴塗作業，過程中包含化學溶劑的揮發，容易造成人體與環境的傷害。近年來許多國家開始注重環境保護，因而訂定相關的法規限制這一類製程溶劑的排放。擁有幾乎無化學揮發性質的「靜電粉體噴塗技術」於是漸漸取代舊式噴塗作業，成為產業未來之發展方向。靜電粉體噴塗乃利用靜電效應使粉狀塗料吸附於工件表面，之後再作高溫烘烤使塗料融解包覆工件。其特質在於未吸附之粉體若未遭受污染，將可回收重新使用，達到經濟又無化劑汙染之目標。唯目前業者仍多採手動噴塗，依靠經驗或直覺方式來執行。業者認為使用手工可以適應多樣化的工件造型，成本也較為低廉。但畢竟人工施作之品質不易掌握，效能也不穩定。於是本研究建議使用兩支五個自由度(5 Degree-of- freedom, 5-DOF)機器手臂來做噴塗，即可涵蓋工件之每個角落。研究將採工業仿真方式運用虛擬實境技術，透過虛擬機構互動演算噴塗均勻度、粉體浪費量、及路徑長度以測試噴塗效能，並規劃出可採用機器手臂施作之實境工作路徑。

Painting with chemical solution is notorious for its pollution nature. More are in favor of electrostatic powder painting technique for it hardly emits any harmful ingredient into the atmosphere. Based on current acknowledgement of the environment status, strict laws and treaty have been signed world wide to avoid more chemical pollution. The electrostatic powder painting technique takes two steps to accomplish a process, a static powder adhering process and a curing process. The curing is a heat treating process that is somewhat easier to manipulate for a homogenous outcome, while the adhering process is more sophisticated than just covering up a product with powders. Wastes may happen when careless operations are applied. In fact, the quality and efficient of the whole process may solely rely on a well defined paint path.
More industry managers select manual operations to carry out the painting process for they believe the human hands are dexterous enough to adapt the versatile part shapes and are less expensive to hire. That assumption contradicts the results that the process inefficiencies are all from the malpractices of the paint paths. Therefore, this research propose well planned path with 5-DOF robots. In the dual, paths are generated based on part geometry and certain electrostatic behaviors, and then the robot may adapt a path by its joint parameters. Surface coverage, total waste, and path length are the criteria for adjusting the path generating plan. Then the iterative planning processes are performed in a virtual environment that emulates the real facilities. The results showed that the virtual facilities is effective, thus the product quality and production efficiency of an electrostatic painting process can be digitally controlled.

目錄
第一章 緒論 1
1.1 研究背景 1
1.2 研究動機 2
1.3 研究目標 3
1.4 研究限制 3
1.5 論文架構 4
第二章 文獻探討 5
2.1 靜電粉體噴塗相關資訊 5
2.1.1 靜電噴塗之原理 6
2.1.2 靜電噴塗之參數 7
2.2 機器手臂相關資訊 8
2.3 路徑規劃 (Path planning) 9
2.4 幾何特徵 10
2.5 虛擬實境 11
2.5.1 虛擬實境之要素 11
2.6 文獻總結 14
第三章 研究方法 16
3.1 研究流程 17
3.2 前處理作業 19
3.2.1 噴塗角度 19
3.2.2 子面域切割 23
3.3 累積粉體機制 25
3.3.1 噴塗含蓋檢驗 26
3.3.2 噴塗方向 28
3.3.3 子面域結構 31
3.3.4 粉量計算 32
3.3.5 噴塗效能 34
3.4 路徑規劃 35
3.5 機器手臂 38
第四章 實作範例 39
4.1 範例實作說明 39
4.2 虛擬環境之設計 40
4.2.1 噴塗室之環境設計 40
4.3 範例工件 41
4.3.1 面域切割 41
4.3.3 路徑規劃 43
4.3.4 間接粉量影響 49
4.3.5 修改路徑演算法 51
4.3.6 路徑規劃條件式修改 54
4.4 機器手臂 60
第五章 結論與建議 61
5.1 結論 61
5.2 論文貢獻 61
5.3 未來研究 62
參考文獻 63

表目錄
表2.1 靜電噴漆之相關研究 15
表4.1 路徑效能評估 48
表4.2 粉體均勻度 48
表4.3 間接噴塗之路徑效能評估 51
表4.4 間接噴塗之粉體均勻度 51
表4.5 修正路徑效能評估 53
表4.6 修正粉體均勻度 54
表4.7 修正條件式效能評估 56
表4.8 修正條件式粉體均勻度 56
表4.9 水平橫掃效能評估 58
表4.10 水平橫掃粉體均勻度 58
表4.12 路徑之均勻度比較 59
表4.11 路徑之粉體浪費量比較 59

圖目錄
圖2.1 粉體顆粒之霧化[Meng et al ., 2009] 6
圖2.2 各區域沉積之粉體體積量[Meng et al ., 2009] 7
圖2.3 噴塗角度之塗層厚度[Gadow et al ., 2010] 8
圖2.4 虛擬實境的3I’s要素 [Burdea and Coiffet, 1994] 12
圖3.1 研究流程 17
圖3.2 各角度噴塗之示意圖 20
圖3.3 垂直噴塗 (噴塗時間 t = 2秒) 21
圖3.4 傾斜10度噴塗 (噴塗時間 t = 2秒) 22
圖3.5 傾斜20度噴塗 (噴塗時間 t = 2秒) 22
圖3.6 工件範例 24
圖3.7 工件範例平面展開之子面域 25
圖3.8 噴塗含蓋子面域 26
圖3.9 噴塗距離 27
圖3.10 噴塗面向示意圖 29
圖3.11 子面域結構 32
圖3.12 粉體累積量 33
圖3.14 路徑規劃之示意圖 37
圖4.1 虛擬環境之設計 40
圖4.2 模型範例示範工件 41
圖4.3 工件表面之面域切割 42
圖4.4 水平橫掃方式 43
圖4.5 路徑規劃流程圖 44
圖4.6 路徑規劃之樹狀圖 45
圖4.7 路徑規劃之示意圖 46
圖4.8 子面域粉體之附著水準 47
圖4.9 間接噴塗路徑規劃之示意圖 49
圖4.10 子面域粉體之附著水準 50
圖4.11 修正路徑規劃之示意圖 52
圖4.10 子面域之粉體附著水準(修正路徑) 53
圖4.12 修正條件之路徑規劃 55
圖4.13 子面域之粉體附著水準(修正條件式) 55
圖4.14 水平橫掃之路徑(路徑5) 57
圖4.15 子面域之粉體附著水準(水平橫掃) 57
圖4.16 機器手臂之關節限制 60

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