臺灣博碩士論文加值系統

在沖壓加工當中，因為不斷的進行往復衝擊運動，沖頭和模具在經過一定使用壽命後會產生磨耗、斷裂、塑性變形等破壞，造成沖壓失效或是製造出不合格產品，現行在產線上針對模具失效與否多為人工檢視，而為了早期發現失效，利用各種感測器（力學、聲波、位移等等）對模具狀態進行分析的研究被提出，基於對這些研究的探討以及對於馬達訊號的分析後，訂定了我們研究發展的方向。研究過程中對多個不同種類的模具—沖剪、引伸、連續模具，使用伺服沖床及機械式沖床進行沖壓，再藉由沖床設備回傳的電氣信號（電壓、電流），匯入矩陣蒐集後轉化成數值曲線圖形，分析曲線特徵判別與上述所提到的失效方式之關聯，並對各模具的特徵圖形分門別類彙整出一套合理、有效的失效圖形判別，研究中，利用機械式沖床的變頻器訊號開發出一套可用於沖床上進行數值蒐集的系統，最後使用LabVIEW配合多種套件設計出數值蒐集、分析的軟體，完成整體研究目標。試驗完成後對數值特徵，與實際試驗成品比對判斷，在單一功能模具或是複合模具沖壓時，總結其數值特徵變化，多呈現在波形圖中高峰值上升或下降，抑或是波形寬度的改變，實際的結果如：沖剪模具在失效發生時，因為剪切力下降、沖程增長，電流數值圖特徵變化，根據失效程度的不同峰值皆有0.5~1安培的增長趨勢，波形寬度也有100~500毫秒的增長，引伸、料條剪斷等沖壓行為則會因為失效的產生，摩擦力下降，導致峰值下降，但在數值細節上，因使用的機台、加工穩定性、試驗用的金屬鈑件特性不同等諸多因素，在結果的呈現上，多數試驗成果有相當的參考價值。而除了本研究設計之失效方式外，仍有許多不同的變數可以加入試驗中，對此提出之研究結論和建議，冀望能成為之後研究的參考。

In the stamping process, due to the continuous reciprocating impact movement, the punch and die will have failure modes such as wear, fracture, and plastic deformation after a certain service life, causing the stamping to be interrupted or the manufactured product is unqualified. The occurrence of failures on the production line is mostly manual inspection. In order to detect failures early, research using various sensors (mechanics, acoustic waves, displacement, etc.) to analyze the mold state are proposed.
During the research process, a number of different types of dies (punching, drawing, progressive) were used for stamping using mechanical press or servo press, and then using the electrical signals (voltage, current) returned by the press equipment to transform the numerical matrix create a numerical curve graph, analyze the relationship between the curve feature judgment and the failure mode mentioned above, and collect a set of reasonable and effective failure graph judgments for the characteristic graphs of each die. In the research, we use inverter for mechanical stamping machines. Developed a set of data collection system that can be applied to the theory of this research on the punch press. And Last, LabVIEW was used to design software including data collection and analysis with various packages to complete the overall research goal.
After the test is completed, the numerical feature are compared with the actual test products. When a single-function die or a composite die is stamped, the numerical value change trend is summarized to be roughly the same. Stamping behaviors such as, shearing, etc. will cause the peak value to drop due to failures. However, in terms of numerical details, the results are presented due to many factors such as the machine used, the processing stability, and the feature of the sheet material used in the test. Most of the experimental results have considerable reference value, but there are still many different variables that can be added to the subsequent experiments. The suggestions made on this are hoped to become a reference for future research.

摘要...........................i
Abstract......................ii
誌謝..........................iv
目錄...........................v
表目錄.......................vii
圖目錄......................viii
第一章 緒論.....................1
1.1 前言...................1
1.2 研究動機與目的..........1
1.3 研究方法與步驟..........2
1.4 文獻回顧 ...............5
1.4.1 失效檢測監控方法........5
1.4.2 三相電機偵測方法........6
1.5 論文總覽...............7
第二章 理論基礎.................8
2.1 沖壓機械...............8
2.2 模具失效理論...........9
2.2.1 模具非正常失效.........9
2.2.2 模具正常失效..........10
2.2.3 模具暫時失效..........11
2.3 電氣數值化............11
2.4 數值分析..............13
2.5 程式基礎及數值傳輸原理..15
第三章 研究方法................16
3.1 模具失效規劃...........16
3.2 沖壓機台與控制軟體......23
3.2.1 機械式沖床.............23
3.2.2 伺服沖床...............26
3.3 失效試驗...............28
3.4 失效分析暨控制系統......32
3.4.1 系統架構...............32
3.4.2 程式設計...............32
第四章 結果與討論...............36
4.1 沖剪模具...............36
4.2 引伸模具...............41
4.3 連續模具...............44
4.4 系統判讀...............46
第五章 結論與建議...............48
5.1 結論...................48
5.2 建議...................49
參考文獻.......................50
附錄...........................52
Extended Abstract.............54

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