臺灣博碩士論文加值系統

近年來工具機產業迅速發展的時代，國內工具機大多為中小型加工機，主要以加工汽機車零件、家電零件以及五金等一些小零件為主，為了避開產品價格低廉的競爭，因此本研究選擇了大型車銑複合機作為本次研究的機種以加工離岸大型風扇的大型零組件為主。為了提高加工時整機的穩定性及加工件的加工精度，因此需要提前預測工具機的結構強度。本研究的目的是分析大型車銑複合工具機結構之靜態、動態特性及健康診斷。首先是利用ANSYS軟體，依照現場工作環境的限制及材料性質來對工具機進行模態分析、暫態分析、頻譜分析與空間精度分析，根據靜態分析結果可以找出空間中不同加工位置的變形誤差，在針對這些誤差給與適量的補償值，以提高加工件的加工精度。透過模態可以了解機台主結構在一易受影響的頻率範圍內各階主要模態的特徵參數，並配合模態分析軟體ME‘scope進行模態振形的曲線擬合來驗證機台的頻率，分析結果前三階模態誤差百分比分別為0.2%、4.5%、1.4%，驗證了虛擬模型與實際機台的正確性，以幫助加工者在加工過程中避免主軸轉速落在自然頻率上，減少顫振發生。
此外，本研究也運用了智慧預測診斷系統(PDPS)監測主軸的振動訊號，來評鑑主軸的健康狀態。然而每台設備的使用與維護多少有所差異，當主軸有異常徵兆時，會在某些特定的頻帶或振動特徵上才觀察得到，雖然異常的訊號資料不容易收集，但透過正常振動資料的頻譜特徵建模，可以對機台建立健康診斷模型，並藉由主成份分析法觀看振動訊號特徵來辨別機台的健康情況。

In the era of rapid development of the machine tool industry during recent years, the majority of domestic machine tools are small and medium-sized processing machines, which are mainly processing some small parts such as auto parts, home appliance parts, and hardware. The model of this research was a large-scale turning-milling compound machine in order to avoid competition from low-priced products. The machined parts in this study are primarily, large-scale components of offshore large fans. To improve the stability of the whole machine and the machining accuracy of the workpiece during the process, it is necessary to predict the structural strength of the machine tool in advance. This research aims to analyze the static and dynamic characteristics and health diagnosis of the large-scale turning-milling machine tool structure. In the first step, ANSYS software is used to perform modal analysis, transient analysis, spectrum analysis, and spatial accuracy analysis of the machine tool based on the working environment on-site and the material properties. According to the static analysis results, the deformation errors of different processing positions in the space can be found and an appropriate amount of compensation value for these errors to improve the surface accuracy of the workpiece can be given. Through the modal analysis, you can determine the characteristic parameters of the main machine structure in a susceptible frequency range, and use the modal analysis software-ME ’scope to do the curve fitting of the modal shape to verify the machine frequency. The three modal error percentages of the analysis results are 0.2%, 4.5%, and 1.4%, respectively, which authenticates the virtual model and the actual machine, to help the machining process avoid the spindle speed falling on the natural frequency and reduce the chatter.
In addition, this study also used the prediction diagnosis performance system (PDPS) to monitor the vibration signal of the spindle to evaluate the health status. However, the use and maintenance of each piece of equipment are a bit different. When the spindle has abnormal symptoms, it will be observed in some specific frequency bands or vibration characteristics. Although the abnormal signal data is not easy to collect, through the normal vibration data, spectral feature modeling can establish a health diagnosis model for the machine, and use the principal component analysis method to observe the vibration signal characteristics to identify the health of the machine.

摘要 ...i
Abstract ...ii
誌謝 ..iv
目錄 ...v
表目錄 ...vii
圖目錄 ...ix
符號說明 ...xii
第一章 緒論 ...1
1.1 研究背景 ...1
1.2 研究目的 ...1
1.3 文獻回顧 ...2
1.4 論文大綱 ...5
第二章 基礎理論與實驗設備及工具 ...7
2.1 有限元素法原理 ...7
2.1.1. 有限元素法重要名詞 ...8
2.1.2. 有限元素類型 ...9
2.1.3. 有限元素法之平衡方程式 ...10
2.2. 模態與振動基礎理論 ...12
2.2.1. 單自由度系統 ...12
2.2.2. 模態測試簡介 ...13
2.2.3. 模態分析重要名詞 ...14
2.3. 剛性理論 ...15
2.4. 反作用力理論 ...18
2.5. 空間精度理論 ...19
2.5.1 齊次座標 ...19
2.6. 主成份分析法 ...21
2.7. 實驗設備 ...23
2.7.1. 大型車銑複合工具機LLS-G915 ...23
2.7.2. 有限元素分析軟體ANSYS ...26
2.7.3. 衝擊錘 ...26
2.7.4. 頻譜分析儀 ...28
2.7.5. 三軸加速規 ...29
2.7.6. 模態分析軟體ME’scope ...31
2.7.7. 智慧預測與診斷系統(PDPS) ...31
2.7.8. 單軸加速規 ...33
第三章 有限元素分析 ...34
3.1 有限元素分析 ...34
3.1.1. 建立有限元素模型 ...34
3.1.2. 材料性質 ...35
3.2. 網格設置 ...36
3.2.1. 網格收斂性 ...36
3.3. 模型邊界條件設定 ...37
3.4. 靜、動態特性分析 ...39
3.4.1. 靜剛性分析 ...39
3.4.2. 模態分析 ...41
3.4.3. 頻譜分析(Harmonic) ...42
3.4.4. 暫態分析 ...44
3.5. 空間精度分析 ...45
3.5.1. 空間位置之靜剛性分析 ...46
3.5.2. 空間位置之動態特性分析 ...76
3.6. 反作用力分析 ...80
第四章 模態敲擊試驗與驗證 ...88
4.1. 敲擊點位規劃 ...88
4.2. Novian參數設定 ...90
4.3. 結構自然頻率分析 ...92
4.4. 模態分析與實驗驗證 ...94
第五章 智慧預測診斷 ...96
5.1. 主成份分析法 ...96
5.2. 實驗設備介紹 ...97
5.3. 主軸轉速實驗規劃 ...98
5.4. 振動訊號擷取 ...100
5.5. 訊號處理 ...101
5.6. 特徵萃取 ...101
5.7. 主成份分析法(PCA) ...102
第六章 結論與未來展望 ...107
6.1. 結論 ...107
6.2. 未來展望 ...108
參考文獻 ...109
Extended Abstract ...112
Abstract ...112
1. Introduction ...113
2. Finite Element Analysis and Experiment ...113
3. Spatial precision ...114
4. Prediction diagnosis performance system ...115
5. Conclusions ...116
Reference ...116

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