臺灣博碩士論文加值系統

現今各個產業愈來愈趨向多軸加工和工業 4.0等，許多企業對於工具機的加工彈性、加工速度與加工精度需求也是愈來愈高，而工具機的許多部份由不同廠商而提供的，各組件的配合精度、主結構與各組件的剛性以及動態性能，都會影響多軸工具機的加工精度，在各組件的結構設計上就極為重要。
本研究選擇滾子凸輪旋轉工作台，利用有限元素法依機台環境限制來進行分析，項目有靜態、模態、暫態、頻譜、拓樸最佳化分析，靜態分析可得知機台結構較差的位置。模態分析可了解使機台結構受到影響的自然頻率，顯示其模態特徵，可在加工過程中避免自然頻率，提升加工精度。最後利用加速規與衝擊槌對機台進行模態敲擊試驗，利用ME’scope曲線擬合找出其振型與自然頻率，與分析結果比對，驗證分析的準確性，比對結果為8.5%、8.3%、1.4%。對機台鑄件進行拓樸最佳化設計分析，與原設計分析比對，達成減少重量、提升自然頻率等。
重複精度與分割精度等精度測試在旋轉工作台是非常重要的，透過此項測試，可以得知旋轉工作台在每個角度的誤差，確認其準確性，可以避免被加工件的位置不準確、提高可靠性以及品質。
本研究透過智慧預診機上盒(PDPS)擷取旋轉工作台的振動訊號，使用演算法分析，透過正常的振動訊號建立健康模型，隨時監控其健康狀態，並透過主成分分析法分析其故障特徵，進而診斷機械故障的問題，可提前預測旋轉工作台的異常，降低發生損壞導致機台停機的時間以及維修成本，提升機台的工作效率。

Nowadays, various industries are aiming towards multi-axis processing and Industry 4.0. Many companies have higher requirements for machine tools' processing flexibility, speed, and accuracy. Structural design is extremely important to meet the requirements of today's processing industry. Many parts of machine tools are provided by different manufacturers. The matching accuracy, rigidity, dynamic performance, and topology optimization design and analysis of each component and the main structure will affect the machining accuracy of the multi-axis machine tool.
This study selects a roller cam rotary worktable and utilizes the finite element method to conduct analysis based on the constraints of the machine environment. The projects include static, modal, transient, spectrum, and topology optimization analyses. According to the static analysis results, the position of the poor structure of the rotary table can be known. Through modal analysis, it is possible to understand the range of natural frequencies that are likely to affect the structure of the rotary table and to display the modal characteristics of each order of frequency, which can avoid natural frequencies during processing and improve processing accuracy. Finally, the accelerometer sensor is used to collect the vibration mode data, and the collected data results are compared with the mode shape and frequency by the mode analysis. Accelerometers and impact hammers are used to conduct modal percussion tests on the rotary table, and ME'scope curve fitting software to find out the mode shape and natural frequency. The analysis results are compared, and verifies the modal analysis.The accuracy of the analysis results and the comparison results between the experiment are 8.5%, 8.3%, and 1.4%. The topology optimization design and analysis of the large part of the casting of the machine were carried out. Finally, it was compared with the original design analysis to achieve weight reduction, and increase natural frequency.
Repeatability and segmentation accuracy tests are very important on a five-axis rotary table. Through this test, you can know the error of the rotary table at each angle, confirm the accuracy of the rotary table, and avoid workpieces being machined. The inaccurate position of the rotary table improves its reliability and quality of the rotary table.
The vibration signal of the rotary table is captured by Prediction Diagnosis Performance System (PDPS) and analyzed using an algorithm. The health model is established through the normal vibration signal, and the health status of the rotary table is monitored at any time. Through principal component analysis, analyzing the fault characteristics of the rotary table and then diagnosing the problem of mechanical failure can predict the abnormality of the rotary table in advance, reduce the time of machine downtime and maintenance costs caused by damage, and improve the working efficiency of the machine.

摘要...............................................i
Abstract...........................................ii
誌謝...............................................iv
目錄...............................................v
表目錄.............................................viii
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......................11
2.2 模態與振動基礎理論.........................13
2.2.1. 單自由度系統..............................13
2.2.2. 模態測試簡介..............................15
2.2.3. 模態分析重要名詞...........................16
2.3 主成分分析法..............................17
2.4 實驗設備..................................19
2.4.1 滾子凸輪旋轉工作台.........................19
2.4.2 有限元素分析軟體Ansys......................21
2.4.3 衝擊錘....................................21
2.4.4 頻譜分析儀.................................23
2.4.5 三軸加速規.................................24
2.4.6 模態分析軟體ME’scope.......................26
2.4.7 智慧預測與診斷系統(PDPS)....................26
2.4.8 單軸向加速規...............................28
2.4.9 四通道擷取卡...............................28
2.4.10 Renishaw XL-80............................30
2.4.11 Renishaw XR20-W...........................31
第三章 滾子凸輪旋轉工作台結構有限元素分析.............32
3.1有限元素分析.....................................32
3.1.1建立有限元素模型...............................32
3.1.2材料性質......................................33
3.2網格設置........................................34
3.2.1網格收斂性....................................34
3.2.2網格結果......................................35
3.3模型邊界條件設定.................................36
3.4.靜、動態特性分析................................37
3.4.1.靜態分析.....................................37
3.4.2.模態分析.....................................41
3.4.3.頻譜分析(Harmonic)...........................43
3.5.結構最佳化設計.................................45
3.5.1分析結果.....................................45
3.5.2 整機最佳化結果.............................47
第四章 實驗與驗證..................................50
4.1 敲擊點位規劃...............................50
4.2 Novian參數設定............................51
4.3 結構自然頻率分析...........................52
4.4 模態分析與實驗驗證.........................55
4.5 重複精度與定位精度規範.....................56
4.5.1 國際標準 ISO230-2.........................57
4.5.2 德國標準 VDI 3441.........................57
4.6 精度實驗前置...............................58
4.6.1 設備架設...................................58
4.7 實驗規劃...................................59
4.8 實驗結果...................................59
第五章 智慧預測診斷................................65
5.1 主成分分析法..............................66
5.2 實驗設備介紹..............................67
5.3 轉速實驗規劃..............................67
5.4 振動訊號擷取..............................68
5.5 訊號處理..................................69
5.6 特徵萃取..................................69
5.7 主成分分析法(PCA).........................70
第六章 結論與未來展望..............................75
6.1 結論......................................75
6.2 未來展望..................................76
1 參考文獻........................................77
Extend Abstract...................................79
Abstract..........................................79
1. Introduction..............................80
2. Finite Element Analysis and Experiment....80
3. Structural optimization...................82
4. Prediction diagnosis performance system...83
5. Conclusions...............................84
Reference.........................................84

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