臺灣博碩士論文加值系統

現今汽車已朝向電動化及智能化控制發展，車室內相關電子資訊設備應用大幅增加，需要考量整體性散熱性能。本研究主要探討車用散熱風扇的產品設計與模具開發，以TS16949品質管理系統為基礎，透由新產品開發程序的產品設計、模具設計、製程改善、到試量產階段等，期望建立一套車用散熱風扇開發的最佳化流程及驗證。
主要採取的研究方法，利用DOE實驗設計的田口品質法、及模流分析的FEM 有限元素法，探討如何進行最佳化設計、以及可能的製程公差變異數分析，包括：車用散熱風扇產品的重量減量、模具射出品質、與射出成型時間等，三大品質面向進行改善，預期找出模具射出成型最佳化的成型參數。本研究除了以實際開模進行射出成型，驗證與模流分析的差異之外；將再進一步藉由ANN 類神經網路模擬方法，預測出重量、品質、與時間的最佳化成型參數及結果。
本研究貢獻度在於：透由實際開模射出成型，配合田口實驗設計，射出成型參數製程的改善前後比較結果，解決傳統老師傅經驗傳承問題。並透由ANN 類神經網路的快速預估系統，大幅減低射出成型材料浪費、減化射出成型週期、並提升車用散熱風扇的產品品質，達到模具製程智慧化目標，協助模具產業提升整體競爭力。

Nowadays, automobiles have developed towards electrification and intelligent control. While the application of related electronic information equipment in the automobile interior has increased significantly, it is necessary to consider the overall heat dissipation performance. The product design and mold development are discussed in this research and founded on ISO/TS 16949 quality management system. Through the new product development methods of product design, mold development, process improvement, and pilot run to build the optimization process and validation about automotive cooling fan development.
The research methods for this research are the Taguchi method of DOE and the mold flow of FEM to discuss the manufacture optimization process and ANOVA of product tolerance. The issue includes the reduced weight of the automotive cooling fan, product quality of mold injection, and the manufacture cycle time. Expected to find out the optimal mold injection parameters through improved three quality faces. This research not only verifies the difference between reality and mold flow results through the actual development of the mold for injection molding but also predicts optimal injection parameters and results for weight, quality, and time by ANN methods.
This research aims to solve the problem of traditional master's experience inheritance through the actual development of the mold with optimal injection parameters by the Taguchi method. Through the quick estimation system by ANN to reduce weight and manufacture cycle time of the automotive cooling fan and improve the product quality. Final achieve goals of injection manufacturing process intelligence to assist the mold industry in enhancing the overall competitiveness.

謝誌 iii
目錄 iv
圖目錄 vii
表目錄 ix
第一章、緒論 1
研究背景 1
研究動機與目的 2
第二章、文獻探討 3
2.1 車用散熱風扇品質系統要求 3
2.1.1 ISO/TS 16949品質管理系統 3
2.1.2 TS16949五大核心應用工具 4
2.1.3 TS16949新產品開發流程 5
2.2 塑膠模具設計製造 7
2.2.1塑膠產品射出原理 7
2.2.2 DFMA設計方法 8
2.2.3 CAE模流分析 9
2.3穩健設計與製造最優化 10
2.3.1 六標準差 (Six Sigma) 10
2.3.2 QFD品質機能展開 11
2.3.3 田口品質工程分析方法 (Taguchi Method) 12
2.3.3.1 田口方法實驗步驟 12
2.3.3.2 田口直交表設計 12
2.3.3.3 田口品質特性與訊號雜音比 (S/N Ratio) 13
2.3.3 ANN類神經網路 14
第三章、研究方法 15
3.1 研究方法與架構 15
3.2 預期成果 17
第四章、車用散熱風扇設計分析 18
4.1 以QFD方法做為車用散熱風扇的設計輸入 18
4.2 車用散熱風扇設計參數與流程 21
4.2.1車用散熱風扇設計參數 23
4.2.2車用散熱風扇扇葉之立體模型建構流程 24
4.3 車用散熱風扇模具設計流程與要點 25
4.3.1 模具標準化 25
4.3.2 車用散熱風扇模具設計方法 25
4.3.3 車用散熱風扇模具設計結果 30
4.4 以Moldflow模擬分析車用散熱風扇初步結果 32
4.4.1 產品充填分析 32
4.4.2 射出壓力分析 33
4.4.3 壓力損失分析 33
4.4.4 結合線及強度評估 34
4.4.5 翹曲分析 34
4.4.6 以Moldflow模擬分析驗證結果 35
4.5 以實驗設計方法優化車用散熱風扇分析結果 36
4.5.1 因子與水準選定 36
4.5.2 田口方法直交表配置 37
4.5.3 田口方法實驗結果與分析 39
4.5.4 田口方法最佳化結果 42
4.5.4.1 重量最佳化結果 42
4.5.4.2 時間最佳化結果 44
4.5.4.3 品質最佳化結果 47
第五章、以模具驗證車用散熱風扇設計與分析 49
5.1 車用散熱風扇成型材料選用 49
5.2 塑膠成型射出機選用 51
5.3 車用散熱風扇模具加工製造 55
5.3.1車用散熱風扇模仁加工 56
5.3.2車用散熱風扇三版式模座 58
5.4 實際產品與實驗結果驗證 59
5.4.1 車用散熱風扇產品第一次試模 59
5.4.2 車用散熱風扇產品正式試模 63
5.4.3 最佳化射出驗證 65
5.5 應用ANN人工神經網路預測品質 68
5.5.1 ANN人工神經網路 輸入層 (Input layer) 68
5.5.2 ANN人工神經網路 隱藏層 (Hidden layer) 69
5.5.3 ANN人工神經網路 輸出層 (Output layer) 70
5.5.4 ANN人工神經網路結果 71
第六章、結果與建議 74
6.1 結論 74
6.2 後續建議 77
參考文獻 78

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