臺灣博碩士論文加值系統

為了在小而多樣化的市場中保持工藝穩定性和提高生產良率，數字化設備和通過物聯網智能管理工具是必要的。儘管許多傳統製造工廠已經使用物聯網技術，但由於缺乏系統化的工具，無法管控每個切削刀具的追踪流程和狀態，這很容易導致機器停機，甚至因刀具相關問題而損壞機器主軸。因此，本研究中的刀具管理系統(Tool Management System, TMS)是基於瀏覽器/服務器網頁架構設計的，旨在使用非關聯式數據庫來儲存具有非固定結構的刀具數據。TMS整合成兩種管理模式：刀具管理和工程開發，刀具管理的功能主要是通過特定的代碼查詢數據庫，保存刀具的使用記錄，使得加工人員、採購人員、倉儲人員和管理者能夠在每個階段獲得有關每個工具的有用信息，例如刀具的剩餘使用壽命、刀具庫存量以及刀具線上或離線的存放位置等。本文以FANUC CNC控制器為實例，定義宏程序及編寫PMC ladder等方法解析刀具在機台的在線時間、累積加工時間以及出線時間，且能通過Focas2與控制器進行連接取得切削參數，將其輸入至多項式網路即可計算出刀具剩餘使用壽命，避免在刀具壽命終止前更換，造成成本浪費。除了記錄刀具的使用情況，當工具的庫存水平低於安全水平時，會立即通知採購員向工具供應商下訂單，以縮短準備工具的時間。另一方面，工程開發的功能是為CAD/CAM製造人員設計的，可以通過TMS查詢刀具庫存，隨時可以獲得合適的匹配部件，而圖檔交換格式文件用於組裝工具組件時能在CAM軟體中生成3D模型以進行模擬測試，減少作業時間，生產人員就能根據模擬得到的刀具清單進行刀具準備；測量部門的工作人員也能同步測量和更新TMS的刀具補償數據。因此，操作員可以快速地將刀具放入刀庫或刀塔上的相應編號，並通過TCP/IP更新CNC控制器的正確補償值。

To maintain process stability and yield improvement in a small and diverse market, digitization equipment and managing tools intelligently through the IoT are necessary. Although many traditional manufacturing factories have used IoT technologies, they cannot control the tracking flow and condition of each cutting tool owing to a lack of systematic tools. This easily causes machine downtime or even damage to the machine spindle due to tool-related problems. Therefore, the tool management system (TMS) in this study is designed based on a browser/server web architecture and is designed to use a non-relational database for storing tool data with a non-fixed structure. The TMS is proposed to integrate two management modes: tool management and engineering development. The functions of tool management are mainly about querying the database through specific codes and keeping the usage records of tools. It enables processing staff, purchasing staff, warehousing staff, and administrators to have useful information on each tool at each stage, such as remaining useful life (RUL), the amount of tool inventory, the storage location of the online or offline tools, and so on. This thesis takes the FANUC CNC controller as an example, analyzing the online time, cumulative machining time, and offline time of the tools on the machine by defining the macro program and writing PMC ladder. Moreover, the user can input cutting parameters from controller through Focas2 to calculate the RUL through a polynomial network, so as to avoid replacement before termination of the tool life, which will cause cost waste. In addition to recording the usage of the cutting tools, when the inventory level of the tools is lower than the safety level, the purchaser is immediately notified to place an order with the tool supplier for shortening the tool preparation time. On the other hand, the functions of the engineering development are designed for CAD/CAM manufacturing staff to query the tool inventory through the TMS to obtain suitable matching components in real-time. The drawing exchange format (DXF) files are used to assemble tool components and generate 3D models in CAM software for simulation tests. Then, the production staff prepares the tools according to the tool list from the simulation. The staff of the measurement department also measures and updates the tool compensation data of the TMS. Thus, the operator quickly places the tool into the corresponding number on the tool magazine or turret and update the correct compensation value of the CNC controller via TCP/IP.

摘要....................................................i
Abstract...............................................ii
誌謝...................................................iii
目錄...................................................iv
表目錄..................................................vi
圖目錄..................................................vii
第一章 緒論..............................................1
1.1 研究動機與目的...................................1
1.2 文獻回顧.........................................1
1.2.1 刀具管理系統研究..................................1
1.2.2 資料庫應用........................................1
1.2.3 2D視圖轉換3D零件檔................................2
1.3 研究流程..........................................2
1.4 論文架構..........................................3
第二章 刀具管理系統框架....................................5
2.1 Web應用框架.......................................5
2.2.1 關注點分離(Separation of concerns)................6
2.2.2 MVC架構簡介.......................................6
2.2.3 Django的MTV架構簡介...............................6
2.2 NoSQL資料庫系統概述................................8
2.2.1 大數據與雲端計算...................................8
2.2.2 分片集群(Sharded Cluster).........................9
2.2.3 數據分片.........................................11
2.2.4 MongoDB副本集(Replica Set).......................14
第三章 智慧化預估系統整合..................................19
3.1 工件材料的機械性質與刀具幾何的關係..................19
3.2 刀具壽命預測系統..................................21
3.3 預測系統整合.....................................22
第四章 刀具管理系統功能...................................24
4.1 刀具管理系統介面集成..............................24
4.1.1 ERP數據整合......................................24
4.1.2 NX CAM整合.......................................24
4.1.3 ZOLLER系統整合...................................24
4.2 刀具基本數據建立..................................24
4.2.1 刀具登錄.........................................25
4.2.2 切削參數管理.....................................27
4.2.3 編碼系統.........................................27
4.3 庫存管理.........................................29
4.3.1 刀具借出/歸還....................................30
4.3.2 刀具組合/拆卸....................................30
4.3.3 庫存預警/盤點....................................33
4.3.4 儲位管理.........................................34
4.4 生產管理.........................................36
4.4.1 DXF切削刀具模型生成...............................37
4.4.2 整合Zoller刀具量測儀..............................40
4.4.3 FANUC控制系統整合.................................42
4.5 統計分析.........................................48
4.5.1 刀具使用率分析....................................48
4.5.2 刀具成本分析......................................49
4.5.3 刀具故障率分析....................................49
4.5.4 刀具壽命統計......................................50
4.6 系統維護.........................................51
4.6.1 數據備份.........................................51
4.6.2 安全管理.........................................52
4.6.3 性能優化.........................................54
4.6.4 系統更新.........................................55
第五章 系統操作實例與驗證..................................56
5.1 刀具資訊管理......................................56
5.2 生產任務管理與CAM編程.............................62
5.3 性能測試.........................................63
5.3.1 查詢數據測試.....................................64
5.3.2 新增數據測試.....................................65
5.3.3 更新數據測試.....................................66
5.3.4 刪除數據測試.....................................68
第六章 結論與未來展望....................................70
6.1 結論............................................70
6.2 未來展望........................................70
參考文獻 ...............................................71
Extended Abstract......................................76
1. Introduction...................................77
2. Research Methodology...........................77
3. Experimental results and verification..........79
4. Conclusions....................................81

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