臺灣博碩士論文加值系統

大型龍門五軸工具機的特點包括剛性強、效率高、可加工大型且曲面複雜之工件。然而隨著工業4.0的發展，大型龍門五軸工具機需要具備更高的彈性、更高的精度和智慧化的功能，以滿足現代製造的需求，以應對不斷變化的加工要求和不斷升級的製造需求。
本研究透過有限元素法對大型龍門五軸工具機進行結構分析，包括靜態、模態、頻譜、暫態分析、空間精度分析、拓樸最佳化，以瞭解整機的結構特性。首先依據靜態分析結果，可得知機台移動到不同的工作範圍時而有不同的結構變形誤差。
透過模態實驗驗證模態分析結果的正確性，實驗與分析結果的誤差在9.3%、6.6%、11%、2.5%，皆在可接受範圍內，也確認邊界條件設定無誤，增加分析的可信度。從分析結果中，我們可以得知機器的結構弱點和共振頻率，進而在加工過程中避開上述頻率，有助於提升加工精度和加工件價值。
本研究之大型龍門五軸工具機，因其主要部件皆為FC300灰鑄鐵，雖然剛性強、耐振性佳等特點，但在設計時通常都是採用以往的設計經驗法則，所以有不少改進改良與改善的空間，透過Ansys workbench拓樸分析對本研究機台其中的部件結構做拓樸最佳化設計，後再與原始設計進行比對，達成此目標的指標:降低重量、提升剛性以及自然頻率等。
五軸同動精度測試(R-TEST)對於工具機的重要性不可忽視。透過這項測試，可以確保工具機各軸之間的協調性和準確性，從而確保加工件的精度和一致性。這對於避免加工誤差、提高產品品質和可靠性至關重要。此外，五軸同動精度測試還可以幫助優化加工效率，提高加工效率和生產力。五軸同動精度測試是保證工具機加工精度和品質的關鍵步驟，對於提升工具機性能和產品的加工品質具有重要意義。
除了常規的維護作業外，本研究還使用了智慧預測診斷系統(PDPS)來監測主軸的振動訊號，以評估主軸的健康狀態。由於每台設備的使用和維護習慣各異，主軸異常徵兆可能只在特定頻帶或振動特徵上才能觀察到，因此異常的訊號資料不易收集。然而，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。使用主成分分析法觀察振動訊號特徵，可以協助辨別機台的健康狀況。這種方法可以提前預測主軸的問題，減少機台停機時間和維修成本，同時提高機台的效率和生產力。

The characteristics of a large gantry type 5-axis CNC machine tool include strong rigidity, high efficiency, large machining and components including complex precision surface. However, with the introduction of industry 4.0, machine tools are required to be equipped with greater flexibility, higher precision and more intelligent functions in order to satisfy the demands of modern production, and rapidly adapt to the changing, upgrading, processing and production demands.
By using finite element method, the study analyzes the characteristics of the structure of a large gantry type 5-axis CNC machine tool, including its static, modal, spectrum, transient state analysis, spatial precision analysis, and topology optimization. Firstly, according to the static analysis results, we realize that machine tools generate different component deviations when moved between different working spaces. However, the results obtained from experimental modal analysis demonstrate that the margins of error, 9.3%, 6.6%, 11%, and 2.5%, are within the acceptable tolerance level. Thus validating that the boundary conditions were appropriately set-up. Which further solidifies the credibility of this study. The analytical findings reveal the weaknesses of a machine's structural and resonance frequency, which can be addressed during the machining process to improve accuracy and value of parts processed.
The large gantry type 5-axis CNC machine tool in this study is mainly made of FC300 gray cast iron. Although it has high rigidity and shock resistance, the machine tool is typically created using past design rules. For improvement, the topology optimization of the component structure of this research machine is carried out using Ansys Workbench topology analysis, and then compared with the original design, the indicators to achieving this goal are: reduced weight, enhanced rigidity and increased natural frequency.
The significance of the five-axis synchronous precision test (R-TEST) for machine tools cannot be overlooked. Through this test, we ensure the coordination and precision between the tooling machine's axes, thereby ensuring the precision and uniformity of the workpiece. This is essential for preventing machining errors and enhancing product quality and reliability. In addition, R-TEST can assist in optimizing machining efficiency and enhancing productivity. The five-axis synchronous precision test is essential for ensuring the machining precision and quality of a tooling machine, and it has a significant impact on the tooling machine's and product's performance.
In addition to the routine maintenance, this research also uses Prediction Diagnosis Performance System (PDPS) to monitor the vibration signals of the spindle and to further evaluate the normal operation of the spindle. Due to the different usage and maintenance behavior of each device, abnormal signals of spindle may be observed only in specific frequency bands or vibration characteristics, making it difficult to collect abnormal signal data.However, by modeling the frequency spectrum characteristics of normal vibration data, a health diagnosis model can be established for the machine. Principal component analysis can be used to observe the characteristics of vibration signals to help identify the health status of the machine. This strategy can help predict axis problems in advance, thus reducing machine downtime and maintenance/repair costs, and simultaneously increase machine efficiency and productivity.

摘要...i
Abstract...iii
誌謝...v
目錄...vi
表目錄...ix
圖目錄...x
符號說明...xiii
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 ...6
第二章 基礎理論與實驗設備及工具...8
2.1 有限元素法原理...8
2.1.1 有限元素法重要名詞...9
2.1.2 有限元素類型...10
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...15
2.3 工具機誤差與空間精度理論...17
2.3.1 機械座標定義...17
2.3.2 齊次座標轉換矩陣...17
2.4 主成分分析法...19
2.5 實驗設備...22
2.5.1 大型五軸龍門工具機 FD-5460+5A...22
2.5.2 有限元素分析軟體Ansys...24
2.5.3 衝擊錘...25
2.5.4 頻譜分析儀...26
2.5.5 三軸加速規...27
2.5.6 模態分析軟體ME’scope...28
2.5.7 IBS非同動位移計...29
2.5.8 智慧預測診斷系統(PDPS)...29
第三章　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...34
3.2 網格設置 ...35
3.2.1 網格收斂性...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靜剛性分析...37
3.4.1 模態分析 ...39
3.4.2 頻譜分析(Harmonic)...40
3.4.3 暫態分析 ...42
3.5 空間精度分析...43
3.5.1 空間位置之靜剛性分析...45
3.5.2 空間位置之動態特性分析...58
3.6結構拓樸最佳化...63
3.6.1 結構設計優化...63
3.6.2 分析條件設定...64
3.6.3 拓樸最佳化分析結果...66
3.6.4 底座設計最佳化結果比較表...69
3.6.5 整機拓樸最佳化結果...71
第四章　實驗測試與驗證...74
4.1 模態實驗...74
4.1.2 敲擊位置規劃...74
4.1.3 敲擊實驗...75
4.2 Novian參數設定...76
4.3 結構自然頻率分析...78
4.4 模態分析與實驗驗證...81
4.5 同動精度量測規範...84
4.6 同動測試前置作業...84
4.7 實驗規劃...86
4.8 實驗結果...87
第五章　智慧預測診斷...91
5.1 主成分分析法簡介...92
5.2 實驗設備介紹...93
5.3 主軸轉速實驗規劃...94
5.4 訊號處理...95
5.5 特徵萃取...96
5.6 主成分分析法(PCA)...97
第六章　結論與未來展望...103
6.1 結論...103
6.2 未來展望...105
參考文獻...106
Extend Abstract...109
Abstract...109
1. Introduction...110
2. Finite Element Analysis and Experiment...110
3. Spatial precision...112
4. Prediction diagnosis performance system...113
5. Conclusions...114
Reference...115

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