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強力刮齒製程之電腦數值模擬;Computer Numerical Simulation of Power Skiving Processing
No full text[[abstract]]強力刮齒為目前最熱門的圓柱形齒輪製造方法，相較於刨齒和滾齒，其具有高效率和高精度等優勢。近年強力刮齒備受業界及學術界重視，但目前國內齒輪製造商尚未掌握此關鍵技術。 本研究著墨於強力刮齒刀具的設計參數與加工參數，探討其對於切削痕跡與接觸點受力的影響。文內使用的強力刮齒刀具齒形是由最小平方法獲得，再由三維座標轉換矩陣模擬其切削運動。在具有雙自由度進給的齒輪加工系統上，使用雙嚙合方程式，具有兩個進給量：刀具轉角與刀具軸向位移。因需取得切削痕跡，本研究僅使用一條嚙合方程式，將刀具軸向位移(Axial Feed)轉換為相對於刀具轉角(Spindle Rotation Angle)的函數。 觀察強力刮齒刀做動建立切削行為，模擬齒面上的切痕分布。分析得應變變因，可從中得到在某刀具設計參數、加工裝配參數下可獲得較高的精度或效率。同時，亦觀察切削某瞬間轉角下嚙合時之接觸點數，偶數表兩側切削力相等；奇數表兩側為不均勻切削力。為獲得較佳的受力，提出了修改刀具設計參數。 期望最佳化上述參數，透過優化的參數，依使用者的需求給予建議。本論文的結果可用於模擬強力刮齒加工齒輪齒面上的切削痕跡與接觸點數受力狀況。
The Power-Skiving? method is widely used to generate the stacked cylindrical involute gear for its low cutting tool clearance between adjacent stack gears. In this study, we explored the influence of cutter geometry and machine setups on the cutting marks on the generated tooth surface and the even-contact condition between cutter and tooth surface. The cutting edge profile of Power-Skiving cutter is derived from work gear geometry by using the conjugate theory and represented as a polynomial function by the Least Squares Fitting Method. The cutting marks on the generated tooth surface is formed by summarizing all the cutting edge locus in the coordinate system of the generated tooth surface during the Power-Skiving cutting motion with specified machine setups. The height of cutting marks can be reduced by changing the feed rate of cutter in the workpiece axial direction. We observed the number of contact points between the cutting edge of cutter and the generated tooth surface in the drive and coast sides with respect to the cutter rotation angle and found that the contact point number is varied with respect to the cutter rotation angle and the number of simultaneous contact points in the drive and coast sides is not always the same. The unbalanced contact point number in the drive and coast sides will induce the unbalanced cutting forces in the forward and reversed sides of the cutting spindle, which will lead to tooth profile error in the generated tooth surface. Therefore, the even-contact condition between cutter and workpiece can be guaranteed by specified the cutter geometry and machine setups in the Power-Skiving process. The results of this thesis can be used to minimize the height of the cutting marks with specified axial feed rate of cutter spindle and the even-contact condition between cutter and workpiece can be guaranteed with specified cutter geometry and machine setups of Power Skiving process
6061-O鋁合金/熱塑性碳纖複材之異質超音波銲接製程研發;
No full text[[abstract]]本研究的目標是進行鋁合金/熱塑性碳纖複材之異質超音波銲接的研發，內容包含超音波刀具設計與製作、鋁合金同質超音波銲接製程開發、鋁合金/碳纖複材之異質超音波銲接製程開發。對於刀具開發，首先依據銲接需求進行超音波刀具設計，銲頭為10×10 mm的菱形咬花平面；接著，透過有限元素分析對超音波刀具進行模態分析及簡諧分析，模擬刀具的共振頻率及振幅；完成刀具製作後，使用雷射位移感測計進行共振頻率量測與驗證。對於鋁合金同質製程開發，首先進行鋁合金6061-O超音波銲接製程研發，利用剪力拉伸試驗與金相顯微分析，了解三個主要製程參數(能量、下壓力及振幅)與銲點品質間的關係。再使用中央複合設計試驗(CCC)進行參數分析與最佳化，其最佳參數組合為能量3113 J、下壓力768 N、振幅100%。對於鋁合金/碳纖複材製程開發，先以前述成果為基礎，分析三個主要參數對銲點品質的影響程度，再運用試片表面處理技術提升銲點品質，其較佳參數組合為能量1400 J、下壓力120 N、振幅100%、鋁合金表面酸洗。
The objective of this study is to develop the dissimilar ultrasonic welding (UW) process for aluminum alloy (Al) and thermoplastic carbon fiber reinforced plastic (TP-CFRP) sheets. The main contents include the design and manufacturing of UW tools, development of Al/Al similar UW process, and development of Al/CFRP dissimilar UW process. For tool development, a UW tool with 10×10 mm diamond-shaped surface texture was designed based on the welding requirements. Next, the modal analysis and harmonic analysis of the UW tool were conducted by the finite element analyses to estimate the harmonic frequency and amplitude of the designed tool. After tool manufacturing, the harmonic frequency and amplitude of the UW tool were obtained and validated by the laser displacement sensor. For Al/Al similar UW process, Al 6061-O sheets were used to understand the relations between three important processing parameters, welding energy, punching force and amplitude, and welding qualities. Then, the parameter analysis and optimization were carried out by the central composite circumscribed (CCC) design tests. The optimal processing parameters were the energy of 3113 J, force of 768 N and amplitude of 100%. For Al/CFRP dissimilar UW process, the previous results were first taken as a reference. The effects of three processing parameters on the welding quality were then studied. Then the welding quality was further improved by surface treatment technology. The good processing parameters were the energy of 1400 J, force of 120 N, amplitude of 100%, and nitric acid surface cleaning
雙光柵生物感測器結合奈米金效應之研究;
No full text[[abstract]]本研究為雙光柵耦合生物感測器結合奈米金之修飾進行靈敏度與生化檢測。晶片製作運用PDMS二次翻印光柵母模後，壓印在鋼板上，利用射出成型大量生產品質均一的光柵晶片，再利用濺鍍的方式製作第二層的二氧化鈦波導層，並透過調整濺鍍的時間與含氧量，在濺鍍參數為含氧量40%、波導層厚度為90nm的條件下製作的晶片，由小範圍折射率(n=1.333到n=1.343)蔗糖溶液檢測未修飾奈米金晶片靈敏度可達-36 RIU^-1。 將雙光柵耦合生物感測器結合奈米金之效應，將晶片修飾奈米金的時間為40min有最好的吸收度0.11(a.u.)，分別將第一光柵與第二光柵修飾上奈米金，並對雙光柵進行糖水實驗，靈敏度分別為-34.19 (RIU^-1)與-35.4 (RIU^-1)，比較後發現修飾奈米金的光柵位置靈敏度差別不大，與沒有修飾的晶片相比靈敏度有些許的降低。 比較有無修飾奈米金之晶片進行Anti-DNP生化檢測，結果發現無修飾奈米金晶片的LOD為2E-7 g/ml，與分別在第一與第二光柵修飾奈米金的晶片相比，第一光柵修飾奈米金的雙光柵晶片LOD為1.3E-7 g/ml，第二光柵修飾奈米金的雙光柵晶片LOD為9.8E-8 g/ml，有修飾奈米金的晶片LOD相較於無修飾奈米金的晶片有些微提高
結構光結合機械手臂重建工件三維模型之研究;Three Dimensional Model Reconstruction Using Structured-light Scanner And Robotic Arm
No full text[[abstract]]有鑒於文獻中常用來計算掃描組態的平整塊演算法(flat patch recursive algorithm)在掃描效率上的低落，本研究將影像分割常用的區域成長(Region Growing)概念，擴展於物體三維網格模型上計算出掃描組態，並且以七種物體模型進行模擬測試，之後整合結構光掃描系統、六軸機械手臂進行實際掃描並和文獻演算法進行比較，模擬及實驗結果顯示：本研究所提出的演算法隨著模型網格數增加，姿態數及耗費時間會漸漸少於文獻演算法，且整體涵蓋率相差不大，可有效縮短掃描時間並防止多視角點雲間定位誤差的累積。
The study integrates structure light system with six-axis manipulatorto examine the algorithm performance in different situation. Generally, based on the CAD model, flat patch recursive algorithm is used to calculate the scanning gestures for robot equipped with a 3D scanner. However, the required number of gestures calculated by flat patch recursive algorithm is significant for CAD model with huge number of meshes. To improve the efficiency of existing scanning gesture searching algorithm, this study expanded the concept of region growing which is commonly used in image segmentation to three-dimensional mesh model to calculate the potential scanning gestures. In this study, seven different objects with CAD models have been used to compare performance between the proposed algorithm and flat patch recursive algorithm. The experimental result shows that although the scanning area is a little bit less than the existing algorithm, the number of scanning gesture of proposed algorithm is significantly reduced and thus prevents accumulating error resulted from multiple view registration. In addition, the computation time of proposed algorithm is less than the one of flat patch recursive algorithm
機器學習應用於細胞自噬檢測;
No full text[[abstract]]細胞自噬為近年來生醫領域中新興的研究課題，許多研究表明癌症等疾病與細胞自噬息息相關，一般藉由顯微鏡進行觀測或儀器進行量測。人工使用顯微鏡觀測速度緩慢且耗時，同時又有判定標準不一致的問題產生，使用相關儀器則必須對細胞施以螢光劑進行染色，然而在進行研究時會添加各式藥劑，若藥劑與螢光劑產生化學反應，則會使得螢光劑失去效用造成計數困難，因此需要一個客觀且公正的方法對細胞影像做判讀。使用影像處理與機器學習的技術，不僅能克服螢光劑的使用，且能因應拍攝環境的變化，透過學習的方式改變判斷準則，使得檢測更為方便且精準，故本研究使用影像處理與機器學習的方式，在不施加螢光劑的情況下，使用影像處理分割出影像中感興趣的區域，接著計算區域的幾何特徵與紋理特徵，最後使用支持向量機建立機器學習的檢測系統，找出影像中有自噬現象細胞並統計其濃度，與人工檢測結果相比，兩者的絕對誤差最低為0%，最高為15%，平均為5%。由於此檢測方式是透過監督式學習方法，可對不同的細胞進行學習與辨識，除了可擴大此檢測系統的應用範圍，亦提供生物醫學研究一個便利的細胞自噬檢測工具
具轉角平滑化功能之五軸刀尖點插補器設計;Study on Corner Smoothing for Interpolation Technology for Five-Axis Tool Center Point Trajectory
No full text[[abstract]]本論文提出一具有轉角平滑化功能的五軸刀具中心點插補演算法，透過設定各軸速度、各軸加速度、各軸急衝度以及轉角容許值，產生平滑的進給率曲線，藉以預測加工時間與轉角精度。首先，使用齊次轉換矩陣建立五軸工具機的機械座標與刀具座標之間的相對關係，並透過順逆向運動學進行五軸機械座標與刀具座標的轉換。接著計算插補程序所需資訊，包含是否開啟刀具跟隨功能時的最大速度限制，主動軸與從動軸的判別以及透過設計後插補器解決多線段相接時向量改變導致轉角速度不連續，造成各軸加減速過大的問題，並透過雙向預讀演算法決定各線段的初速度與末速度，避免線段過小時來不及加減速至末速的情況。接著進入插補程序，透過推導的13種加減速規劃方法，並利用上述資訊規劃進給率加減速曲線，接著將此加減速曲線進行後插補，得到平滑且連續的路徑。最後，在海德漢iTNC530控制器上進行實驗，利用相同的參數設定與海德漢控制器所輸出的五軸插補點進行比較。
In this paper, an corner smoothing for interpolation technology for five-axis tool center point trajectory is proposed to generate smooth feed-rate profile and tool center point (TCP) trajectory. The developed method according to set each axes maximum speed, acceleration, jerk, and five-axis kinematic limitation to determine TCP and rotary axes maximum feed-rate of multi-axis synchronized motions. The generalized forward/inverse kinematics equations of five-axis machine tools are derived based on homogeneous transformation. The proposed algorithms of the TCP feed-rate profile is evaluated by interpolation information process included three steps: (1) Determined maximum feed-rate in the block by TCP and rotary axes velocity formulation. (2) Chosen Master axis by ratio between movements and velocity of TCP and rotary axes. (3) Determine corner speed of TCP and rotary axes. (4) Used forward and backward look ahead algorithm to obtain initial speed and end speed of each block. (5) According to the maximum achievable acceleration to select acceleration/deceleration (ACC/DEC) method. (6) Used the after interpolator to generate smooth feed-rate profile. In the end of this paper, the simulation result validate the proposed algorithm almost identical to Heidenhan interpolation results
自激式熱聲引擎之設計;Design of Self-excited Thermoacoustic Engine
No full text[[abstract]]本研究主要是致力於設計自激式熱聲引擎，是以頻率響應的觀點為設計理念，藉由加工設計與製造並將各個加工件裝配後製出自激式熱聲引擎實驗平台。利用自激式熱聲引擎實驗平台運動時所產生的電壓訊號做為訊號感測，用於量測不同多孔材料及長度的實驗情況，再透過頻譜圖去分析出多孔材料的特性。
This paper is mainly designed to design self-excited thermoacoustic engine, is based on the concept of frequency response design concept, by processing design and manufacturing and assembly of the workpiece after the self-excited thermoacoustic engine experimental platform.The voltage signal generated by the self - excited thermoacoustic engine experiment platform is used as the signal sensing to measure the experimental conditions of different porous materials and porosity, and then analyze the characteristics of the porous material through the frequency spectrum
自動化生產系統開發;Automated production system development
No full text[[abstract]]過去自動化系統整合上，常見二大問題:1.連續加工的抽驗尺寸，導致不良品整批報廢損失。2.加工品良率一直無法有效明顯提升。為了改善其問題，本論文建立相關定位量測應用平台。並針對輪圈加工製程，開發設計視覺定位搭配雷射量測應用，與線外量測補償之軟硬體，分析最佳夾持點與誤差補償進行加工，達到成品良率提升之目的。在開發應用主要分為三部份，第一：供料定位，以視覺辨識與伺服控制系統，結合人機介面軟體技術開發，完成自動化之定位應用。第二：最佳夾持點，以雷射測距搭配線性馬達控制系統，結合數據分析與CNC通訊，進行夾持多角度定位，完成原料最佳放置點之開發應用。第三：線外量測，對成品進行雷射測距之數據分析，完成相關刀具數據補償與成品全檢。另外，藉由大量的數據收集與分析，將可提供更可靠的製程改善，達到降低不良率之目的。
In the past, there were two common problems with automation system integration. The first one is to perform spot check during the generating process which usually causes defected items. The defected items must be discarded. The second one is to increase the yield rate which was not been improved during the past years. In order to resolve the problems, this study tried to establish a positioning measurement platform. At the same time, I developed the visual positioning system with laser measurement The hardware and software are built for off-line measurement compensation during rim finishing process. I tried to analyze the best nipping point and performed error compensation for processing, and thus the yield rate can be enhanced. The development process can be divided to 3 parts. First, I used visual identification, servo control systems and human-machine interface software technology to complete the automatic positioning system. Second, the laser ranging with linear motor control system, data analysis and CNC communication is used to find out the best product nipping point of the raw material. Third, I used laser ranging to analyze finished product, completed the relevant tool data compensation and finished product inspection. In addition, with a large amount of data collection and analysis, the data could be used to further improve the process, and enhance the yield rate
工具機循圓誤差之解析;The Analysis of The Errors in Machine Tools' Circular Test
No full text[[abstract]]本論文以數學的方式，從體積誤差推導工具機之誤差模型，分析誤差源對循圓的影響化成方程式加入誤差模型，最後導入循圓量測資料以計算各誤差源在循圓區間的大小，並與市售量測儀器Renishaw double ball bar的檢測值相互比對以建構出循圓誤差完整且合理的計算方式與流程。實驗方面，本論文以東台三軸加工機VC-608為實驗機具架設量測儀器Renishaw 之double ball bar 進行循圓測試，擷取double ball bar的量測資料導入所設計的分析流程以解析出各項誤差源，輔以Renishaw 之ballbar 20將循圓結果分析出誤差源以交互比對。最後通過比對結果以確認本論文的分析方式與Renishaw有何異同，並且能透過這個過程能知道Renishaw的分析結果是否正確。
This thesis show that the machine tools’ error model was derived by volumetric error and joined the equation derived by the influence of the error source on ball bar measurement. Last, use the error model on the measuring data to calculate the values of the error sources, and build the reasonable analysis process, and then compared the detection values with the commercially available measuring instruments, Renishaw’s double ball bar. In experiment, this thesis use Renishaw’s double ball bar to do circular test on the Tongtai’s VC608, and then, capture the measuring data to calculate the error sources, compare with the digitals showed by Renishaw ballbar20, an analyzing program designed by Renishaw. Finally, confirm the digitals’ similarities and differences between this thesis and Renishaw to know the results of Renishaw’s analysis are correct
基於三維射線法之多物理量加工模擬系統;Multi Machining Error Simulation System Based on Tri-Dexel Data Structure
No full text[[abstract]]本研究主要目的在開發一套虛擬五軸加工系統，透過APT刀具與Tri-Dexel模型進行加工模擬。透過事前模擬來避免產生不可預期的錯誤，進而解決加工參數設定錯誤所導致的加工成本上升。在模擬切削過程中使用者可隨時檢查切削中的工件是否符合預期，如果不符合使用者可以即時中止模擬，檢討原因後調整參數再次進行模擬。 本系統首先將讀入STL三角網格的三維資料結構轉換為Tri-Dexel資料結構，接著利用本研究推導的APT刀具與讀入的路徑CL點資料結合加工誤差資訊，對Tri-Dexel模型進行干涉判斷與布林運算，可以得到經過切削後的Tri-Dexel模型資料。同時，透過切削過程中所獲得之體積移除率乘上切削力係數可以得到即時的切削力資訊。最後將切削後的Tri-Dexel模型透過Refinement演算法重建回STL三角網格資料，以利使用者監控加工過程是否符合預期。
In this research, we develop a multi-axis CNC machining simulation system. By using Tri-Dexel data structure and with the automatically programmed tool (APT), we can effectively simulate a multi-axis machining behavior in order to avoid undesirable machining errors, hence reducing costs. This system potentially can be integrated with a PC-based controller to simulate the machining on-line. If NC errors are found, the user can stop and suspend the machining. NC tool-path or machining parameters such as federate can be modified or adjusted to reduce the cutting force and regenerate the machining tool-path. Our research transform the STL data of the model into the Tri-Dexel data structure. We then use implicit equations of the APT cutter to calculate the intersections between the Tri-Dexel model and the APT cutter. The NC tool-path provides the multi-axis movement of the cutter. The Tri-Dexel model is intersected and updated after each step of the movement. Through this simulation, our system can calculate the material removal rate (MRR), then multiplied by the cutting force coefficient to obtain the instant cutting force information. In addition, by integrating multiple machining system information, such as servo dynamic error, machine structure deformation error, and spindle thermal error, our system can simulate the predicted NC tool path to include these multiple physical properties into our simulation. The result can be used to estimate and possibly correct the predicted machining error