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研究生：	蕭意瑾 Xiao, I-Chin
論文名稱：	車用攝像鏡頭內部防水結構設計與O型環密封技術優化與應用 The Design of Waterproof Structures Inside Automotive Camera and Optimization and Application of O-ring Sealing Technology
指導教授：	蕭世文 Hsiao, Shih-Wen 謝孟達 Shieh, Meng-Dar
學位類別：	碩士 Master
系所名稱：	規劃與設計學院 - 工業設計學系 Department of Industrial Design
論文出版年：	2025
畢業學年度：	113
語文別：	英文
論文頁數：	115
中文關鍵詞：	橡膠、防水、ALGOR 、有限元素分析、田口方法
外文關鍵詞：	Rubber Sealing, Waterproof Design, ALGOR, Finite Element Analysis (FEA), Taguchi Method
相關次數：	點閱：23 下載：1
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本研究旨在設計與優化車用倒車攝像鏡頭內部的防水密封結構。倒車攝像鏡頭為現代車輛之重要安全輔助裝置，透過視覺與聽覺資訊輔助駕駛判斷，其裝設位置通常位於車外，需長時間暴露於各種惡劣環境條件下，如風雨、日曬、高溫、濕度變化及氣壓波動等。因此，對於倒車攝像鏡頭而言，相較於以往的產品，防水標準需達到最高級別。如果無法達到最高防水標準，攝像鏡頭的耐用度和堅固度將會受到影響，同時，車子的安全係數也相應降低。
目前市面上有多種的倒車攝像鏡頭，各具優缺點，本文分析現有產品功能及特色，並整合相關技術，探索市場上產品的狀況。雖然現有產品已具備基本防水功能，然而實際使用中仍常發生滲水、不良率偏高及結構壽命不足等問題，顯示設計與生產端仍有優化空間。此外，即使在設計技術相當成熟下，生產線仍有一定的失敗率與不良品問題，並且產品的耐久性常不佳。為此，本文提出一套結合有限元素模擬與品質工程之分析流程，針對攝像鏡頭內部防水橡膠密封結構進行優化設計與驗證。
本研究使用田口實驗方法與有限元素分析進行車用攝像鏡頭的防水橡膠性能實驗。首先，先行開發本研究的鏡頭。後以田口實驗設計法為基礎，規劃四個控制因子（壓縮量、溝槽寬度、溝槽圓角、防水橡膠造型），建立 (L9(34)) 直交表進行九組模擬組合。將此九組模型的上蓋、防水橡膠與下蓋之二維結構進入到應力非線性有限元素分析，模擬防水橡膠在不同幾何參數下的應力分布情形。再計算 S/N 比以評估最佳實驗，並透過S/N主響應表與主響應圖預測出最佳參數實驗10。
分析結果顯示，最佳實驗為實驗9之A3B3C2D1，其對應參數為壓縮量0.45mm、下蓋溝槽寬度1.4mm、下蓋溝槽圓角半徑0.2mm及X 型橡膠截面，並且研究出如果無考慮到田口交互作用之下，預測出最佳參數組合的實驗10並無實驗9來的佳。此外，本文進一步探討各因子對應性能表現之貢獻度，分析其水準差異與排列順序，並比較成功與失敗實驗之設計差異。
綜合而言，本研究提出一套結合模擬與統計分析之設計流程，不僅可作為車用攝像鏡頭防水結構設計之系統化參考，亦有助於提升產品密封品質與結構耐久性，降低不良率與生產成本，進而延長產品壽命並提升行車安全性，提供機構設計工程一套有效且具數據支撐的優化方法。

This study aims to design and optimize the internal waterproof sealing structure of automotive rearview cameras. As a critical safety-assist device in modern vehicles, the rearview camera provides visual and auditory feedback to help drivers make judgments, especially during reversing. These cameras are typically installed outside the vehicle and are exposed to harsh environmental conditions such as wind, rain, sunlight, high temperatures, humidity fluctuations, and pressure variations. Therefore, rearview cameras must meet the highest waterproof standards to ensure durability and structural integrity. Failure to do so compromises both the longevity of the camera and overall vehicle safety.
Currently, various types of rearview cameras exist on the market, each with its own strengths and weaknesses. This study analyzes the functionalities and features of existing products and integrates relevant technologies to evaluate the current market landscape. Although most commercial products possess basic waterproof capabilities, issues such as water ingress, high defect rates, and insufficient structural lifespan persist in real-world applications. Even with mature design techniques, production lines still face a certain failure rate and challenges in product durability. To address these problems, this research proposes an analytical framework that integrates finite element simulation with quality engineering to optimize and validate the waterproof rubber sealing structure within the camera module.
In this study, the Taguchi method and nonlinear finite element analysis (FEA) are employed to investigate the performance of the waterproof rubber seals. A camera model is first developed, followed by the design of experiments based on four control factors—compression amount, groove width, groove fillet radius, and rubber cross-sectional shape. An L9(3⁴) orthogonal array is constructed, generating nine simulation combinations. Each model consists of a top cover, rubber seal, and bottom cover represented in 2D cross-sections, and their stress distributions are analyzed under different geometric parameters. The signal-to-noise (S/N) ratio is then calculated to evaluate experimental performance, and the main effect table and plot are used to predict the optimal parameter combination (Experiment 10).
Results indicate that Experiment 9 (A3B3C2D1) yields the best performance, with the following parameters: compression amount of 0.45 mm, groove width of 1.4 mm, fillet radius of 0.2 mm, and an X-shaped rubber cross-section. It is further observed that the predicted optimal design (Experiment 10), which does not account for interaction effects, performs worse than Experiment 9, highlighting the limitations of the Taguchi method in certain contexts.
Additionally, this study examines the contribution and ranking of each factor and analyzes performance differences between successful and failed experimental setups. In conclusion, the proposed simulation and evaluation framework offers a systematic reference for designing waterproof structures in automotive rearview cameras. It not only improves sealing quality and structural durability but also reduces defect rates and production costs, thereby extending product lifespan and enhancing overall safety. This methodology provides a practical and data-driven approach for mechanical design optimization in engineering applications.

摘要	i
SUMMARY	iii
ACKNOWLEDGEMENTS	v
TABLE OF CONTENTS	vi
LIST OF TABLES	ix
LIST OF FIGURES	x 
CHAPTER 1 INTRODUCTION	1
1 Background	1
2 Research Motivation	2
2.1 Issues in Current Vehicle Camera Systems	2
2.2 Challenges In Current Commercial Camera Systems	2
2.3 Consequences of Sealing System Failure	3
2.4 Issues Caused By Improper Design	3
2.5 Reasons and Benefits of Improving Waterproof Rubber	4
2.6 Research Background and Motivation	5
3 Research Framework	5
CHAPTER 2 LITERATURE REVIEW	8
1 Waterproofing Methods	8
2  Properties of Rubber	10
2.1 Introduction to Rubber Materials	10
2.2 Rubber Sealing Performance	10
2.3 Geometric Nonlinearity and Material Behavior of Rubber	14
3 Causes of Water Ingress	15
4  Exploration of Waterproof Rubber	16
4.1 Basic Introduction to Waterproof Rubber	16
4.2 Sealing Requirements	17
4.3 Strain Relationship and Boundary Conditions	18
4.4 Compression Conditions and Waterproof Contact Stress Behavior	25
4.5 Influence of Pressure on Groove Width	31
5 Underwater Pressure Calculation	32
6  Taguchi Method	34
6.1 Quality Characteristics	35
6.2 Experimental Factors and Selection	35
6.3 Orthogonal Array	37
6.4 Process Optimization	38
6.5 Signal-to-Noise (S/N) Ratio	38
CHAPTER 3 DESIGN AND DEVELOPMENT OF AUTOMOTIVE CAMERA SYSTEMS	40
1 Market Survey of Products	40
2 Product Design	43
2.1 Exterior Design	43
2.2 Mechanical Design	45
3 Basic Structure of the Waterproofing System	46
3.1 Water Flow Behavior	47
3.2 Considerations in Waterproof System Design	47
3.3 Empirical Values for Waterproof System Design	48
4 Description of Selected Factors	49
CHAPTER 4 EXPERIMENTAL METHODOLOGY	52
1 Waterproofing Methods	52
2  Simulation Procedure	53
3  Taguchi Method-Based Experimental Design	54
3.1 Analysis of Influencing Factors	55
3.2 Selection of Control Factors	55
3.3 Factor Level Definition	57
3.4 L9(3⁴) Orthogonal Array Design	57
3.5 S/N Ratio And Stress Result Records	58
4  Construction of Stress Analysis Models	59
4.1 Waterproof Structure Analysis	61
4.2 Taguchi Experimental Matrix and Simulation Results	68
4.3 S/N Ratio Response and Main Effects Analysis	69
CHAPTER 5 RESULTS AND DISCUSSION	71
1 Optimal Parameter Analysis	71
1.1 Evaluation Metrics for Experimental Data	72
1.2 Optimal Parameter Configuration : Experimental Group 9	73
1.3 Stress Validation for Experimental Group 9	73
1.4 Analysis of Experimental Group 9	74
1.5 Water Flow Resistance of Seal	74
2 Experimental 9 vs.  Predicted Optimal (Experiment 10)	76
3 Evaluation of Taguchi and Effectiveness	78
4 Analysis of Other Experimental Cases	79
5 Influence of Factors and Level Comparison	83
5.1 Performance Variation across Factor Levels	84
5.2 Stress Analysis Results of Experiment 9	86
5.3 Impact of Reaction Force on Cover Assembly	93
CHAPTER 6 CONCLUSION	95
1 Findings Summary	95
2 Research Conclusions	95
3 Design Recommendations and Future Research Directions	96
REFERENCES	97
                                    

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