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研究生： 陳民山
Tran, Minh-Sang
論文名稱： 噴射點膠機的電磁致動器之設計與實驗
Design and Experiments of Linear Electromagnetic Actuators for Jet Dispenser
指導教授： 黃聖杰
Hwang, Sheng-Jye
學位類別： 博士
Doctor
系所名稱： 工學院 - 機械工程學系
Department of Mechanical Engineering
論文出版年： 2020
畢業學年度： 108
語文別： 英文
論文頁數： 167
中文關鍵詞： 噴射點膠機 、線性馬達 、電磁致動器 、動圈致動器 、動磁致動器 、作動頻率 、微滴
外文關鍵詞： Jet dispenser, linear motor, solenoid actuator, moving magnet actuator, moving coil actuator, operating frequency, droplet
相關次數： 點閱：68  下載：0 
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    • 在這項研究中，提出了基於電磁的線性致動器（LEA）來驅動噴射點膠機的點膠系統，致動器具有三種類型，即電磁致動器（SA），動圈致動器（MCA）和動磁致動器（MMA）。電磁的線性致動器產生的驅動力必須大於噴射點膠機針頭的阻力。 致動器驅動力的值取決於作用在針頭上的阻力，阻力包括了阻尼力、O型環與針頭間的摩擦力、彈簧的壓縮力還有質量的慣性力，前面三種力是根據實驗模型所量測到的，而最後一個力是由於分配器針頭運動的極高速度而根據理論計算的。在設計過程中，驅動力是通過有限元分析（FEA）進行預測的。將模擬軟體用於模擬本研究自製的模型之前會透過其他文獻的實驗結果進行比較來評估有限元素分析解果的準確性。然後，根據主要組件的基本幾何尺寸（包括線圈繞組，永磁體和鐵殼），構建了電磁的線性致動器的三個樣式的有線元素分析的簡化2D模型。有限元分析模型的尺寸也會根據情況進行修改，以產生較高的驅動力，SA， MMA和 MCA三種模型的驅動力平均增加力分別是49.5，47和33.4%。
    根據有限元分析結果的修改尺寸並製造了三個執行器的實驗原型。測試了三個電磁的線性致動器原型的運行條件，並測量了驅動力和作動頻率。本研究也針對溫度對施加電流和驅動力的影響進行觀察。最後，在各種背壓，工作頻率，針頭位移和流體溫度條件下，對基於電磁的線性致動器（ELA）的點膠機產生的膠狀點的大小進行了經驗研究，此外，本研究也提出了一種基於分析基板上點的形狀來計算點體積的近似方法。
    模擬和實驗結果表明，動磁致動器(MMA)和動圈致動器(MCA)的推力在整個行程均保持不變，其變動幅度可忽略不計，動磁致動器(MMA)和動圈致動器(MCA)解決了即電磁致動器(SA)的缺點，即電磁致動器(SA)的推力在行程結束時急劇下降，會造成很大的變動幅度，此外，即電磁致動器(SA)的工作頻率在PWM佔空比為50％時最高只能達到10–20 Hz，而動磁致動器(MMA)和動圈致動器(MCA)在200 Hz時也能正常作動。根據實驗結果，設置參數對膠狀點大小的影響順序為流體溫度，背壓，衝程長度和作動頻率，且MMA/MCA形式的噴射點膠機可以用來對黏度為4000 cP的材料進行作動，從生產結果來看，動磁致動器(MMA)和動圈致動器(MCA)所製造的膠狀點和膠狀線達到了穩定生產的需求，證明了動磁致動器(MMA)和動圈致動器(MCA)可有效的取代電磁致動器(SA)並應用於噴射點膠機上。

    Three linear electromagnetic actuators (LEAs), namely solenoid actuator (SA), moving coil actuator (MCA), and moving magnet actuator (MMA), are proposed for driving a jet dispenser of a dispensing system. The necessary thrust force generated from proposal LEAs must be higher than a driving force impacting the jet dispenser needle. The driving force magnitude is the total resistance force acting on the needle, including the damping force, the friction force between the O-rings and needle, the compression spring force, and the acceleration force of mass. These three first physical quantities are measured by an experiment setup, while the last one is calculated based on theory due to the extremely high velocity of the dispenser needle. For the LEAs design process, the thrust force is predicted by the finite element analysis (FEA). The accuracy of FEA results for the LEA models has been evaluated by comparing them with semi-empirical results from literature before the software is used to simulate the author's own proposal models. Then, three FEA simplified 2D models of SA, MCA, and MMA based on the basic geometric dimensions of the main components, including coil windings, permanent magnets, and iron shells, are built. The FEA models are modified to generate better models with a higher thrust force value. The average percentage increase of thrust force is 49.5, 47, 33.4% for SA, MMA, and MCA models after modification, respectively.
    Three actuator prototypes are fabricated based on the modified dimensions from the FEA step. Three LEA prototypes and their operation conditions are tested and the thrust force and operation frequency are measured. The temperature effects on the drop of applied current and thrust force are also investigated in this research. The fluid dots’ size produced by the LEAs jet dispensers is empirically investigated under various conditions of backpressure, operating frequency, needle displacement, and fluid temperature. Besides, an approximate method is proposed to calculate the dot volume based on analyzing the shape of dots on the substrate.
    Simulation and experiment results showed that the thrust force of MMA and MCA are maintained over the entire stroke length and its drop is negligible. The MMA and MCA have also solved the disadvantages of SA when SA’s thrust force dropped sharply at the end of the stroke. Besides, SA's operating frequency reaches a maximum of 10 – 20 Hz with the PWM duty cycle 50%, while MMA and MCA can operate at frequencies near 200 Hz. The influence order of the setup parameters on the fluid dot size is fluid temperature, backpressure, stroke length, and operating frequency. MMA/MCA jet dispensers can jet materials with a maximum viscosity of 4000 cP. Experiment results of making fluid dots and fluid lines from the proposed LEAs (MMA and MCA) are to meet stable operating requirements. From obtained results, proposed MMA and MCA can be considered to replace SA and are potential actuators to be applied for driving the jet dispenser.

    論文摘要 I ABSTRACT III ACKNOWLEDGMENT V CONTENTS VI LIST OF FIGURES XI LIST OF TABLES XVII CHAPTER 1. INTRODUCTION 1 1.1 Applications of dispensing technology 1 1.1.1 Underfill encapsulation 1 1.1.2 Glob top 2 1.1.3 Dispensing solder paste 3 1.1.4 Dispensing gasket 4 1.1.5 Doming 4 1.1.6 Microarray in medical 5 1.1.7 Binder jetting (BJ) 6 1.2 Dispensing technology 7 1.2.1 Needle/contact method 7 1.2.2 Non-contact method 8 1.3 Mechanical jet configuration 11 1.4 Actuators for jet dispenser needle 12 1.4.1 Piezo-stack actuator 13 1.4.2 Magnetostrictive actuator 13 1.4.3 Electropnuenatic actuator 13 1.4.4 Solenoid actuator 14 1.5 Comparison of actuators driving jet dispenser 14 1.6 Research motivation 16 1.7 Work objective 17 1.8 Organization of the Thesis 18 CHAPTER 2. LINEAR ELECTROMAGNETIC ACTUATORS 21 2.1 Linear electromagnetic actuator (LEA) 21 2.1.1 Solenoid model 21 2.1.2 AC linear induction actuator 22 2.1.3 Voice coil actuator 23 2.1.4 B-H curve effect on LEAs 23 2.1.5 Proposal LEAs for jet dispenser 24 2.2 Analysis methods for SA, MMA, and MCA 25 2.2.1 Simplified analysis 25 2.2.2 Finite element analysis 28 2.3 Verifying accuracy of FEA result via published experimental results 30 2.4 Temperature effect to LEAs 34 2.4.1 Thermal generation in LEAs 34 2.4.2 Heat dissipation on LEAs 36 2.4.3 High-temperature effects 37 CHAPTER 3. DESIGN OF PROPOSAL LEAS 39 3.1 Proposal design flowchart for LEAs design 39 3.2 Calculation of necessary thrust force 40 3.2.1 Jet valve configuration 40 3.2.2 Calculation of necessary thrust force 45 3.3 Fabricating jet valve prototype and measuring necessary thrust force 51 3.4 Modeling proposal actuators 55 3.5 LEAs’ models after modified 58 CHAPTER 4. FABRICATION OF PROPOSED ACTUATORS AND SETUP OF MEASUREMENT SYSTEM 62 4.1 Proposed jet dispenser sketches 62 4.2 LEAs fabrication 64 4.2.1 SA fabrication 64 4.2.2 MMA fabrication 69 4.2.3 MCA fabrication 73 4.3 Thrust force measurement system 77 4.4 Operating frequency measurement system 79 4.5 LEAs’ assembly 81 4.6 Control signal 83 4.7 Fluid dot experiment setup 85 4.8 Method of measuring the volume of fluid dots 86 CHAPTER 5. RESULTS AND DISCUSSIONS 90 5.1 Necessary thrust force 90 5.2 Simulation results for LEAs 92 5.2.1 Comparison between models before and after modified 92 5.2.2 Simulation results of LEA models after modified 94 5.3 Measurement results with no temperature effect 96 5.3.1 Experiment results of thrust force 96 5.3.2 Comparison of simulation and experimental results of thrust force 98 5.3.3 The minimum exciting current 101 5.4 Measurement results with temperature effect 105 5.4.1 Coil temperature 105 5.4.2 Current drop 112 5.4.3 Thrust force drop 118 5.5 Operating frequency of LEAs 123 5.5.1 Operating frequency of SA prototype 123 5.5.2 Operating frequency of MMA and MCA prototype 126 5.6 Fluid dot 131 5.6.1 Fluid dots’ images 131 5.6.2 Fluid dots’ volume 135 5.6.3 Effect of setting parameters to fluid dot size 137 5.6.4 Maximum viscosity 149 5.7 Fluid line 151 CHAPTER 6. CONCLUSIONS AND FUTURE WORKS 155 6.1 Conclusions 155 6.2 Disadvantage of the design and future works 156 6.3 Contribution of the work 158 REFERENCES 160

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