胚料在螺帽成型機成型的過程中，有時候會因高壓而黏貼於公模內，致使後通出機構無法將其頂出。因此，必須利用前通出機構來控制公模內的通出桿，強迫胚料停留在母模內，以利後通出機構通出胚料。習用的螺帽成型機在生產厚度不同的螺帽時，需要更換不同的凸輪，或者只有幾種規格可供調整通出行程，頗為不便。為了因應業界對可調整行程的需求，宜研究將前通出機構之通出行程，由原本的固定式或僅有幾種通出行程，改成可調整行程之前通出機構，並且可以微調至任何所需的通出行程，以生產各種厚度的螺帽。
本研究主要目的是針對螺帽成型機中的前通出機構，用一套系統化的流程來進行構造合成與尺度合成，設計出可任意調整通出行程之前通出機構。一個可調整行程之前通出機構由驅動機構以及調整機構兩子機構所組成。文中，首先根據文獻分析結果，與某螺帽工廠提供的經驗，分別訂定兩子機構構造合成所需的設計需求與限制。接著，根據所提出的構造需求，本文使用型態表分析法進行構造合成，分別合成八個可行的驅動機構構造與十二個調整機構構造。隨後再用決策矩陣評估出三個較佳的驅動機構構造與三個調整機構構造，可組合得九個可調整行程之前通出機構構造。本文選擇其中兩個最佳的可調整行程之前通出機構構造來進行機構尺度合成。
在尺度合成方面，本文以一組通出桿通出量與滑件位移量關係曲線作為設計需求，以最小化凸輪體積為目標來合成驅動機構的主凸輪與從動件。其次，以九組通出桿通出量與滑件位移量關係曲線作為設計需求，將調整後所得的九組曲線和設計需求曲線之間的偏差量最小化為目標，來合成調整機構的各元件尺寸。合成過程中，以向量迴路法和凸輪機構合成法來建立運動方程式，配合空間限制和其它必要的限制，利用最佳化設計的方法來合成機構尺度。本文所合成的可調整行程之前通出機構共有兩型，其中一型可以完全達到運動要求，在調整性方面也相當便利，可以直接運用在現有的機台中。另外一型雖也可以達到運動需求，但是在設計限制之下無法合成出調整機構的凸輪尺度。
本文所設計的新型可調整行程之前通出機構的優點，在於其所需的通出行程為可任意調整，符合各種螺帽規格所需的通出量。此外，本文針對螺帽成型機可調整行程之前通出機構所提出的設計步驟，亦可應用於其他相關機構之構造合成與尺度合成。

In the nut forming process, workpieces may stick to male dies because of high pressure forming. As a result, the knock-out mechanisms attached to female dies fail to knock out workpieces. Hence, ejector mechanisms attached to male dies are required to restrict workpieces to stay in female dies for being knocked out. Moreover, it is inconvenient to change the cam components when forming nuts with different thickness by a traditional nut forming machine. Thus, in order to satisfy the adjustment requirement, a nut forming machine must equip with adjustable ejector mechanisms to produce nuts with various thickness.
The main purpose of this study is to design new adjustable ejector mechanisms for a nut former by using a systematic method for the structural synthesis and dimensional synthesis of the mechanisms. An adjustable ejector mechanism consists of a driving mechanism and an adjusting mechanism. In the structural synthesis process, the design requirements and constraints for the structural synthesis are concluded from the results of references analysis and the experience of a nut factory. According to the structural requirements for an adjustable ejector mechanism, eight feasible driving mechanisms and twelve adjusting mechanisms, respectively, are synthesized via the morphological chart analysis method. By using the method of decision matrix, nine better adjustable ejector mechanisms are then synthesized. Finally, the two best designs are selected for the dimensional synthesis of new adjustable ejector mechanisms.
In the dimensional synthesis of the driving mechanism, a relative displacement curve of the ejector and slider of the ejector mechanism is used for the design requirement. According to the design requirement, the driving cam-follower mechanism of the ejector mechanism is synthesized by minimizing the cam size. In the dimensional synthesis of the adjusting mechanism, nine relative displacement curves of the ejector and slider of the ejector mechanism are used for the design requirements. According to the design requirements, the dimensions of the adjusting mechanism of the ejector mechanism is synthesized by minimizing the difference between the nine relative displacement curves and those generated curves after adjustment. In the synthesis process, the required kinematic equations are established by the vector-loop approach and cam synthesis method. An optimization design method is applied to synthesize the ejector mechanism under space limitations and other necessary constrains of the mechanism. As a result, there are two new adjustable ejector mechanisms are synthesized. One is shown to fulfill the functional requirements for an adjustable ejector mechanism. The other is not feasible due to the space limitations.
The main advantage of the new design is that the ejection stroke of the synthesized ejector mechanism can be adjusted for forming nuts with different thickness. The design procedures used in this study can also be provided for the structural synthesis and dimensional synthesis of other adjustable ejector mechanisms for nut formers.

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