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研究生: 曾廣平
Tseng, Kuang-Ping
論文名稱: 適用於臥式車床之整機測試模組與輪圈動平衡預測機制
Integrated-Test Module and Wheel Dynamic Balance Prediction Mechanism for Horizontal Lathe Machines
指導教授: 鄭芳田
Cheng, Fan-Tien
共同指導教授: 楊浩青
Yang, Haw-Ching
學位類別: 碩士
Master
系所名稱: 電機資訊學院 - 製造資訊與系統研究所
Institute of Manufacturing Information and Systems
論文出版年: 2019
畢業學年度: 107
語文別: 中文
論文頁數: 48
中文關鍵詞: 鋁輪圈加工自動化機台效能深度學習動平衡
外文關鍵詞: Wheel Machining Automation System (WMA), Machine performance, Deep Learning, Dynamic balance
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  • 工具機設備出貨妥善率對於工廠產能具有關鍵性影響,現有的機台組裝精度量測與跑合測試僅由人工進行檢驗,僅能達成機台規格誤差量測與補償。此外,輪圈動平衡問題被視為影響運動穩定性的重要因素,當轉子在旋轉時,因質量分佈不均産生離心力,在軸承上會引起振動,産生雜訊和加速軸承磨損,嚴重影響産品性能與壽命。
    為解決上述兩問題,本論文開發兩種智能化模組,分別為整機測試模組與輪圈動平衡預測機制,並應用於輪圈加工臥式車床。整機測試模組基於機台跑合資料收集與分析,透過分析機台耗電量與實際運動表現,建構一個可自動監測組裝完成機台各項運轉性能表現的系統。而輪圈動平衡預測機制使用振動原始資料,並運用深度學習架構進行預測分析,針對不平衡重量與角度進行預測。
    在結果上,整機測試模組可即時評估機台整體運作效能,提供與比較機台組立(人員差異) 和電控設定之差異性;至於輪圈動平衡預測機制,則其重量之平均絕對誤差小於1.15克,而角度平均絕對誤差則為7.97度。綜上所述,本研究所提出的兩種模組與機制,均可成功應用於臥式車床,優化機台自身的功能性與生產力。

    The availability of machine tool is a critical impact for the factory capacity. The existing measurements and tests are done manually. They can only conduct the measurements and compensations of the machine specification error. In addition, wheel dynamic balance is considered to be an important factor affecting the rotatory stability. When the rotor rotates, the centrifugal force is generated due to uneven mass distribution, which causes vibration on the bearing, creates noise, accelerates bearing wear and seriously affects product performance and life.
    Therefore, this research develops two types of intelligent modules and applies them to the horizontal lathe machine, which is the Integrated-Test Module and Wheel Dynamic Balance Prediction Mechanism. Integrated-Test Module is designed based on the collection and analysis of machine tool running data. Through analyzing machine power consumption and the actual performance, an automated system can be constructed to monitor various operational performances of an assembled machine tool. Wheel Dynamic Balance Prediction Mechanism uses vibration raw data and the deep-learning method in modeling and prediction analysis for the unbalanced weights and angles.
    In conclusion, Integrated-Test Module can integrate two variables, assembly operator and electronic control setting, in real time, to evaluate the overall machine operational efficiency. And for Wheel Dynamic Balance Prediction Mechanism, the mean absolute error of the weight is 1.15 grams, and the mean absolute error of angle is 7.97 degrees. Consequently, the two modules and mechanisms proposed in this research can be successfully applied to the horizontal lathes to optimize the functionality and productivity of the machine tools.

    摘 要 III SUMMARY IV 誌 謝 XIII 第一章 緒論 1 1.1 研究背景 1 1.2 研究動機與目的 3 1.2.1 整機測試模組 3 1.2.2 輪圈動平衡預測機制 5 1.3 研究流程 7 1.4 論文架構 7 第二章 文獻探討與理論基礎 8 2.1 文獻探討 8 2.1.1 整機測試模組 8 2.1.2 輪圈動平衡預測機制 9 2.2 理論基礎 11 2.2.1 整機測試模組 11 2.2.1.1 機台跑合測試項目 11 2.2.2 輪圈動平衡預測機制 12 2.2.2.1 平衡精度與物理公式 12 2.2.2.2 卷積神經網路(Convolutional Neural Network, CNN) 14 第三章 研究方法 17 3.1 整機測試模組 (Integrated-Test Module) 17 3.1.1 測試環境要求 17 3.1.2 測試資料來源與感測器安裝 17 3.1.3 可攜式資料收集模組(黑盒子) 19 3.1.4 資料擷取區段 20 3.1.5 效能評分設計 23 3.2 輪圈動平衡預測機制 (Wheel Dynamic Balance Prediction Mechanism) 25 3.2.1 資料收集與處理 25 3.2.2 卷積神經網路架構 29 3.2.2 神經網路Loss Function 30 3.2.3 集成預測 31 3.2.4 輪圈動平衡預測機制流程 32 第四章 整機測試模組實作與輪圈動平衡預測機制驗證 33 4.1 整機測試模組實作 33 4.1.1 實作流程 33 4.1.2 整機測試操作流程 34 4.1.3 機台後續追蹤與驗證 36 4.2 輪圈動平預測機制驗證 38 4.2.1 實驗設計 38 4.2.2 實驗描述 40 4.2.3 動平衡推估實驗結果 41 4.2.4 有效頻寬分析 43 第五章 結論與未來研究 45 5.1 結論 45 5.2 未來研究 46 參考文獻 47

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