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研究生: 蔡育庭
Tsai, Yu-Ting
論文名稱: 均勻表面感應加熱之快速模具與熱澆道發展
Development of Uniform Surface Induction Heating System for Rapid Mold and Hot Runner Heating
指導教授: 黃聖杰
Hwang, Sheng-Jye
學位類別: 碩士
Master
系所名稱: 工學院 - 機械工程學系
Department of Mechanical Engineering
論文出版年: 2011
畢業學年度: 99
語文別: 中文
論文頁數: 118
中文關鍵詞: 電磁感應加熱線圈設計磁場集中器溫度均勻性
外文關鍵詞: Electromagnetic induction heating, Coil design, Magnetic flux concentrators, Temperature uniformity
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  • 近幾年,因為光電產業、微生醫晶片、微電路印刷板、光學薄膜、導光板、非球面光學透鏡等精密電子零件發展,其產品生命週期較短且量產需求增大,影響產品精度與生產速度要求較傳統產品更為嚴苛。因此,使用電磁感應加熱之議題漸漸被提出且尚待完整技術突破,此技術具有加熱速度快、能源利用率高之優點,將應用電磁感應加熱技術於射出成形製程,以改善射出件之縫合線、高亮面、熱應力等常見不良缺陷成品。
    本研究著重於小面積加熱、局部面積加熱及大面積加熱,加熱工件為SKD 61,透過凹形線圈、七吋矩形線圈及十四吋柵欄式線圈等線圈設計,再搭配磁場集中器擺放方式,經由測試實驗可得加熱速率分別為3.21 oC/sec、5.63 oC/sec及1.86 oC/sec;溫度均勻性分別達到95.56%、92.27%及88.80%。
    本研究亦著重於熱澆道系統,加熱工件為熱澆道,透過線圈設計,搭配磁場集中器擺放方式,經由測試實驗可得加熱速率及溫度均勻性,分別為2.06 oC/sec及95.51%。並且發展新的纏繞線圈方法比傳統纏繞線圈方式更能使得熱澆道表面能夠均勻受熱及高溫度均勻性。

    In recent years, the optoelectronics industry, micro-health chips, micro-printed circuit boards, optical film, light guide plates, non-spherical optical lenses and other high precision electronic components had been developed. Shorter life cycle of product and increased quantities of products had affected the precision and production speed requirements of products. Therefore, a new technology of using electromagnetic induction heating with higher heating speed, high energy efficiency was proposed. This system is easy to implement and is inexpensive. Thus, the new system is expected to be popular among the molders, applying the electromagnetic induction heating technology to injection molding process in order to improve part quality without welding lines, and with highlight surface, low thermal stress.
    In this thesis, small area heating, local area heating and large area heating were concerned, did the test experiments through coil design of the concave type coil, seven-inch ring type coil and fourteen-inch parallel type coil with magnetic flux concentrators placed method. According to the result of coil test experiments, heating rate were 3.21 oC/sec, 5.63 oC/sec and 1.86 oC/sec and temperature uniformity were 95.56%, 92.27% and 88.80% respectively.
    In this thesis, hot runner system was also concerned, did the test experiments through coil design and magnetic flux concentrators placed method. According to the result of coil test experiments, heating rate and temperature uniformity were 2.06oC/sec and 95.51% respectively. And a new wire winding method was developed to heat the hot runner from outer surface and had better temperature uniformity in comparison to the traditional wire winding method.

    摘要 I Abstract II 致謝 III 目錄 V 表目錄 IX 圖目錄 X 符號表 XIV 第一章 緒論 1 1-1 前言(Preface) 1 1-2 射出成型基本介紹(Introduction of Injection Molding) 2 1-2-1 射出成型流程(Injection Molding Process) 2 1-2-2 模具溫度對射出成型的影響(Effect of Mold Temperature) 4 1-2-3 模具控溫的方法(Methods of Mold Temperature Control) 5 1-3 文獻回顧(Literature Review) 6 1-3-1 輻射(Radition Heatung) 6 1-3-2 火焰加熱(Flame Heating) 6 1-3-3 鍍層滯熱(Coating Layer for Heat Hysteresis) 7 1-3-4阻隔式電加熱(Electric Heating with Insulating Layer) 7 1-3-5 蒸氣式快速加熱(Vapor Rapid Heating) 7 1-3-6 感應加熱(Induction Heating) 8 1-4 研究動機與目的(Aims of Thesis) 13 1-5 文章架構(Layout of Thesis) 13 第二章 感應加熱的基本介紹及理論 14 2-1 感應加熱的原理(Fundamental of Induction Heating) 14 2-2 感應加熱的特性(Characteristics of Induction Heating) 15 2-2-1 相對導磁係數(Relative Permeability) 15 2-2-2集膚效應(Skin Effect) 15 2-2-3 電阻率(Electrical Resistivity) 16 2-2-4 磁滯現象(Hysteresis Phenomenon) 17 2-2-5 渦流損(Eddy Current Loss) 18 2-2-6 鄰近效應(Proximity Effect) 18 2-2-7 自感、自感作用、自感電勢(Self Induction) 18 2-3 線圈設計與溫度分佈(Temperature Distribution with Coil) 22 2-4磁場控制技術(Magnetic Flux Control Technique) 22 2-5 感應加熱的熱傳模式(Heat Transfer of Induction Heating) 24 2-5-1 傳導(Conduction) 24 2-5-2 對流(Convection) 25 2-5-3 輻射(Radiation) 26 2-6 感應加熱的應用與優點(Applications and Advantages) 27 2-6-1 感應加熱的應用(Applications of Induction Heating) 27 2-6-2 感應加熱的優點(Advantages of Induction Heating) 27 第三章 感應線圈實驗與結果 29 3-1 加熱設備與冷卻系統(Systems of Heating and Cooling) 29 3-2 紅外線熱影像儀與合成樹脂塗料(Thermal Instruments) 32 3-3 磁場集中器(Magnetic Flux Concentrator) 34 3-4 加熱線圈及工件(Heating Coil and Workpiece) 34 3-5 實驗步驟(Experiment Process) 36 3-6 實驗量測(Experiment Measure) 37 3-7 溫度均勻性分析(Temperature Uniformity Analysis) 39 3-7-1溫度均勻性分析(Description of Uniformity Analysis) 39 3-7-2 凹形均勻性分析(Uniformity Analysis for Zigzag) 40 3-7-3 矩形均勻性分析(Uniformity Analysis for Rectangle) 40 3-7-4 柵欄式均勻性分析(Uniformity Analysis for Parallel) 40 3-8 實驗過程及結果(Experiment Processes/Results) 41 3-8-1 凹形線圈(Zigzag Type Coil) 41 3-8-2 七吋矩形線圈(Rectangle Type Coil) 42 3-8-3 十四吋柵欄式線圈(Parallel Type Coil) 42 第四章 熱澆道實驗與結果 68 4-1 實驗設備(Experiment Equipments) 68 4-2 量測儀器及位置(Measure Instruments/Position) 72 4-3 實驗步驟(Experiment Processes) 74 4-4 實驗過程及結果(Experiment Process/Results) 76 4-4-1 單層線圈(Single Coil-Layer) 77 4-4-2 雙層線圈(Two Coil-Layers) 77 第五章 田口式實驗計畫法 91 5-1 簡介(Introduction) 91 5-2 田口方法實驗設計(Experiment Design Methods) 92 5-3 實驗結果與資料分析(Experiment Results/Data Analysis) 96 5-3-1 實驗結果(Experiment Results) 96 5-3-2 因子反應分析(Factor Response Analysis) 96 5-3-3 最佳設計組合與預測值(Prediction) 96 5-3-4 確認實驗(Confirmation) 97 5-4 凹形線圈實驗結果比較(Comparison) 97 第六章 結論與未來展望 109 6-1 結論(Conclusions) 109 6-2 未來展望(Future Work) 109 參考文獻 110 索引 113 作者自介 118

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