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系統識別號 U0026-3108202015170400
論文名稱(中文) 基於射嘴壓力曲線之射出成型自適應品質監控系統之研究
論文名稱(英文) Study of an Online Monitoring Adaptive System for Injection Molding Process Based on Nozzle Pressure Curve
校院名稱 成功大學
系所名稱(中) 機械工程學系
系所名稱(英) Department of Mechanical Engineering
學年度 108
學期 2
出版年 109
研究生(中文) 范姜嘉辰
研究生(英文) Jia-Chen Fan-Jiang
學號 N16074132
學位類別 碩士
語文別 中文
論文頁數 76頁
口試委員 指導教授-黃聖杰
口試委員-李輝煌
口試委員-彭信舒
口試委員-朱孝業
中文關鍵字 射出成型  壓力曲線  射出壓力峰值  黏度因子  保壓切換位置  射出速度  自適應調控系統  統御曲線 
英文關鍵字 Injection Molding Process  Pressure Curve  Pressure Peak  Viscosity Index  Switchover Position  Injection Speed  Adaptively adjustment system  Master Curve 
學科別分類
中文摘要 射出成型是一極為非線性之製程,有許多因素會對產品品質造成影響,其中因環境變化所造成熔膠壓力不同會直接影響其材料性質,使其在長時間生產下會造成產品品質不穩定之現象,而熔膠壓力所衍生出的各種相關參數都和產品品質有重大的關聯,因此需要透過自適應控制來進行關鍵參數調控來解決此問題。
本文定義產品重量為產品品質指標,並以穩定產品重量為最主要目標,由相關實驗以及文獻發現射出過程中射出壓力峰值和黏度因子與產品重量有相關的趨勢,藉由此關係瞭解到讓不同模次產品壓力曲線維持穩定便能掌握產品品質穩定,因此本文建立了一套自適應調控系統並結合在前置實驗所得出的統御曲線,經由線上量測射嘴端熔膠壓力,從熔膠壓力中擷取峰值,並即時計算黏度因子。擷取射出過程相關資訊後,與統御曲線比對來判斷此模次品質是否合格,若合格參數不變,而在不合格的情況下,系統會回饋經修改後的保壓切換位置以及射出速度等參數到射出機台以穩定產品品質,由實驗就果發現配合系統之機台在長時間生產狀況下,仍能使產品品質維持在合格範圍內並保持產品品質之一致性。
在本文的實驗中也驗證了自適應調控系統的可行性,使用自適應系統控制的狀況下,能有效調整每一模次適當之保壓切換位置以及射出速度,以此穩定每一模次的產品品質,其產品品質表現優於無使用系統之狀況,並能在不使用模內相關感測器的狀況下,也能讓產品重量的變異係數降低至0.05%,使射出成型機台能夠自適應調控並維持一定品質之要求。
英文摘要 Injection molding is a popular process for mass production of polymer products, but due to the characteristics of the injection process, there are many factors that will affect product quality in long fabrication processes. Therefore, it is critical to find the parameters most highly related to products and to use adaptive adjustment systems to control these parameters. In this study, product weight is defined as product quality, where the purpose of the system is to maintain variations in the product weight. Based on the literature review and the preliminary experiment, it was found that the peak pressure and viscosity index have a strong relationship with product weight. This relationship can be used to obtain the master curve that can be used in the adaptive adjustment system.
In this study, the relationship between product weight and specific parameters were used to build an adaptive adjustment system, and the master curve obtained from the preliminary experiment was used to be the algorithm of the system, if the quality of the product is qualified, the parameter will not change; if the quality is unqualified, then the system will adjust the correct injection speed and switchover position to machine depending on the master curve. With this system, an injection molding machine can sustain good quality during long fabrication processes.
In this thesis, a comparison of the experiment results is used to prove that the proposed system can effectively and correctly adjust the injection speed and switchover position, and can monitoring pressure data only depending on the nozzle pressure sensor. With this system, the coefficient of variation of product weight can be decreased to 0.05%.
論文目次 摘要 I
Extended Abstract III
致謝 XXIX
目錄 XXX
表目錄 XXXIII
圖目錄 XXXIV
符號說明 XXXVII
第1章 、緒論 1
1-1 前言 1
1-2 研究動機和目的 2
1-3 文獻回顧 6
1-4 文章架構 10
第2章 、理論背景 12
2-1 前言 12
2-2 射出成型過程 12
2-3 P-V-T關係 16
2-4 射出壓力曲線與統御曲線 19
2-5自適應控制 22
第3章 、實驗設備介紹 23
3-1射出成型機 23
3-2射出機控制面板 26
3-3 實驗模具 28
3-4 實驗材料 30
3-5 射嘴壓力感測器 32
3-6 擷取器 34
第4章 、前置實驗與統御曲線 36
4-1 前置實驗設計 36
4-2 保壓時間8秒之實驗結果 37
4-3保壓時間3秒和鎖模力設變實驗 40
4-4 保壓時間3秒之全因子實驗之結果 46
4-5 統御曲線決策流程 53
第5章 、自適應調控實驗 55
5-1 未使用自適應調控系統之實驗結果 57
5-2 使用自適應調控系之實驗結果 60
5-3 實驗結果分析 65
第6章 、實際產線之應用 67
6-1 應用情境 67
第7章 、結論與未來展望 68
7-1 結論 68
7-2 未來展望 69
參考文獻 71
索引 75
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