倒車雷達感測外殼精密鍛造成形技術之開發

經濟的繁榮、交通建設的便利，汽車成為現今的社會不可或缺的代步工具，隨著汽車產業的高速發展，汽車的數量逐年增加，駕駛員在駕車時的視野範圍是很有限的，透過車內和外側的反光鏡可以大幅度提高駕駛員的視野範圍，但對於車正後方的障礙物以及高度不足以通過反光鏡看到的或者距離車身過近的障礙物都可能處於駕駛員的視野死角或者視野模糊區中。因此，人們對汽車操縱的便利性提出了更高的要求，希望有種裝置能夠解決汽車倒車時給人們帶來的不便，於是倒車雷達就此誕生並廣泛運用。倒車雷達的主要功能是在倒車時，利用超音波量測距原理，由裝置於車尾保險槓上的超音波感測器發送超音波，超音波遇到障礙物後反射至超音波感測器，從而計算出車體與障礙物之間的實際距離，因此感測探頭外殼的設計相當重要，它關係到超音波發射與接收影響著感測器計算出實際距離的準確度。本研究以開發倒車雷達探測頭外殼之金屬成形製造為重心，市面上的金屬探頭加工法為CNC電腦車床切削加工占大宗，但隨著汽車加裝倒車雷達的普及化產品需求量增加生產速度與製造成本成為重要的考量因素，故本文以鍛造加工方式用AL-6082鍛造出金屬感測探頭外殼藉此改善生產速度與製造成本。本研究流程由產品設計開始，經模具設計、模具開發與製造、鍛造成形、成品比對等過程，首先設計較佳的感測探頭外型並規劃開發出適合的成形模具，再以材料試驗獲得AL-6082之材料性質，並將材料數據帶入有限元素金屬成形分析，分析過程進行不同的參數設定(不同胚料、不同摩擦、不同持壓、不同背壓等)透過分析結果，獲得預估的鍛造時所需之成形力、產品成形性、材料應力大小與分佈狀況作為開發模具之依據，最後實際鍛造出探頭外殼成品。本文運用一道次鍛造加工法期望能達到縮短加工時間、價低材料成本並提高生產量為目標，來滿足龐大的市場需求量。

關鍵字

倒車雷達感測外殼； AL-6082 ；鍛造；有限元素軟體

並列摘要

Owing to the booming economy in booming global economy, as well as simple convenience, most people rely on automobiles for transportation. With the rapid development of the Taiwanese automobile industry, the number of vehicles is increasing each year. However, the design of modern automobiles severely limits driver vision. It could markedly improve drivers’ field of view through the car within and outside of the mirror UNCLEAR TRY Design changes can significantly improve driver field of vision both internally and externally. However, for obstacles immediately behind the car, obstacles located too close to the ground or car to be visible in the mirror can create dead spots and poor visibility areas that limit driver vision to see through the mirror or distance of obstacles is too close to the car may be in drivers’ vision dead ends and blurry vision area UNCLEAR. Therefore, people higher demand in convenience of vehicle handling and expect a system to make reversing more convenient UNCLEAR TRY Given the visibility problems associated with current automobile design, consumers increasingly demand more convenient vehicle handling – including systems for increasing the convenience of reversing. The parking sensor thus has been developed and widely applied. The parking sensor uses ultrasound principles to measure distance when reversing. Ultrasound signals are transmitted from an ultrasound sensor installed on the rear of the bumper. When encountering an obstacle, the ultrasound reflex to UNCLEAR sends a signal to the ultrasound sensor. The ultrasound uses this signal to measure the distance between the vehicle and the obstacle. For this reason, the design of the sensor shell is very important, and involves issues of ultrasound transmission and reception. Additionally, the design of the sensor shell affects sensor which count accuracy of actual distance TRY distance sensors. This study emphasizes [the development of parking sensor shell and metal forming manufacture TRY metal forming manufacture and the development of parking sensor shell. MAYBE CNC lathe cutting devices are the major machinery applied in metal sensor shell manufacture. However, as installing parking sensor is widespread and product requirements are increasing, [producing speed and manufacture prime cost became the most essentially considerate event UNCLEAR TRY faster and more cost effective manufacturing of parking sensors is becoming increasingly important. This article [talks about OR discusses] using Forging AL-6082 to forge a metal sensor shell to improve production speed and manufacturing costs. The research begins from product design, then moves through die design, exploitation and manufacture, before proceeding to finished product contrast, etc UNCLEAR TRY other aspects like a comparison of finished products. First, this study attempts to design an improved sensor shell and plans the development of suitable forging die. Next, this study obtains the material properties of AL-6082 from material testing. Additionally, limited element metal forming analysis is performed, including analysis of material data. The analysis process involved different parameter settings (e.g., different billet, friction, holding time, counter pressure, etc.). To obtain the expected required stress when forging, forging products and material stress-effective situations regard as were regarded as die exploitation basis being performed on a die exploitation basis] based on the analytical results. To forging concrete finished products of sensor shell in the end. This study applied single pass forging to shorten manufacturing time, lower material costs and increase production quantity to satisfy huge market demand.