- 學位論文
雨刷系統之故障分析程序建立與工具發展及應用
Fault Analysis Procedures, Tool Development and Application for Wiper System
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摘要
雨刷系統為汽車的重要組件之一，雨刷與馬達組件運轉所產生的振動噪音問題愈來愈受重視。本文針對雨刷與運轉馬達之部件進行振動與噪音之分析與診斷，分為四個主題進行研究。針對雨刷膠條的橡膠材料，經由拉伸試驗取得的應變應力曲線，本研究發展圖像自動化辨識程式模組。可得到應變率及對應應力之數據，並進行曲線嵌合，以獲得超彈性材料模型的參數，可成功應用於雨刷在不同下壓力之變形與刷拭角度分析。針對實車有雨刷刷拭噪音的案例影片，建立雨刷刷拭異音之特徵分析程序。探討雨刷的運作情形，分析其噪音之特徵頻率，並整理特徵頻率對應的噪音種類，發現同類型異音之頻譜特性皆有良好對應。未來連結雨刷刷拭的邊界與工況，可探討不同因素對聲音特徵之影響，以改善刷拭噪音問題。針對雨刷馬達進行振動耐久試驗時，馬達外殼出現裂縫的失效案例。本研究探討振動試驗失效之雨刷馬達改善程序，透過實驗量測振動響應，確認失效原因來自共振。再建立等效於實際結構之雨刷馬達分析模型，以分析馬達引發共振的結構模態，確認外殼裂縫與模態振型之應力集中位置相關。最後進行設計變更改善斷裂部位，並驗證設計變更之可行性，也通過振動試驗。針對三種故障雨刷馬達，包括：蝸桿蝸輪、軸承及換向器，建立噪音與振動的量測、分析、診斷程序。由量測馬達之噪音與三軸向振動訊號，進行時頻、時間波形與頻譜分析，可以區別出馬達不同故障之特徵，也建立雨刷馬達三種故障形式的噪音與振動特徵之分析方法與工具程式。本研究對雨刷系統中，膠條與馬達之振動噪音議題，建立量測分析診斷程序，發展對應的分析工具與應用，有助於雨刮膠條與馬達的設計開發與產品改善。
並列摘要
The wiper system is one of the important components of car, and noise and vibration generated by the wiper and motor components have attracted much attention. This work focuses on noise and vibration analysis and diagnosis of the wiper and the running motor components, and conducts four project studies. For the rubber material of the wiper strip, the strain-stress curve can be obtained through the tensile test. This work develops an automatic image recognition program module. The data of strain rate and corresponding stress can be obtained, and the curve fitting can be performed to obtain the parameters of the hyperelastic material model, which can be successfully applied to the analysis of the deformation and wiping angle of the wiper under different forces. From the video of real car with windshield wiper noise, the analysis procedure of windshield wiper noise is established. By examining the operation of the wiper, the characteristic frequency of its noise is analyzed and sorted out different types of noise. It is found that the spectral characteristics of the same type of abnormal sound have a good correspondence. In the future, linking the wiper boundaries and working conditions, one can explore the influence of different factors on the sound characteristics, so as to improve the wiping noise problem. A failure case where cracks appeared in the motor housing during the vibration durability test for the wiper motor. This study discusses the improvement procedure of the wiper motor that fails in the vibration test. Through the experimental measurement of the vibration response, it is confirmed that the cause of the failure comes from resonance. The analysis model of the wiper motor is then constructed equivalent to the actual structure to analyze the structural mode of the resonance caused by the motor. This also confirms that the shell crack is related to the stress concentration position of mode shape. Finally, the design modification is carried out to improve the fractured part. The feasibility of the design change is verified, and the vibration test is also passed. For three kinds of faulty wiper motors, including worm gear, bearing and commutator, the measurement, analysis and diagnosis procedures of noise and vibration are established. By measuring the noise and tri-axial vibration signals of the motor, the time-frequency, time waveform and spectrum analysis can be performed to distinguish the characteristics of different motor faults. The analysis method and tool program are also established to characterize noise and vibration of the three fault types of the wiper motor. This work establishes the measurement, analysis and diagnosis procedures to deal with the noise and vibration of wiper system, and develops corresponding analysis tools for practical applications, which will help the design and development of the wiper system and product improvement.
參考文獻
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