汽缸壁拋光專用機之設計與驗證研究

對類似於割草機用之小型汽缸內壁的拋光加工而言，目前尚無專用之機器設備，因此，本研究以創新設計的手法來開發一台雙軸之拋光加工機器設備，以滿足此工業上之特殊功能需求。本研究著重以創新設計程序產生設計構想，並將構想製作出原型機後，進行實驗驗證。在創新設計方面，本研究利用有系統的發想程序(設計方法)，包括「溫故知新」、「無中生有」之創新思維，從工程規範之訂定，透過手繪構想草圖及3D之CAD 模型等呈現構想，且確認構想之可行性，並且繪製工程圖，從而開發完成具有高速轉軸(可達轉速12,000 rpm)之拋光機的變速箱原型。且原型機經跑合測試後，證實符合拋光機之整機設計所設定的原預期目標與工程規範。另外，本研究所研發之原型機使用本實驗室所發展之非線性隔振元件，成功隔離振動源。在實驗驗證方面，本研究係以田口法分析，以實驗設計之手法利用設備之振動量為指標，經由實驗訊號之分析，找出提升原型機性能之因子與改善方式，經多次實驗分析後，診斷出造成振動之原因，主要以對心不準與軸質量平衡，最為顯著;且經反覆直交表搜尋最佳化之改良組合，相較於改善前之實驗一與實驗二，分別改善了24％與35％，確實改善機器之性能，降低原型機之振動量。且實驗分析過程中，嘗試使用不同指標，找尋更靈敏指標因子，來突顯效果之靈敏度。以上，本研究創新之處為使用創新設計方法、引用非線性隔振元件，且於實驗分析時嘗試使用不同指標，完成設計、製作拋光機之變速箱原型與驗證。

關鍵字

汽缸拋光機；創新設計；設計程序；田口法；最佳化；高速傳動軸

並列摘要

At present, the polishing processing for inner wall of the cylinder of small volume engines (like lawnmower) still lacks for special equipment. Therefore ,the research is to develop a double-spindle machine for polishing with innovative method, in order to satisfy with this industrial need specially. The thesis focuses on innovate thinking – create new ideas with “process of innovation design”, prototype is produced from ideas and verification . On the aspect of innovation design, the research utilized a systematical concepts process (design methodology) that generates creative ideas for conceptual design, including “Wen-Gu-Zhe-Xin(溫故知新)” and “Wu-Zhong-Sheng-You(無中生有)” of innovate thinking. Meanwhile, from the making of engineering specifications, draft sketches and 3D CAD models were used to display possible solutions and thus verify the feasibilities of those ideas. Moreover, design procedure drawing thus the prototype of the Power Transmission Box for high-speed of 12,000 rpm is designed and manufactured. After the test run, the prototype(Power Transmission Box) can fulfill the initial goal and engineering specifications of the machine for polishing of the cylinder. In addition, the non-linear elements that developed in the NTUT lab. has also introduced to proto-unit for isolating the possible vibrations nearby. On the aspect of experiment, the research adopted “Taguchi’s Method” to find out the factor and method of improving prototype’s performance via the signal analysis of index utilizing experiment design method, and vibration of the machine is used as an index. After several tests and analysis, the causes of vibration has been found out by diagnosis which are mainly resulted from the misalignment and balance of the spindle. And after searching for the improved parameters of optimization by repeatedly using Orthogonal Array, compared with Exp.1 and Exp.2, is improved to 24％ and 35％ individually. The performance is improved and the vibration is reduced definitely. During the signal analysis, different indexes are used to search for more sensitive index factor and emphasize the sensitivity of effects. The research is innovative in “concepts process”, “using non-linear elements” and “different indexes (during signal analysis)”. The thesis achieves in design and production of “the Power Transmission Box of Polishing Machine”and verification .

並列關鍵字

Polishing Machine ； Innovation Design ； Process ； Taguchi’s Method ； Optimization ； High-speed Transmission

參考文獻

7.林佑諦，全電式無導柱射出成形機之設計與開發，碩士論文，國立成功大學，2003。

30.ASME B17c-1927.

40.Joseph Edward Shigley and Charles R Mischke, Mechanical engineering design, New York : McGraw-Hill , 1989.

1.W.L. Li, J. J. Tsai, S. Tseng, and I. F. Young,"Generation of New Ideas for Product Functions and Engineering Innovation Practices:A Hands-on Project Model for Machatronics Education," Exploring Innovation in Education and Research ,Tainan, Taiwan, 2005.05.