運用6σ(六標準差)探討點焊時極頭與鈑件調整之良品條件的確立

Application of the 6 Sigma, to explore the welding cap tip and panel position to adjustment to best condition.

邱洪源(Hung-Yuan Chiu)

指導教授 ： 鍾雲恭

元智大學/工程學院/工業工程與管理學系/碩士(2012年)

https://doi.org/10.6838/YZU.2012.00193

摘要

依據台灣交通部所頒訂的台灣車輛安全檢測基準＆車輛型式安全審験管理法，其中規定，自2008年１月１日起，總重量2.5公噸以下的新型式M1類的車輛，以及自2009年１月１日起，總重量2.5公噸以下的各型式M1類車輛，均必須符合〝前方及側方碰撞的乘員保護〞之規定。所謂的前方及側方碰撞試驗，指的是實車碰撞試驗，有前方碰撞試驗(Frontal Collision) ，其中又分為重疊前方碰撞(Overlap)試驗與偏置前方碰撞ODB(Offset Deformable Barrier)試驗，另外還有側面碰撞試驗(Lateral Collision )，我們國內目前僅有實施後兩項。
2010年開始，所有新開發的完成車輛，不論是國產車或進口車都必須滿足歐洲經濟委員會ECE( Economic Commission for Europe)的法規要求，也就是ECE No.94及ECE No.95條。在此條款的要求下，不論是國內或國外之汽車製造廠，對於汽車結構件的焊接強度都實施嚴格的把關與管理，否則在嚴苛的認證試驗條件下是無法通過認證的，當然也就無法在市場銷售。
影響車體焊點強度的控制因素有相當的多，例如，電流、壓力、時間、分流…等，這些都是一般常在論文中為大眾所探討的影響因子，本研究雖是同樣運用6標準差的改善5步驟配合實驗設計手法的應用，但是所探討的是一般較少為人剖析的點焊極頭在執行點焊時，其位置、角度與鈑件間隙，對於汽車車體焊點強度的影響，藉由要因分析、製程能力分析、回歸方程式、反應曲面等應用，藉此找出主要影響因子的良品條件，同時進行管制，以確保汽車結構件的焊接品質及確保車體保有最佳的安全焊點強度。

關鍵字

型式安全審驗 ； 安全檢測基準 ； 實車碰撞試驗 ； 實驗設計 ； 特性要因分析法 ； 製程能力分析 ； 標準差 ； 回歸方程式 ； 反應曲面

並列摘要

According to the Examination for Vehicles Safety Testing Direction & Vehicles Safety Type Approval Management Regulations published by the Ministry of Transportation, begin in 2008 Jan 1st, all M1 type vehicles with the total weight below 2.5ton must satisfy the regulation of 〝Occupant protection of the front and the side collision〞.What we called Occupant protection of the front and the side collision, Addressed to the Frontal Collision section in the Vehicle Crash Test, which includes Overlap examination, ODB (Offset Deformable Barrier) examination, and Lateral Collision examination. Taiwan only performs ODB and Lateral Collision examination.
And from the year 2010, all newly develop finished vehicles, either domestic vehicles or imported vehicles, must satisfy regulations published by ECE (Economic Commission for Europe), which are ECE No.94 and ECE No.95. Under the demands of these regulations, either domestic or overseas car manufactures should apply severe observation and administration on welding spots intensity of the vehicles’ structure portion. Otherwise, under the extreme conditions of the certification examination, these portions would fail and the vehicle will not be able to sell into the market.
There are several control factors which would affect the intensity of the welding spots, such as electric current, pressure, time, stream...etc, these factors are frequently discussed in general dissertation. Although this research is also the application of the five steps to improve in 6- sigma with cooperate with research methodology, but this time we will discuss about welding gun position、 angle and panel gap , to affecting automotive body’s welding strength, which is less anatomized. Through Cause and Effect Diagram, Process Capability Analysis, Predicted Linear Regression Equations, Response Surface Methodology (RSM), and other practices to determine the major control factors of conditions for non-defective products, and restrain simultaneously to ensure the welding spots’ quality of vehicle structure portion and maintain the optimum safety welding spot intensity.

並列關鍵字

Vehicles Safety Type Approval Management Regulations ； Examination for Vehicles Safety Testing Direction ； Vehicle Crash Test ； Design Of Experiment ； Cause and Effect Diagram Analysis ； Process Capability Analysis ； 6 Sigma ； Predicted Linear Regression Equations ； Response Surface Methodology ； RSM

參考文獻

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