建立降低保險桿射出生產週期製程參數之研究

A Study on Constructing the Process Parameters in Reducing Injection Cycle Time for Bumper Production

孫東照(Tung-chao Sun)

國立虎尾科技大學/工程學院/機械與機電工程研究所/碩士(2007年)

摘要

近年來在全球化的浪潮下，汽車零組件市場的競爭在國際上日趨激烈，加上大陸市場的興起，各汽車零組件廠無不加速提升本身的競爭力，除了市場銷售的佔有率，成本上的考量也是不可忽視的要素。因此，本研究之目的在於降低射出生產的週期，透過田口式實驗設計建構出最適化的製程參數模式，以提供射出成型週期改善的參考。在研究中，以公司生產編號HD04096的保險桿為實驗案例，並以射出成型條件、模具、原料三大方面選取實驗因子，實驗因子包括安全門關、中子入、關模、射出、計量、開門開模、中子出、押出進(擊桿頂出)、頂出系統、冷卻系統、原料流動率等11個因子。透過田口實驗法L12直交法與現場實作結果，分析研判並建立可達到降低保險桿射出生產週期的模式。並以此模式作為生產可發現，射出生產週期的時間由原本120秒降至約61秒，此改善模式大大提升生產效率，相對之下，可降低生產成本。

並列摘要

Due to globalization, the competition of automobile aftermarket tends to become intensively and fast. Except that, the rise and affiliation of mainland china make the factory owners to raise their competitiveness. In addition to focus the market share, it is also an important issue to think about the cost down. Therefore, the purpose of this study is attempting to reduce the circle time of injection process for bumper production. Using Taguchi’s method to construct the proper process parameters and their levels combinations offering the obtained results to improve injection cycle time.

In this research, taking the bumper coded HD04096 as a study case and choosing the injection conditions, tooling and material as the influential factors. The process factors include door close, hydraulic cylinder in, tooling close, injection, loading, door and tooling open, hydraulic cylinder return, extrusion, ejector system, cooling system and melt index. After constructing a Taguchi L12 orthogonal array and performing experiments, it is sufficiently to analyze and construct a cycle time method. Based on this method to produce a bumper in workshop and it is found that the cycle time may be reduced from 120 to 61 seconds. In other words, it greatly increases the company’s competitiveness.

參考文獻

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