太陽能板之超音波金屬連續熔接機研發及其加工參數研究

The Design and Fabrication of Continuous Ultrasonic Welding Machine for Solar Plate and Its Processing Parameters

李青鴻(Ching-Hung Li)

指導教授 ： 許坤明

國立虎尾科技大學/工程學院/機械與電腦輔助工程系碩士班/碩士(2012年)

https://doi.org/10.6827/NFU.2012.00132

摘要

本研究為研發出可焊接10公分以上太陽能板之超音波金屬連續熔接機，可調式的機台設計可符合不同尺寸大小太陽能板之加工。此機台主要利用超音波傳動子連接聲波焊頭，透過聲波焊頭之放大位移效應，將此振動能量傳遞到加工鋁條上，而鋁條與太陽能板之熔接面產生摩擦，而瞬間產生擴散接合，達到超音波金屬熔接之效果。
此外，超音波金屬熔接加工效率，重點在於聲波焊頭之設計，聲波焊頭之優劣會影響到加工效果，因此本論文使用ANSYS有限元素分析軟體，針對廠商所提供的資料進行聲波焊頭分析與設計，藉由有限元素分析軟體進行模態分析求得模型自然頻率值分佈情形，再利用田口法求得符合設計之目標值，找出聲波焊頭最佳尺寸參數，並模擬進行比對。最後利用頻率量測儀對最佳化後聲波焊頭進行實際量測，結果顯試測得頻率為34.8KHz，並符合模擬分析值。在聲波焊頭加工上也能大幅節省尺寸修正的試誤時間，並能提升焊頭效能。
最後使用此機台來進行加工測試，配合光學式顯微鏡及拉伸試驗機，在不同熔接參數條件下，研究超音波熔接後之影響，再以田口法找出最佳製程參數及加工因子之貢獻率，以提升加工品質。

關鍵字

聲波焊頭 ； 擴散接合 ； 有限元素分析 ； 模態分析 ； 田口法

並列摘要

This study developed a continuous ultrasonic welding machine for solar plates that exceed 10 cm, and the adjustable machine design can fulfill processing for solar palates of various sizes. This machine mainly uses ultrasonic boosters to connect to the horns. Through the amplification displacement effects of the horns, the vibration energy is transferred to the processing aluminum bars, which rub against the welding surface of the solar plates causing friction and instantly generate diffusion bonding, thereby achieving ultrasonic welding.
In addition, the processing efficiency of ultrasonic welding depends on the horn design, the quality of which influences the processing effects. In this study, ANSYS finite element analysis software was used to analyze the horn data provided by manufacturers and to design new horns. Finite element analysis software was also used to perform model analysis to determine the natural frequency value distribution of the model. The Taguchi method was employed to determine a suitable target value for the design and to identify the optimal horn size parameters. Then, a simulation was conducted to compare these values. Finally, a frequency meter or measuring instrument was used to measure the optimized horn, obtaining a frequency of 34.8 kHz, which matched the simulation value. The results show that the new model effectively reduces the time spent correcting the horn size using trial-and-error methods and improves horn performance regarding horn processing.
A processing test for the new model was performed using an optical microscope and a tensile testing machine. Under various welding parameters, the effects of ultrasonic welding were investigated. The Taguchi method was employed to identify the optimal process parameters and processing element contribution rates to improve the processing quality.

並列關鍵字

Horns ； Diffusion Bonding ； Finite Element Method ； Model Analysis ； Taguchi Method

參考文獻

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