帶鋸機之智能化的關鍵技術研發

帶鋸機是將工件加工成適合尺寸以利後續製程作精密加工的主要工具機。不同工件材料的參數選用及鋸帶壽命預估以增進切削效益及防止鋸帶斷在貴重之工件材料中，一直是帶鋸機業界及使用者的重大挑戰。在智慧生產的趨勢下，使用各種感測器監控製程，再以大數據分析巨大資料庫做為決策依據是目前的一個重要趨勢。本研究的目標在於展示基於製程的瞭解及關鍵感測器的開發製作，應用極少的感測器來監控製程，就可以達到智慧製造的目的。進刀切削力是本研究使用之龍門帶鋸機中製程的關鍵，首先找出可以在原設計之下加裝進刀力量感測器的位置，接著使用分析軟體設計製作高強健度的結構強度與高靈敏度的應變之力量感測器。接著裝置感測器於機台上進行進刀力量、鋸帶齒型磨耗及加工表面粗度的相關性研究。實驗結果發現，此感測器分可以有效應用於帶鋸機台上，進刀力量的激烈上升與一個鋸切過程中的進刀力量震幅劇烈增加是鋸帶壽命終結的表徵。磨耗量測結果顯示刀面與刀腹變鈍時，會對排屑以及鋸切的工件造成影響。鋸帶的使用會造成鋸帶齒型磨耗與工件表面粗糙度的上升。鋸帶使用的時間增長，馬達電流值也會跟著上升但趨勢較不明顯。鋸帶進刀力量的即時監控、齒型磨耗的觀察及工件表面的粗糙度量測可以是鋸帶壽命預估的表徵。根據不同帶鋸機的規格需求及工件材料成本可以選用不同的方法作為監控的技術。建立不同工件材料及加工條件下的鋸帶進刀力量資料庫是提供兼顧切削效益及鋸帶壽命之優化加工參數組合的重要依據。將進刀力量感測器與控制器結合成回饋控制系統，可以提供不同形狀工件之穩定進刀力量，測試結果顯示甚至在極端型鋼的切削中也可以控制相對穩定的進刀力量。在穩定切削之下，一個工件切削製程之進刀力量振幅也相對減少，可以提升鋸帶壽命。

關鍵字

監控；感測器；智慧製造；帶鋸機；壽命

並列摘要

Band sawing is one of the preferred methods used to cut off raw materials into customer ordered pieces for the following precision manufacturing. Currently the choice of operation parameters to cut different material and the duration to replace a band saw rely on human experience. The advent of high strength, hard to cut material and the drive for high efficiency make it a compelling issue to develop a systematic method to determine the operation parameters for sawing and the assessment of usage duration of a band saw blade. The wave of smart manufacturing propels the widely use of various sensors to monitor the manufacturing process. Big Data Analytics is then employed to deduce the vast volume of data collected from sensors into information for decision making. This study is aimed to elaborate that insight of the manufacturing process and novel design of the sensor can effectively monitor the manufacturing process without large amount of sensors and the resulting vast data. Further, relating the collected data to other essential phenomena of sawing process can provide a data base for the choice of operation parameters under different saw cutting conditions. A downward force needed to advance the band saw during cutting is a key factor for saw cutting. This study developed a force sensor to monitor the downward cutting force of sawing. The implement of this sensor leads to a powerful methodology for the operation of band sawing and the assessment of the life duration of a band saw. A comprehensive stress-strain analysis enables the design of a robust sensor with high sensitivity. An industry grade packaging allows the use of this sensor in a harsh cutting environment. Our cutting tests indicate that this sensor can reliably measure the cutting force exerting on the band saw. The average cutting force and the amplitude of force variation during one cutting process increase as the band saw blade near the end of its effective cutting duration. The increasing cutting usage of a band saw and thereby more resulting wear of the saw blade also lead to higher roughness of the surface of the cutting piece. Moreover, our investigation reveals that maintaining a stable downward cutting force is pivotal to reduce wear and thereby increase the life duration of a band saw. A feedback control together with force measurement makes possible a stable force exerting on the band saw during cutting even under challenging conditions. This study leads to a powerful methodology for effective, efficient band saw cutting and longer life duration of a band saw.

並列關鍵字

Sensor ； Smart Manufacturing ； Bandsaw ； Monitor ； Life

參考文獻

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帶鋸機之智能化的關鍵技術研發

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