超聲波焊接參數(shù)優(yōu)化實(shí)驗(yàn)設(shè)計(jì).doc

超聲波焊接參數(shù)優(yōu)化實(shí)驗(yàn)設(shè)計(jì)1. 實(shí)驗(yàn)?zāi)康模和ㄟ^(guò)實(shí)驗(yàn)的方法尋求End Cap and Housing超聲波焊接的最佳參數(shù)2. 實(shí)驗(yàn)物料及設(shè)備：物料： RTP399 PC注塑產(chǎn)品設(shè)備：BRANSON 2000ae超聲波焊接機(jī)超聲波焊接機(jī)規(guī)格：三種模式：時(shí)間模式、能量模式、峰值功率模式焊接時(shí)間(Weld time):0.01-30 seconds 保持時(shí)間(Hold time):0.01-30 seconds振幅(Amplitude):10%-100%(機(jī)器默認(rèn)狀態(tài)為100%)觸發(fā)(Trigger Force):1-24下降速度(Down Speed):10-153. 客戶要求：根據(jù)客戶圖紙01-00237-00 版本號(hào)P4要求，End Cap 和Housing 經(jīng)超聲波焊接機(jī)焊接后拔出力不小于20磅力(Force to remove End Cap form Housing to be at least 20 pounds )1磅力=4.45牛頓 所以20磅力=89牛頓4. 可能影響焊接后拔出力的因素(魚骨圖)環(huán)境法人壓縮空氣濕度過(guò)大End Cap 和Housing 經(jīng)超聲波焊接機(jī)焊接拔出力不小于20磅下降速度不當(dāng)氣壓不穩(wěn)定觸發(fā)壓力不當(dāng)保持時(shí)間不當(dāng)焊接時(shí)間不當(dāng)氣壓大小不當(dāng)拔出力測(cè)試時(shí)方法不正確拔出力測(cè)試時(shí)操作不當(dāng)Housing放入超聲波機(jī)夾具時(shí)操作不當(dāng)裝End Cap 時(shí)員工操作不當(dāng)機(jī)物夾具不當(dāng)不同的模號(hào)配合不一致5. 實(shí)驗(yàn)設(shè)計(jì)：1.實(shí)驗(yàn)前通過(guò)以下方法來(lái)排除一些因素對(duì)實(shí)驗(yàn)的影響：1.1.僅使用同一模號(hào)的End Cap與同一模號(hào)的Housing裝配（排除不同的模號(hào)配合不一致）1.2.使用同一個(gè)經(jīng)過(guò)培訓(xùn)合格的員工裝配End Cap和Housing（排除裝End Cap 時(shí)員工操作不當(dāng)）1.3.使用同一臺(tái)超聲波焊接機(jī)和夾具（排除夾具不當(dāng)和壓縮空氣濕度過(guò)大）1.4.使用同一個(gè)經(jīng)過(guò)培訓(xùn)合格的員工操作超聲波焊接機(jī)（排除Housing放入超聲波機(jī)夾具時(shí)操作不當(dāng)）1.5.使用同一臺(tái)拔出力測(cè)試機(jī)和同一個(gè)經(jīng)過(guò)培訓(xùn)合格的測(cè)試員測(cè)試（排除拔出力測(cè)試時(shí)操作不當(dāng)和拔出力測(cè)試時(shí)方法不正確）2.根據(jù)超聲波焊接機(jī)的工作原理可以排除以下因素對(duì)實(shí)驗(yàn)的影響：2.1.下降速度：BRANSON 2000ae工作時(shí)間，焊頭下降過(guò)程中分下降和觸發(fā)兩個(gè)階段，下降階段焊頭不接觸產(chǎn)品，只有觸發(fā)階段焊頭才與產(chǎn)品發(fā)生接觸；所以下降階段速度的大小只會(huì)影響生產(chǎn)周期，不會(huì)影響焊接效果。3.確定實(shí)驗(yàn)因子及因子水平： 通過(guò)以上因子篩選決定出氣壓大小、焊接時(shí)間、保持時(shí)間、觸發(fā)壓力四個(gè)可能影響因子。3.1.第一次實(shí)驗(yàn)設(shè)計(jì)：目的：通過(guò)2-level分析決定顯著因子及因子水平：3.1.1.選擇第一次實(shí)驗(yàn)因子水平：因 子現(xiàn)生產(chǎn)參數(shù)機(jī)床規(guī)格實(shí)驗(yàn)參數(shù)(-)(+)氣壓(Weld Pressure)12-15Psi0-1001020焊接時(shí)間Weld Time0.21-0.24s0.01-30s0.10.3保持時(shí)間Hold Time0.6-0.7s0.01-30s0.50.8觸發(fā)壓力Trigger Force 1-21-24143.1.2.選擇合適的樣本大?。阂阎膫€(gè)中心點(diǎn)，五個(gè)重復(fù)試驗(yàn)MinitabStatDOEFactorialCreate Factorial DesignStd OrderRun OrderCenter PtBlocksWeld PressureWeld TimeHold TimeTrigger ForcePull Force (Unit:N)Mark in End Cap(帽子壓傷)48111200.30.84117.0 X24211200.30.81152.9 81301150.20.652.554.9 12411200.30.54121.2 78511200.10.84113.5 52611200.30.51216.1 84701150.20.652.5180.1 X55811100.30.81244.0 X32911200.30.84164.0 X231011100.30.81181.7 771111100.10.84106.1 371211100.10.8173.1 111311100.30.54204.3 X711411100.30.81248.3 X281511200.30.54155.1 161611200.30.84223.1 151711100.30.84121.9 701811200.10.81132.5 641911200.30.8487.7 312011100.30.84193.0 X192111100.30.51169.9 X582211200.10.54291.5 672311100.30.51121.8 X792411100.30.84190.0 X402511200.30.81221.6 X412611100.10.54189.2 512711100.30.5128.5 X72811100.30.81241.5 X82911200.30.81219.2 X273011100.30.54157.9 453111100.10.8481.1 353211100.30.5175.2 X693311100.10.81278.8 393411100.30.8142.4 563511200.30.81229.0 543611200.10.81127.2 803711200.30.8482.4 333811100.10.519.5 763911200.30.54127.8 X824001150.20.652.5114.9 294111100.10.8423.7 724211200.30.81209.6 604311200.30.5442.2 754411100.30.54138.4 X834501150.20.652.583.5 14611100.10.5119.3 464711200.10.8450.0 224811200.10.8171.4 534911100.10.8124.1 65011200.10.8138.9 435111100.30.54187.0 255211100.10.5499.6 X595311100.30.54139.2 X55411100.10.8132.4 215511100.10.8133.4 205611200.30.5177.7 105711200.10.54199.9 615811100.10.8478.8 665911200.10.51107.2 446011200.30.54170.2 X96111100.10.5475.3 686211200.30.51221.4 X346311200.10.5163.7 576411100.10.5428.9 386511200.10.8110.6 176611100.10.5128.2 136711100.10.8486.1 496811100.10.5160.9 46911200.30.51127.2 427011200.10.54126.4 507111200.10.51103.8 627211200.10.8471.0 187311200.10.5130.4 147411200.10.84191.0 367511200.30.51273.7 X747611200.10.54114.3 37711100.30.51141.5 477811100.30.84184.2 657911100.10.5157.7 308011200.10.84119.2 28111200.10.5150.0 268211200.10.5469.3 638311100.30.84121.5 X738411100.10.54118.4 3.1.2.第一次DOE數(shù)據(jù)分析3.1.2.1.實(shí)驗(yàn)測(cè)得Full Force 數(shù)據(jù)的正態(tài)分布分析：MinitabStatBasic StatisticsNormality Test 上圖為正態(tài)分布圖，很明顯這次實(shí)驗(yàn)測(cè)得的Full Force 成正態(tài)分布3.1.2.2.實(shí)驗(yàn)因子交互作用及主效果的顯著性：上圖為單因子對(duì)Full Force的影響；三個(gè)主因子均顯著，且均在高水平獲得大的Full Force, R weld time R weld pressure R Hold time R Trigger force .MinitabStatDOEFactorial Factorial Plots 上圖為交互作用圖，Weld Time 與Hold Time ,Weld Time 與Trigger Force 交互作用顯著. Weld Time顯著性受Hold Time and Trigger Force 交互作用的混淆.三個(gè)因子兩個(gè)水平的中點(diǎn)所獲得的Full Force 均可能滿足客戶的需要(89牛頓)，而且Weld Pressure 過(guò)大可以引起產(chǎn)品外觀壓傷，Weld Time and Hold Time 過(guò)長(zhǎng)會(huì)引起生產(chǎn)周期過(guò)長(zhǎng)；所以需要再做一次實(shí)驗(yàn)。3.1.3.求中位數(shù) 已知客戶要求拔出力不小于20磅力(89牛頓);以現(xiàn)在的生產(chǎn)能力計(jì)算出能滿足客戶需要的中位數(shù)(CPK=1.67)以下為PQ時(shí)的測(cè)量數(shù)據(jù)Full Force (Unit:Pounds)Full Force (Unit:N)Full Force (Unit:Pounds)Full Force (Unit:N)147.18209.952126.67118.68238.08169.462234.3152.64335.96160.022343.8194.91433.93150.992443.89195.31553.36237.452540.81181.6655.23245.772641.28183.7750.13223.082745.98204.61842.11187.392847.1209.6938.53171.462934.46153.351059.76265.933050.62225.261148.48215.743156.49251.381259.7265.673242.97191.221339.03173.683331.8141.511434.85155.083427.35121.711546.72207.93548.05213.821626.78119.173650.84226.241743.86195.183750.37224.151842.34188.413843.74194.641942.96191.173952.88235.322028.08124.964055.92248.84Descriptive Statistics: Full Force (Unit:N)Variable N Mean Median TrMean StDev SE MeanFull For 40 193.17 194.77 193.26 39.90 6.31Variable Minimum Maximum Q1 Q3Full For 118.68 265.93 162.38 223.88CPK=Min (USL-u)/3 or (u-LSL)/3u =1.67*3*6.31+89=31.6131則USL=153 LSL=89 Mean=121,所以目標(biāo)(Target)為121牛頓.3.2.第二次實(shí)驗(yàn)設(shè)計(jì)：目的：在第一次實(shí)驗(yàn)的基礎(chǔ)上設(shè)計(jì)一個(gè)實(shí)驗(yàn)，尋求最佳的參數(shù)：3.2.1.選擇第二次實(shí)驗(yàn)因子水平：假如四個(gè)顯著因子均成正態(tài)分布，那么可以得到89牛頓時(shí)各因子的水平；從主效果圖可以看出四個(gè)顯著因子的中位值均能滿足客戶的需要，所以第二次實(shí)驗(yàn)因子的二個(gè)水平取值如下：因 子現(xiàn)生產(chǎn)參數(shù)機(jī)床規(guī)格實(shí)驗(yàn)參數(shù)(-)(+)(-)(+)氣壓(Weld Pressure)10200-1001115焊接時(shí)間Weld Time0.10.30.01-30s0.150.2保持時(shí)間Hold Time0.50.80.01-30s0.520.65觸發(fā)壓力Trigger Force 141-2412.53.1.2.選擇合適的樣本大?。阂阎膫€(gè)中心點(diǎn)，一個(gè)重復(fù)試驗(yàn)MinitabStatDOEFactorialCreate Factorial Design Std OrderRun OrderCenter PtBlocksWeld PressureWeld TimeHold TimeTrigger ForceFull Force(Unit:N)5111110.150.65172.8784211150.20.521136.6691311110.150.521130.55511411110.20.522.5147.37720501130.1750.5851.5170.2373611110.20.521109.9859711110.150.522.589.88216811150.20.652.5146.96510911150.150.522.5133.662121011150.20.522.5148.396181101130.1750.5851.5165.441131211110.150.652.5129.904151311110.20.652.5123.295171401130.1750.5851.5164.42921511150.150.521186.84381611150.20.651150.82861711150.150.651129.538141811150.150.652.5146.4571911110.20.651179.265192001130.1750.5851.5140.084MinitabStatDOEFactorialResponse optimizer 最佳參數(shù):當(dāng)超聲波焊接機(jī)參數(shù)設(shè)置為Weld Pressure=11.0 ；Weld Time= 0.2； Hold Time=0.65 ；Trigger Force=2.5 時(shí)焊接后產(chǎn)品的拔出力有92.8%的機(jī)會(huì)為123.295牛頓3.3.驗(yàn)證實(shí)驗(yàn)設(shè)計(jì)：目的：驗(yàn)證最佳參數(shù)的可信度XWYZSide 1Side 2mid段差Full Force 序號(hào)0.45+/-0.250.45+/-0.250.45+/-0.250.45+/-0.250.78+/-0.300.78+/-0.300.70+/-0.30.01/-0.25MIN89.910.36270.44330.44890.31120.65720.77940.7234-0.1444120.290720.36480.51680.53250.33440.65240.83510.7440-0.1444162.809730.28830.43370.55480.32730.66810.85080.7060-0.1368207.100240.38710.49450.50920.31920.66810.80470.7288-0.0983183.438550.37240.47120.50870.31110.63010.81180.7511-0.0907130.570460.39520.53200.48640.33390.64530.82700.6908-0.0988149.887370.28070.40230.49400.37240.63770.85790.7136-0.0836133.247280.47120.59280.45600.28880.70600.76680.7738-0.1069129.844190.39520.50920.51680.31870.68320.81940.7288-0.0765182.2151100.41040.57760.48590.29590.66760.77430.7673-0.0603171.3155110.28170.40280.56290.39470.63010.88060.6529-0.0760115.7359120.31920.46360.49450.31920.64530.82750.7136-0.0836114.0201130.44080.61560.49400.30450.62250.83510.7288-0.0907145.5650140.40280.59280.50920.26600.66810.85030.7136-0.1064131.0278150.42510.57000.47070.26550.62250.83510.7592-0.0836143.0927160.43320.57760.48640.29640.63010.80420.7592-0.0831127.0973170.34200.53150.50210.25130.66810.85030.7445-0.0836132.5504180.28120.49400.51680.30400.67620.78140.7136-0.0983125.8468190.35720.51730.48690.27310.67570.80470.7743-0.0684155.3988200.25080.38000.53910.36530.62960.85080.6377-0.0684144.6695210.41850.52440.49400.26600.69080.83510.7668-0.0456143.2674220.41040.57760.51730.28880.66000.81230.7819-0.0993171.1369230.38760.53200.50870.28070.65290.83510.7364-0.0760155