超聲波焊接參數(shù)優(yōu)化實驗設計.doc

超聲波焊接參數(shù)優(yōu)化實驗設計1. 實驗目的：通過實驗的方法尋求End Cap and Housing超聲波焊接的最佳參數(shù)2. 實驗物料及設備：物料： RTP399 PC注塑產品設備：BRANSON 2000ae超聲波焊接機超聲波焊接機規(guī)格：三種模式：時間模式、能量模式、峰值功率模式焊接時間(Weld time):0.01-30 seconds 保持時間(Hold time):0.01-30 seconds振幅(Amplitude):10%-100%(機器默認狀態(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P4要求，End Cap 和Housing 經超聲波焊接機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大End Cap 和Housing 經超聲波焊接機焊接拔出力不小于20磅下降速度不當氣壓不穩(wěn)定觸發(fā)壓力不當保持時間不當焊接時間不當氣壓大小不當拔出力測試時方法不正確拔出力測試時操作不當Housing放入超聲波機夾具時操作不當裝End Cap 時員工操作不當機物夾具不當不同的模號配合不一致5. 實驗設計：1.實驗前通過以下方法來排除一些因素對實驗的影響：1.1.僅使用同一模號的End Cap與同一模號的Housing裝配（排除不同的模號配合不一致）1.2.使用同一個經過培訓合格的員工裝配End Cap和Housing（排除裝End Cap 時員工操作不當）1.3.使用同一臺超聲波焊接機和夾具（排除夾具不當和壓縮空氣濕度過大）1.4.使用同一個經過培訓合格的員工操作超聲波焊接機（排除Housing放入超聲波機夾具時操作不當）1.5.使用同一臺拔出力測試機和同一個經過培訓合格的測試員測試（排除拔出力測試時操作不當和拔出力測試時方法不正確）2.根據(jù)超聲波焊接機的工作原理可以排除以下因素對實驗的影響：2.1.下降速度：BRANSON 2000ae工作時間，焊頭下降過程中分下降和觸發(fā)兩個階段，下降階段焊頭不接觸產品，只有觸發(fā)階段焊頭才與產品發(fā)生接觸；所以下降階段速度的大小只會影響生產周期，不會影響焊接效果。3.確定實驗因子及因子水平： 通過以上因子篩選決定出氣壓大小、焊接時間、保持時間、觸發(fā)壓力四個可能影響因子。3.1.第一次實驗設計：目的：通過2-level分析決定顯著因子及因子水平：3.1.1.選擇第一次實驗因子水平：因 子現(xiàn)生產參數(shù)機床規(guī)格實驗參數(shù)(-)(+)氣壓(Weld Pressure)12-15Psi0-1001020焊接時間Weld Time0.21-0.24s0.01-30s0.10.3保持時間Hold Time0.6-0.7s0.01-30s0.50.8觸發(fā)壓力Trigger Force 1-21-24143.1.2.選擇合適的樣本大小：已知四個中心點，五個重復試驗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.實驗測得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，很明顯這次實驗測得的Full Force 成正態(tài)分布3.1.2.2.實驗因子交互作用及主效果的顯著性：上圖為單因子對Full Force的影響；三個主因子均顯著，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.三個因子兩個水平的中點所獲得的Full Force 均可能滿足客戶的需要(89牛頓)，而且Weld Pressure 過大可以引起產品外觀壓傷，Weld Time and Hold Time 過長會引起生產周期過長；所以需要再做一次實驗。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)在的生產能力計算出能滿足客戶需要的中位數(shù)(CPK=1.67)以下為PQ時的測量數(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(Target)為121牛頓.3.2.第二次實驗設計：目的：在第一次實驗的基礎上設計一個實驗，尋求最佳的參數(shù)：3.2.1.選擇第二次實驗因子水平：假如四個顯著因子均成正態(tài)分布，那么可以得到89牛頓時各因子的水平；從主效果圖可以看出四個顯著因子的中位值均能滿足客戶的需要，所以第二次實驗因子的二個水平取值如下：因 子現(xiàn)生產參數(shù)機床規(guī)格實驗參數(shù)(-)(+)(-)(+)氣壓(Weld Pressure)10200-1001115焊接時間Weld Time0.10.30.01-30s0.150.2保持時間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€中心點，一個重復試驗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):當超聲波焊接機參數(shù)設置為Weld Pressure=11.0 ；Weld Time= 0.2； Hold Time=0.65 ；Trigger Force=2.5 時焊接后產品的拔出力有92.8%的機會為123.295牛頓3.3.驗證實驗設計：目的：驗證最佳參數(shù)的可信度XWYZSide 1Side 2mid段差Full Force 序號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