機械設備的運轉須使用潤滑系統，檢測潤滑油的品質與污染物仍為現今工業裡重要的一環，實驗室先前對此開發出一套油中鐵顆粒濃度之線上自動檢測裝置，使其能即時得知機械設備之運轉狀況，可及早預防機械設備的損壞。該裝置之檢測原理為磁通量檢測法，但是該裝置之霍爾感測器與檢測準確度仍嫌不足，有待改善。因此本研究探討不同霍爾感測器對檢測準確度之影響，最終選用的感測器W135，結果顯示當鐵顆粒濃度為800ppm時，其霍爾電壓差值可達88mV，相較於先前使用的AH49E的8mV，其靈敏度增加達約11倍。
進行放電加工液檢測前，先使用八種不同鐵顆粒濃度之樣品油進行校正，結果顯示其量測誤差皆小於5 ppm。再進行非線上鐵顆粒濃度檢測，當加工量為2000mg時，W135之霍爾電壓值為83mV，相較於AH49E的16mV，其靈敏度增加達約5倍。進行線上鐵顆粒濃度檢測時，W135之霍爾電壓值為80mV，比AH49E之4.2mV高達19倍。結果顯示W135之霍爾感測器遠比AH49E靈敏許多。最後對加工液中的鐵顆粒進行分析，改善裝置的準確度與穩定性。
本研究並改善檢測裝置的顯示單元使其更適合應用於智慧製造工程。使用微控制器Ardunio編譯後搭配LCD面板，可即時顯示油品的鐵顆粒濃度值，且可使用藍芽設備傳送鐵顆粒濃度值至智慧型手機上，達成即時監控油品的品質，使機械設備操作者能簡單觀察機械設備的磨耗狀況。

The operation of mechanical equipment requires the use of a lubrication system. The detection of the quality and contamination of lubricants remains an important part of today's industry. Our laboratory has previously developed an online automatic detection device for the concentration of iron particles in the oil, so that it can instantly know the operation status of the mechanical equipment and prevent the damage of mechanical equipment at an early stage. The detection principle of the device was the magnetic flux detection method, but the Hall sensor and the detection accuracy of the device were still insufficient and need to be improved. Therefore, this study explored the effect of different Hall sensors on the accuracy of detection. The sensor W135 was selected. Results showed that when the iron particle concentration was 800ppm, the Hall voltage difference could achieve 88mV. Compared with the previous results used the sensor AH49E where the Hall voltage difference was 8mV, its sensitivity was increases by about 11 times.
Prior to the detection of the EDM fluid, the calibration was performed using eight different iron particle concentrations. Results showed that the measurement errors were less than 5 ppm. For the non-line detection, when the removal amount was 2000 mg, the Hall voltage value of W135 was 83 mV, which was about 5.18 times higher than that of AH49E (16 mV). For on-line detection, the Hall voltage difference of W135 was 80mV, which is 19 times higher than the 4.2mV of AH49E. Results showed that the W135 Hall sensor was much more sensitive than the AH49E. Finally, the ferrous debris in the EDM fluid was analyzed to improve the accuracy and stability of the device.
This study also improved the display unit of the detection device to make it more suitable for intelligent manufacturing engineering. After compiled the microcontroller “Ardunio”, it matched with the LCD panel, so that the iron particle concentration value of the oil could be instantly displayed in the smart phone using the Bluetooth device to instantly monitor the quality of the oil. The operator could simply observe the wear condition of the mechanical equipment.

論文審定書 i
誌謝 ii
摘要 iii
Abstrat iv
目錄 v
圖次 viii
表次 xiii
第一章 緒論 1
1. 1研究背景 1
1. 2文獻回顧 2
1.2.1 鐵相分析技術之概述 2
1.2.2非線上(off-line)鐵相分析的發展 3
1.2.3線上(On-line)鐵相分析儀之發展 7
1.2.4 C型磁鐵的設計 22
1. 3油中之鐵顆粒濃度檢測技術 23
1.4研究動機 26
第二章 檢測裝置介紹與理論 27
2.1 油中鐵顆粒濃度檢測裝置 27
2.1.1檢測裝置 27
2.2 霍爾元件之選擇 36
2.2.1霍爾元件之介紹 36
2.2.2霍爾元件之選擇 38
2.3 霍爾元件於無鐵顆粒吸附時之訊號測試 47
2.3.1 AH49E 在三種固定磁場下的訊號範圍 47
2.3.2 W135在三種固定磁場下的訊號範圍 48
2.3.3 W315在三種固定磁場下的訊號範圍 50
2.4 霍爾元件之比對 52
2.4.1 AH49E 在三種不同磁場下所量測到的霍爾電壓差之比較 52
2.4.2 W135 在三種不同磁場下所量測到的霍爾電壓差之比較 53
2.4.3 W315 在三種不同磁場下所量測到的霍爾電壓差之比較 55
2.4.4 三種霍爾元件磁場在1000高斯下所量測到的霍爾電壓差之比較 58
2.4.5 三種霍爾元件磁場在2000高斯下所量測到的霍爾電壓差之比較 59
2.4.6 三種霍爾元件磁場在3000高斯下所量測到的霍爾電壓差之比較 60
2.5 磁鐵之設定與比對 61
2.5.1 C型磁鐵之設定 61
2.5.2 C型磁鐵之比對 64
第三章 實驗設備與實驗方法 65
3.1 實驗設備 66
3.1.1放電加工機 66
3.1.2 放電加工之加工液循環系統 67
3.1.3實驗用儀器 68
3.2 實驗材料之特性與前處理 70
3.2.1 實驗之工件材料 70
3.2.2 實驗之工具電極 71
3.2.3 實驗之放電加工液 72
3.2.4 實驗用材料之前處理 72
3.2.5樣品油之製備與處理 73
3.3實驗之流程 78
3.3.1實驗條件設定 78
3.3.2非線上檢測之實驗流程 79
3.3.3 線上檢測之實驗流程 81
3.4 檢測裝置之顯示單元改善 83
3.4.1訊號之轉換 83
3.4.2顯示單元之電路設計 84
3.4.3 顯示單元之PCB板製作 89
3.4.4顯示單元結果呈現 91
第四章 實驗結果與討論 92
4.1非線上檢測結果 92
4.1.1鐵顆粒濃度非線上檢測結果 92
4.1.2鐵顆粒之粒徑與成分分析 94
4.2線上檢測結果 97
4.2.1鐵顆粒於流體中受力情形 98
4.2.2鐵顆粒濃度線上檢測結果 99
第五章 結論與未來展望 103
5.1結論
5.2未來展望 104
參考文獻 105

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