本研究開發一油中鐵顆粒濃度之線上自動檢測裝置，此裝置包含三個單元，分別為鐵顆粒濃度量測單元、驅動單元以及顯示單元。鐵顆粒濃度量測單元採用霍爾IC進行量測，只需啟動電源驅動單元便將量測單元向前推移開始量測鐵顆粒濃度。鐵顆粒被吸附於磁極間隙時，磁極間隙處之磁通密度改變。位於磁極間隙之霍爾IC輸出霍爾電壓訊號，此霍爾電壓訊號再經過轉換成為鐵顆粒濃度。最後經由顯示單元顯示鐵顆粒濃度。
鐵顆粒濃度量測單元使用自行調配八種不同濃度之樣品油進行校正。經過多次檢測後得知，鐵顆粒濃度量測單元之誤差小於8.8 ppm。之後運用此裝置量測放電加工液中之鐵顆粒濃度，並探討油中鐵顆粒濃度對加工後工件表面粗糙度以及材料移除率之影響。實驗結果得知，於200 ppm時更換放電加工液可維持較好之加工品質及加工效率。
此裝置應用於鐵顆粒濃度線上檢測，已可於機械設備運作的情況下檢測油中鐵顆粒濃度，可節省大量取樣樣品油所花費的時間。此裝置可準確量測油中鐵顆粒濃度。使用者可得知準確更換油之時機，節省大量加工成本。且經多次量測後得知線上鐵顆粒濃度之誤差小於10 ppm。本研究結果可以說明機械設備加裝線上檢測裝置，可有效提升加工效率，並改善加工品質。

The on-line automatic detection device of ferrous debris concentration in oils is developed in this study. This device contains three units, each of which is measurement unit of the ferrous debris concentration, drive unit and displayer unit. Measurement unit of the ferrous debris concentration adopts Hall IC. Then start the power supply the drive unit will push the measurement unit to measure the ferrous debris concentration. When ferrous debris are captured at the gap between the poles of the magnet, the magnetic flux of magnetic poles is changed. The Hall IC is located in the magnetic poles gap to output the hall voltage signal which is converted into iron particles concentration. Finally, the ferrous debris concentration is displayed via the display unit.
The ferrous debris concentration is calibrated using given 8 different concentrations. The maximum error of measurement unit of the ferrous debris concentration is less than 8.8 ppm under numerous tests. The ferrous debris concentrations in EDM fluid are detected using this device, and the effect of ferrous debris concentration on surface roughness of the machined workpieces and material removal rate is investigated. Experimental results show that the replacement of EDM fluid at 200 ppm can maintain better processing quality and processing efficiency.
This device is used for on-line ferrous debris concentration detection. This device can be detected the ferrous debris concentration in oils in the operation of mechanical equipment. It can save lots of time to sample the sample oil. This device can accurately measure the ferrous debris concentration in the oil. The user can know the timing of the exact replacement of oil, and then save lots of processing costs. The maximum error of on-line ferrous debris concentration detection is less than 10 ppm under numerous tests. The results of this study can show that on-line detection device installed in mechanical equipment can improve the processing efficiency and quality.

論文審定書 i
誌謝 ii
摘要 iii
Abstract iv
目錄 v
圖次 viii
表次 xi
第一章 緒論 1
1.1 研究背景 1
1.2 文獻回顧 3
1.3 環狀磁鐵設計 12
1.4 放電加工液中之鐵顆粒濃度檢測 13
1.5 研究目的 15
第二章 檢測裝置之設計與製作 16
2.1 鐵顆粒濃度量測單元之設計與製作 18
2.1.1 鐵顆粒濃度量測方法 18
2.1.2 磁鐵設計 20
2.1.3 鐵顆粒濃度量測單元之製作 21
2.2 驅動單元之設計與製作 26
2.2.1 電磁吸盤 26
2.2.2 被吸引桿件之設計 28
2.3 被吸引桿被吸引力比較 33
2.4 顯示單元 34
2.4.1 訊號轉換 34
2.4.2 顯示單元電路 35
2.5 檢測裝置操作流程與數據擷取 39
第三章 檢測結果與討論 41
3.1 霍爾IC元件之選擇與磁極強度之關係 41
3.1.1 樣品油製備 41
3.1.2 霍爾IC元件比較 42
3.1.3 磁極設定 44
3.2 量測元件校正與量測範圍 46
3.4 鐵顆粒濃度 47
3.4.1 量測訊號波形 47
3.4.2 重現性測試與校正曲線 49
第四章 油中鐵顆粒濃度之檢測 51
4.1 實驗設備 52
4.2實驗材料 54
4.3實驗材料前處理 55
4.4 實驗條件設定 56
4.5 實驗流程 57
4.5.1 非線上量測流程 57
4.5.2 線上量測流程 59
4.6 檢測結果 63
4.6.1 非線上檢測結果 63
4.6.2 線上檢測結果 70
4.6.3 加工時間、加工量與鐵顆粒濃度之關係 72
第五章 結論與未來展望 74
5.1 結論 74
5.2 未來展望 75
參考文獻 76

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