本研究提出一套新的聲學振動偵測系統檢測精密型沖壓模具失效情形，其方法為使用低成本的商用微機電麥克風模組監控連動精密型沖壓機台。精密型沖壓機台的沖壓訊號相當微弱，故以永久磁鐵磁將微機電麥克風模組磁吸於精密型沖壓機台模具的下模，如此一來振動訊號便可以金屬塊作為介質直接傳遞至微機電麥克風的音孔，有效阻隔高負載組件或環境噪音的干擾。接收到的振動類比訊號會以專業錄音介面轉換為數位訊號，訊號取樣率為96 kHz以確保在錄製過程中沖擊訊號未被略過。為了辨識精密型沖壓機的單一工作循環訊號，將蒐集到的訊號轉換為20 Hz到40 kHz的頻譜圖。工作循環訊號以視覺被辨識挑選出後，將5 kHz到10 kHz的功率譜密度疊加並轉換為分貝單位。此計算方法可增加沖壓特徵訊號的強度，而背景雜訊的強度則相對削弱，微弱的沖壓訊號可被凸顯出來以便觀察。正常負載破壞的實驗結果顯示，沖壓瞬間的訊號由主要由兩個訊號構成：撞擊訊號及撕裂訊號，由於在精密衝壓的條件中，沖壓截面的撕裂區愈小愈好，故亦可藉由撕裂訊號的成長回推沖頭的使用狀況，故沖頭的磨耗狀況可藉由訊號的組成型態判別，撕裂訊號愈大沖頭磨耗愈嚴重。在另一組使用不同精密沖壓機台的實驗中，機台在過負載的條件下進行破壞實驗，經觀察發現25 kHz至30 kHz的高頻諧波總功率和磨耗程度呈正相關，可作為後續研究參考。此論文研究的偵測系統可有效提升精密型沖壓機的加工良率，並提供一套具有普及可能性新偵測方法。

The thesis presents an acoustic detective system to continuous monitoring of micro-stamping failure utilizing low-cost commercial MEMS microphone modules. A MEMS microphone module is fixed on the bottom die plate with a permanent magnet to receive acoustic signals via metal conduction such that the tiny punch signals can be discriminated out of a noisy machining environment. A commercial audio recorder was used for recording the acoustic signals and converting the analog signals into digital signals at a sampling rate of 96 kHz. The collected signals are converted into frequency spectrum (20 Hz~40 kHz), so the signals of stamping processes can be recognized visually and picked out. The signals are then analyzed with a proposed power spectra density algorithm for the frequency between 5 kHz to 10 kHz. Therefore, background noise and low-frequency vibrations can be excluded to interfere the tiny micro-punch signal. Results show that the punch signal is constructed with a strike signal and a fracture signal during the normal load failure experiment. The strength of the fracture signal grows as the area of the fracture zone expand which also represent the defect level of the punch. Another experiment which provides over load condition to the machine shows that the total power among 25 kHz to 30 kHz is a lot associate with the defect condition as well. The developed method has the potential to predict the abnormal punches created by a defective punch pin. The new method reported in the present study has shown its potentials in Industry 4.0 applications.

論文審定書 i
中文摘要 ii
Abstract iii
目錄 iv
圖目錄 vi
符號表 ix
第一章 緒論 1
1.1研究背景 1
1.2震動感測元件 2
1.2.1加速規 2
1.2.2工業麥克風 5
1.2.3聲發射震動檢測 6
1.3震動聲學訊號分析 7
1.3.1包絡檢波分析 7
1.3.2小波分析 11
1.3.3聲壓 14
1.3.4聲強 15
1.4精密型沖壓沖切面解析 16
1.5研究動機與目的 18
1.6論文架構 19
第二章 實驗方法與架構 20
2.1微機電麥克風 20
2.1.1微機電麥克風模組製程簡介 22
2.1.2微機電麥克風模組一致性測試 23
2.2訊號分析與觀察 24
2.3訊號頻譜繪製 26
2.3.1音框分割 26
2.3.2窗函數取樣 28
2.3.3短時距傅立葉轉換 30
2.4功率譜密度疊加 32
2.5精密型沖壓系統工作循環檢測 33
2.6量測位置比較 36
2.7系統架設與實驗設備 39
第三章 實驗結果與討論 41
3.1 板材厚度比較 41
3.2 正常負載破壞檢測 44
3.3 過度負載破壞檢測 49
第四章 結論與未來展望 61
4.1 結論 61
4.2 未來展望 62
參考文獻 63
自述 69

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