超声波焊接参数优化实验设计.doc

超声波焊接参数优化实验设计1. 实验目的：通过实验的方法寻求End Cap and Housing超声波焊接的最佳参数2. 实验物料及设备：物料： RTP399 PC注塑产品设备：BRANSON 2000ae超声波焊接机超声波焊接机规格：三种模式：时间模式、能量模式、峰值功率模式焊接时间(Weld time):0.01-30 seconds 保持时间(Hold time):0.01-30 seconds振幅(Amplitude):10%-100%(机器默认状态为100%)触发(Trigger Force):1-24下降速度(Down Speed):10-153. 客户要求：根据客户图纸01-00237-00 版本号P4要求，End Cap 和Housing 经超声波焊接机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牛顿 所以20磅力=89牛顿4. 可能影响焊接后拔出力的因素(鱼骨图)环境法人压缩空气湿度过大End Cap 和Housing 经超声波焊接机焊接拔出力不小于20磅下降速度不当气压不稳定触发压力不当保持时间不当焊接时间不当气压大小不当拔出力测试时方法不正确拔出力测试时操作不当Housing放入超声波机夹具时操作不当装End Cap 时员工操作不当机物夹具不当不同的模号配合不一致5. 实验设计：1.实验前通过以下方法来排除一些因素对实验的影响：1.1.仅使用同一模号的End Cap与同一模号的Housing装配（排除不同的模号配合不一致）1.2.使用同一个经过培训合格的员工装配End Cap和Housing（排除装End Cap 时员工操作不当）1.3.使用同一台超声波焊接机和夹具（排除夹具不当和压缩空气湿度过大）1.4.使用同一个经过培训合格的员工操作超声波焊接机（排除Housing放入超声波机夹具时操作不当）1.5.使用同一台拔出力测试机和同一个经过培训合格的测试员测试（排除拔出力测试时操作不当和拔出力测试时方法不正确）2.根据超声波焊接机的工作原理可以排除以下因素对实验的影响：2.1.下降速度：BRANSON 2000ae工作时间，焊头下降过程中分下降和触发两个阶段，下降阶段焊头不接触产品，只有触发阶段焊头才与产品发生接触；所以下降阶段速度的大小只会影响生产周期，不会影响焊接效果。3.确定实验因子及因子水平： 通过以上因子筛选决定出气压大小、焊接时间、保持时间、触发压力四个可能影响因子。3.1.第一次实验设计：目的：通过2-level分析决定显著因子及因子水平：3.1.1.选择第一次实验因子水平：因 子现生产参数机床规格实验参数(-)(+)气压(Weld Pressure)12-15Psi0-1001020焊接时间Weld Time0.21-0.24s0.01-30s0.10.3保持时间Hold Time0.6-0.7s0.01-30s0.50.8触发压力Trigger Force 1-21-24143.1.2.选择合适的样本大小：已知四个中心点，五个重复试验MinitabStatDOEFactorialCreate Factorial DesignStd OrderRun OrderCenter PtBlocksWeld PressureWeld TimeHold TimeTrigger ForcePull Force (Unit:N)Mark in End Cap(帽子压伤)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数据分析3.1.2.1.实验测得Full Force 数据的正态分布分析：MinitabStatBasic StatisticsNormality Test 上图为正态分布图，很明显这次实验测得的Full Force 成正态分布3.1.2.2.实验因子交互作用及主效果的显著性：上图为单因子对Full Force的影响；三个主因子均显著，且均在高水平获得大的Full Force, R weld time R weld pressure R Hold time R Trigger force .MinitabStatDOEFactorial Factorial Plots 上图为交互作用图，Weld Time 与Hold Time ,Weld Time 与Trigger Force 交互作用显著. Weld Time显著性受Hold Time and Trigger Force 交互作用的混淆.三个因子两个水平的中点所获得的Full Force 均可能满足客户的需要(89牛顿)，而且Weld Pressure 过大可以引起产品外观压伤，Weld Time and Hold Time 过长会引起生产周期过长；所以需要再做一次实验。3.1.3.求中位数 已知客户要求拔出力不小于20磅力(89牛顿);以现在的生产能力计算出能满足客户需要的中位数(CPK=1.67)以下为PQ时的测量数据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则USL=153 LSL=89 Mean=121,所以目标(Target)为121牛顿.3.2.第二次实验设计：目的：在第一次实验的基础上设计一个实验，寻求最佳的参数：3.2.1.选择第二次实验因子水平：假如四个显著因子均成正态分布，那么可以得到89牛顿时各因子的水平；从主效果图可以看出四个显著因子的中位值均能满足客户的需要，所以第二次实验因子的二个水平取值如下：因 子现生产参数机床规格实验参数(-)(+)(-)(+)气压(Weld Pressure)10200-1001115焊接时间Weld Time0.10.30.01-30s0.150.2保持时间Hold Time0.50.80.01-30s0.520.65触发压力Trigger Force 141-2412.53.1.2.选择合适的样本大小：已知四个中心点，一个重复试验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 最佳参数:当超声波焊接机参数设置为Weld Pressure=11.0 ；Weld Time= 0.2； Hold Time=0.65 ；Trigger Force=2.5 时焊接后产品的拔出力有92.8%的机会为123.295牛顿3.3.验证实验设计：目的：验证最佳参数的可信度XWYZSide 1Side 2mid段差Full Force 序号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