超声波焊接参数优化试验设计

.实验目的：通过实验的方法寻求EndCapandHousing®声波焊接的最佳参数.实验物料及设备：物料：RTP399PC注塑产品设备：BRANSON2000ae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(Weldtime):0.01-30seconds保持时间(Holdtime):0.01-30seconds振幅(Amplitude):10%-100%(机器默认状态为100%)触发(TriggerForce):1-24下降速度(DownSpeed):10-15.客户要求：根据客户图纸01-00237-00版本号P4要求，EndCap和Housing经超声波焊接机焊接后拔出力不小于20磅力(ForcetoremoveEndCapformHousingtobeatleast20pounds)1磅力=4.45牛顿所以20磅力=89牛顿.可能影响焊接后拔出力的因素(鱼骨图).实验设计：.实验前通过以下方法来排除一些因素对实验的影响：仅使用同一模号的EndCap与同一模号的Housing装配(排除不同的模号配合不一致)使用同一个经过培训合格的员工装配EndCap和Housing(排除装EndCap时员工操作不当)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)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)

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）.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：下降速度：BRANSON2000ae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。.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(-)(十)气压(WeldPressure)12-15Psi0-1001020焊接时间WeldTime0.21-0.24s0.01-30s0.10.3保持时间HoldTime0.6-0.7s0.01-30s0.50.8触发压力TriggerForce1-21-24143.1.2.选择合适的样本大小：已知四个中心点，五个重复试验Minitab>Stat>DOE>Factorial>CreateFactorialDesignStdOrderRunOrderCenterPtBlocksWeldPressureWeldTimeHoldTimeTriggerForcePullForce(Unit:N)MarkinEndCapW子压伤)48111200.30.84117.0X24211200.30.81152.981301150.20.652.554.912411200.30.54121.2

78511200.10.84113.552611200.30.51216.184701150.20.652.5180.1X55811100.30.81244.0X32911200.30.84164.0X231011100.30.81181.7771111100.10.84106.1371211100.10.8173.1111311100.30.54204.3X711411100.30.81248.3X281511200.30.54155.1161611200.30.84223.1151711100.30.84121.9701811200.10.81132.5641911200.30.8487.7312011100.30.84193.0X192111100.30.51169.9X582211200.10.54291.5672311100.30.51121.8X792411100.30.84190.0X402511200.30.81221.6X412611100.10.54189.2512711100.30.5128.5X72811100.30.81241.5X82911200.30.81219.2X273011100.30.54157.9453111100.10.8481.1353211100.30.5175.2X693311100.10.81278.8393411100.30.8142.4563511200.30.81229.0543611200.10.81127.2803711200.30.8482.4333811100.10.519.5763911200.30.54127.8X824001150.20.652.5114.9294111100.10.8423.7724211200.30.81209.6604311200.30.5442.2754411100.30.54138.4X834501150.20.652.583.514611100.10.5119.3464711200.10.8450.0224811200.10.8171.4534911100.10.8124.165011200.10.8138.9435111100.30.54187.0255211100.10.5499.6X595311100.30.54139.2X55411100.10.8132.4215511100.10.8133.4205611200.30.5177.7105711200.10.54199.9615811100.10.8478.8

665911200.10.51107.2446011200.30.54170.2X96111100.10.5475.3686211200.30.51221.4X346311200.10.5163.7576411100.10.5428.9386511200.10.8110.6176611100.10.5128.2136711100.10.8486.1496811100.10.5160.946911200.30.51127.2427011200.10.54126.4507111200.10.51103.8627211200.10.8471.0187311200.10.5130.4147411200.10.84191.0367511200.30.51273.7X747611200.10.54114.337711100.30.51141.5477811100.30.84184.2657911100.10.5157.7308011200.10.84119.228111200.10.5150.0268211200.10.5469.3638311100.30.84121.5X738411100.10.54118.4第一次DOE数据分析口回区实验测得FullForce数据的正态分布分析:Minitab>Stat>BasicStatistics>NormalityTest口回区PSProbPlul:PullFwrut(StDcJ71.3133g：DarinqNormmlixT对A-3quareStDcJ71.3133g：DarinqNormmlixT对A-3quared：fJ03CF-U3ILE：U.JULIPullForce(上图为正态分布图，很明显这次实验测得的FullForce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:|^|Va.inLEffects£dfPtJ.LFsrce(MainEffectsPlot(datameans)forPullForce(*Contorocinl)省£三d160-145J13aJ115T100「Q皆(J3©方mIkwsicpressurweldTimeHoldTimeTngcerbcrc上图为单因子对FullForce的影响；三个主因子均显著，且均在高水平获得大的FullForce,Rweldtime>Rweldpressure>RHoldtime>RTriggerforce.Minitab>Stat>DOE>Factorial>FactorialPlots二3七电aro,uti口tlTlctforEuJJL?ere*InteractionPlot(datameans)forPullForce(WeldPrcs5Lr-20«1D■"r一一f，—1M-—*■WaldTiTe■ns♦0.11・11L--■-*K-_一'一f・一1HoldTime■JO•0.5TriggerFon38SO190eo上图为父互作用图，WeldTime与HoldTime,WeldTime与TriggerForce父互作用显者.WeldTime显著性受HoldTimeandTriggerForce交互作用的混淆.MainEffectsPlotfarPullForce(MainEffectsPlot-DataMeansforPullForce(WeldPressur160-HoldTimeTriggerForeWeldPressur160-HoldTimeTriggerForeWeldTime三个因子两个水平的中点所获得的FullForce均可能满足客户的需要（89牛顿），而且WeldPressure过大可以引起产品外观压伤，WeldTimeandHoldTime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FullForce(Unit:Pounds)FullForce(Unit:N)FullForce(Unit:Pounds)FullForce(Unit:N)147.18209.952126.67118.68238.08169.462234.3152.641335.96160.022343.8194.91433.93150.992443.89:195.311553.36237.452540.81181.6：655.23245.772641.28183.7750.13223.082745.98；204.611842.11187.392847.11209.6938.53171.462934.46153.351059.76265.933050.621225.26]1148.48215.743156.49251.38

1259.7265.673242.97191.221339.03173.68133:31.8141.511434.85155.083427.35121.711546.72207.93548.05213.821626.78119.17136:50.84226.24]1743.86195.183750.37224.151842.34188.413843.74194.641942.96191.17n39152.88235.3212028.08124.964055.92248.84DescriptiveStatistics:FullForce(Unit:N)VariableNMeanMedianTrMeanStDevSEMeanFullFor40193.17194.77193.2639.906.31VariableMinimumMaximumQ1Q3FullFor118.68265.93162.38223.88CPK=Min(USL-u)/36or(u-LSL)/36u=1.67*3*6.31+89=31.6131则USL=153LSL=89Mean=121，所以目标(Target)为121牛顿.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：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(WeldPressure)10200-1001115焊接时间WeldTime0.10.30.01-30s0.150.2保持时间HoldTime0.50.80.01-30s0.520.65触发压力TriggerForce141-2412.5选择合适的样本大小：已知四个中心点，一个重复试验Minitab>Stat>DOE>Factorial>CreateFactorialDesignStdOrderRunOrderCenterPtBlocksWeldPressureWeldTimeHoldTimeTriggerForceFullForce(Unit:N)5111110.150.65172.8784211150.20.521136.6691311110.150.521130.55511411110.20.522.5147.377

20501130.1750.5851.5170.2373611110.20.521109.9859711110.150.522.589.88216811150.20.652.5146.96510911150.150.522.5133.662121011150.20.522.5148.396181101130.1750.5851.5165.441131211110.150.652.5129.904151311110.20.652.5123.295171401130.1750.5851.5164.42921511150.150.521186.84381611150.20.651150.82861711150.150.651129.538141811150.150.652.5146.4571911110.20.651179.265192001130.1750.5851.5140.084Minitab>Stat>DOE>Factorial>Responseoptimizer

当超声波焊接机参数设置为WeldPressure=11.0;WeldTime=0..2；HoldTime=0.65;TriggerForce=2.5时焊接后产品的拔出力有92.8%的机会为123.295牛顿验证实验设计：目的：验证最佳参数的可信度XWYZSide1Side2mid段差FullForce序号0.45+/0.250.45+/0.250.45+/0.250.45+/0.250.78+/0.300.78+/0.300.70+/0.30.01/0.25MIN89.910.36270.44330.44890.31120.65720.77940.7234-0.1444120.290720.36480.51680.53250.33440.65240.83510.7440-0.1444162.809730.28830.43370.55480.32730.66810.85080.7060-0.1368207.100240.38710.49450.50920.31920.66810.80470.7288-0.0983183.438550.37240.47120.50870.31110.63010.81180.7511-0.0907130.570460.39520.53200.48640.33390.64530.82700.6908-0.0988149.887370.28070.40230.49400.37240.63770.85790.7136-0.0836133.247280.47120.59280.45600.28880.70600.76680.7738-0.1069129.844190.39520.50920.51680.31870.68320.81940.7288-0.0765182.2151100.41040.57760.48590.29590.66760.77430.7673-0.0603171.3155110.28170.40280.56290.39470.63010.88060.6529-0.0760115.7359120.31920.46360.49450.31920.64530.82750.7136-0.0836114.0201130.44080.61560.49400.30450.62250.83510.7288-0.0907145.5650140.40280.59280.50920.26600.66810.85030.7136-0.1064131.0278150.42510.57000.47070.26550.62250.83510.7592-0.0836143.0927160.43320.57760.48640.29640.63010.80420.7592-0.0831127.0973

170.34200.53150.50210.25130.66810.85030.7445-0.0836132.5504180.28120.49400.51680.30400.67620.78140.7136-0.0983125.8468190.35720.51730.48690.27310.67570.80470.7743-0.0684155.3988200.25080.38000.53910.36530.62960.85080.6377-0.0684144.6695210.41850.52440.49400.26600.69080.83510.7668-0.0456143.2674220.41040.57760.51730.28880.66000.81230.7819-0.0993171.1369230.38760.53200.50870.28070.6529