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Design and Prototyping of a Real-Time Measurement System for Precision Steel Ball
|關鍵字:||Precision Steel Ball;精密鋼珠;Real-Time Measurement;eddy current;即時量測;渦電流||出版社:||機械工程學系||摘要:||
Steel ball is one of the most fundamental elements for power transmission components. Its precision directly affects the performance of these components. Technologies for real-time in-line inspection of precision steel balls are thus highly demanded for in-process quality control. This research is aimed for developing a real-time measurement system for such purpose. The goal is to develop a low-cost and non-contact measurement instrument for fast and robust on-line inspection with accuracy higher than 5m. The research started with the requirements of steel balls for industrial bearings. With their fabrication processes considered, possible measurement methods and required resolution of sensors are investigated. The eddy current sensing technology is selected under such considerations as it also provides high-speed measurement required for real-time in-process inspection. Mechanisms of the inspection platform and signal conditioners are then designed based on the measurement methods and the requirements. Virtual instruments software is designed and developed for mechatronics integration. The developed system is then tested to verify its robustness, accuracy and stability.
The tested signal to noise (S/N) ratio of the developed system is over 200, showing the high robustness of the system. The standard deviation to mean ratio (/) for single steel ball is 0.04% that showed high repeatability of the measurement. Linear regression of measured data with different distance between the probe and the ball also showed high linearity as the linearity index R2L of the regression is higher than 0.999. Further tests with five different-size standard steel balls showed high repeatability as the standard deviations of all measurements are within 0.002V. Linear regressions of measured data showed high linearity for balls of different sizes as R2Ls of regressions are higher than 0.995. These tests showed that the accuracy of the developed system is within 5m with standard deviation within 2m. The gauge repeatability and reproducibility (GR&R) tests, based on ISO 16949 and ISO 9000 standards, of the system with a 9.5261 (3/8”) diameter standard steel ball are further conducted. The results showed that part variation, total variation, and six sigma tolerance are 0.00006, 0.00025 and 0.00083 respectively. Total percentage of GR&R is 28.83 which implied the developed inspection system is satisfactory according to the standards. These tests verified that the system is capable for real-time in-process inspection of precision steel balls as well as for final inspection of grade 100 bearing steel balls with acceptable resolution, accuracy, repeatability and robustness.
|Appears in Collections:||機械工程學系所|
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