本論文針對焊道研磨的製程部分，提出線上檢測的概念，並以圖型化的方式說明檢測的結果。透過分析了機器視覺、三次元量測儀及接觸式偏角感測器的三種量測方法，最後依據焊道研磨製程的條件，選擇使用接觸式偏角感測器，來測量焊道研磨前後的工件平面度。在研磨實驗的前後，讀取機器手臂檢測路徑中的數據資料，再依時間軸圖型化分析數據，並建立平面度的檢測標準，即完成檢測焊道研磨工件的平面度。因應工業4.0(Industry 4.0)的智慧製造理念，預期提高研磨製程的完善率和建立大數據系統，期望透過數據蒐集並分析，達到高效率、高精度的研磨製程結果。本研究系統量測架構為ABB IRB 120機器手臂和METROL Sensor，路徑規劃和圖型化分析則使用ABB的RobotStudio和MATLAB完成。最後，在限制工件無法移動的條件下，建立一個不需重裝的線上量測架構和檢測平面度的判斷方式。

This thesis presents the concept of on-line measurement on weld beads in grinding process and analyze the measurement results using graphical method. Among three measuring methods including the machine vision, the coordinate measuring machine and the contact-type deflection sensor, the use of the contact-type deflection sensor is most suitable for weld beads in grinding process. There are three major steps in the grinding experiment. First, read the data from the detection path of the robot arm; second, plot the data with respect to the time; finally, determine the detection standard of grinding surface and analyze the flatness of the grinding workpiece. According to the concept of Industry 4.0, the efficiency and precision of the grinding process could be improved by collecting and analyzing the big data of the grinding system. In this study, the surface measurement system consisted of an ABB IRB 120 robotic arm and a METROL Sensor. The algorithms of path planning and graphical analysis were performed using the ABB's RobotStudio and MATLAB software, respectively. In the case of static workpiece, an on-line measurement procedure was carried out in this study to determine the flatness without reloading the tools.

目錄
第1章 序論............................................1
1.1 研究動機..........................................1
1.2 研究目的..........................................2
1.3 研究範圍..........................................2
第2章 文獻探討........................................3
2.1  機器視覺..........................................3
2.2  三次元量測儀.....................................3
2.3  偏角接觸式感測器...................................4
第3章 系統規劃..........................................6
3.1  系統架構..........................................6
3.2  系統說明..........................................7
3.3  檢測系統設備.......................................8
3.4  機器手臂路徑誤差...................................13
3.5  訊號迴路..........................................15
第4章  實驗規劃.........................................17
4.1  實驗流程..........................................17
4.2  資料說明..........................................19
4.3  預期結果..........................................21
4.4  實驗環境..........................................22
第5章  實驗結果與分析....................................23
5.1 實驗路徑............................................23
5.2 研磨前平面檢測......................................25
5.3 研磨後平面檢測......................................28
5.4 研磨前後比較分析.....................................30
5.5 量測平面度分析......................................31
第6章 結論..............................................33
6.1  結論..............................................33
6.2  未來展望...........................................33
References.............................................34

	
圖目錄
圖1.1 三次元量測儀示意圖(Coordinate Measuring Machine)………1
圖2.1 AOI系統架構………………………….…………………………………………………. .3
圖2.2 三次元量測儀………..………………………………………………………………….…4
圖2.3 直線接觸式感測器………..….……………………………………………………………5
圖2.4 偏角接觸式感測器…………………………………………...……………………………5
圖3.1 系統架構圖………….……………………….…………………………………………….6
圖3.2 焊道工件(研磨後)………………………………………………………………………….7
圖3.3 ABB IRB120 機器手臂外觀………………………………………………………………8
圖3.4 METROL CSH121A-AL 感測器外觀………………….………………………………..10
圖3.5 CSH121A-AL 偏角感測器迴路圖………………………………………………………11
圖3.6 氣動研磨工具外觀…….……………………………………………………...………….12
圖3.7 手臂路徑誤差說明圖……….…………………………………………..………………..14
圖3.8 IRB 120 I/O擴充模組示意圖…………………………………………...…………..15
圖3.9 ABB IRB 120 電控箱擴充模組線路圖…………………………………………………16
圖3.10 訊號迴路接線圖…………………………………………...……………………………16
圖4.1 實驗流程圖………...…………………………………………..…………………………18
圖4.2 輸出資料說明……….…………………………………………………...……………….19
圖4.3 資料圖型化呈現…….……..……………………………………………………………..20
圖4.4 Z軸座標差說明圖…...……………………………………………...……………………21
圖4.5 實驗環境……….…………………………………………………………………………22
圖5.1 研磨路徑模擬示意圖…….………………………………………………………………23
圖5.2 路徑起始點與結束點示意圖…….…………………………...………………………….24
圖5.3 控制器介面……….……………………………………………..………………………..25
圖5.4 實驗檢測研磨平面示意圖……...………………………………………………………..26
圖5.5 研磨前平面路徑Z軸與訊號回授示意圖…………………………………..……………26
圖5.6 第一段研磨前路徑Z軸座標與訊號回授…….……….…………………………………27
圖5.7 研磨後平面路徑與訊號回授示意圖………………….…………………………………28
圖5.8 第一段研磨後路徑Z軸座標與訊號回授…..………………………………………..29
圖5.9 研磨前後檢測路徑比較..…...…...…..…..…………………………..…..30
圖5.10 研磨前後感測器回授比較………………………………………………….…………..31
圖5.11 量測平面度分析說明……...…………………………………………..………………..32

表目錄
表3.1 ABB IRB 120規格…………..……………………………………..……………………..9
表3.2 ABB IRB 120 性能……………………………………………………………………….9
表3.3 ABB IRB 120 機器手臂工作空間範圍………………………………………………….9
表3.4 METROL CSH121A-AL 規格…….…..………………………...………………………11
表3.5 氣動研磨工具規格…….…………………………………………………………………12

References
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