隨著筆記型電腦朝向輕薄化與高密度設計發展，電子連接器的微型化趨勢對其結構強度與組裝精度提出更高要求。特別是線對板連接器（Wire-to-Board, WTB）於量產測試中出現拉拔脫落現象，顯示傳統設計流程在面對尺寸公差與裝配偏差時，仍存在潛在風險。
本研究針對此問題，建立一套整合幾何公差分析、3D裝配模擬與有限元素分析的初始設計優化流程，以提升連接器設計準確性與產品可靠性。研究中首先透過Creo建立結構模型並進行間隙分析，以最壞情況模式計算公差累積，找出影響拉拔力的關鍵尺寸。接著應用田口方法規劃四項控制因子與三水準直交表L9(3⁴)，並以Ansys Workbench進行非線性接觸模擬，分析九組設計組合下固定端子區域的應力分布。
模擬結果顯示，最佳化參數組合A3B3C3D1（母端寬度0.54 mm、倒圓角0.7 R、公端厚度0.95 mm、材料選用NY66）相較原始設計可降低平均應力約6.77%，有效減少端子脫落風險。變異數分析進一步指出，公端材料選用（D因子）貢獻度高達94.12%，為影響拉拔力的主要因素，其次為公端厚度（3.27%）與母端寬度（2.39%），而母端倒圓角影響最小（0.21%）。
此外，研究針對固定端子區域進行重點驗證，確認優化設計能有效降低插拔過程中的受力負荷，提升接觸穩定性與機械強度。整體結果證實，於設計初期導入結構優化與材料選型策略，可顯著提升連接器的拔出性能與長期穩定性，並為未來高密度電子產品的連接器設計提供具體改進依據。

As notebook computers evolve toward thinner profiles and higher-density designs, the trend of miniaturizing electronic connectors imposes greater demands on structural integrity and assembly precision. In particular, wire-to-board (WTB) connectors have exhibited pull-out failures during mass production testing, revealing latent risks in conventional design processes when confronted with dimensional tolerances and assembly deviations.
To address this issue, this study establishes an initial design optimization framework that integrates geometric tolerance analysis, 3D assembly simulation, and finite element analysis to enhance connector design accuracy and product reliability. A structural model was first built using Creo, followed by clearance analysis under worst-case scenarios to identify critical dimensions affecting pull-out force. The Taguchi method was then applied using an L9(3⁴) orthogonal array with four control factors and three levels. Nonlinear contact simulations were conducted in Ansys Workbench to evaluate stress distribution in the fixed terminal region across nine design combinations.
Simulation results indicate that the optimized parameter set A3B3C3D1 (female width: 0.54 mm, fillet radius: 0.7 R, male thickness: 0.95 mm, material: NY66) reduces average stress by approximately 6.77% compared to the original design, effectively mitigating the risk of terminal detachment. Further analysis of variance (ANOVA) reveals that the material selection for the male terminal (Factor D) contributes 94.12% to the pull-out force, followed by male thickness (3.27%) and female width (2.39%), while the fillet radius of the female terminal has minimal impact (0.21%).
Additionally, focused verification of the fixed terminal region confirms that the optimized design significantly reduces mechanical loading during insertion and extraction, improving contact stability and structural strength. Overall, the results demonstrate that introducing structural optimization and material selection strategies in the early design phase can substantially enhance the pull-out performance and long-term reliability of connectors, providing a concrete basis for future improvements in high-density electronic product design.

目  錄
圖目錄	VIII
表目錄	X
第一章	緒  論	1
1-1	前言	1
1-2	實習內容	2
1-3	文獻回顧	3
1-4	研究動機	6
1-5	研究目的	6
第二章	研究理論	8
2-1	連接器	8
2-1-1	基本結構與功能概述	8
2-1-2	線對板連接器	9
2-2	公差分析理論	9
2-3	田口方法	10
2-3-1	直交表	11
2-3-2	訊號雜訊比	12
2-3-3	變異數分析	13
第三章	研究方法	15
3-1	研究流程	15
3-2	影響因素分析	16
3-3	實物觀察	16
3-3-1	公母端實物	16
3-3-2	標準拉拔程序	17
3-3-3	應力集中現象	18
3-4	公差分析	19
3-5	軟體分析	22
3-5-1	間隙分析	23
3-5-2	作動分析	25
3-5-3	作動軌跡分析	27
3-6	分析項目統整	28
3-7	改善方案	28
3-7-1	母端卡合結構1寬度調整	29
3-7-2	公端卡合結構2厚度調整	29
3-7-3	母端卡合結構2倒圓角	31
3-7-4	公端材質選用	31
3-8	實驗設計	33
3-8-1	田口方法應用	33
3-8-2	驗證區塊選定	34
3-8-3	網格劃分	34
3-8-4	實驗步驟	35
第四章	實驗結果與討論	37
4-1	實驗數據	37
4-2	田口方法實驗結果	43
4-3	S/N數值分析	44
4-4	變異數分析	45
4-5	確認實驗	45
第五章	結論與未來展望	49
5-1	結  論	49
5-2	未來展望	50
參考文獻	51

圖目錄
圖 1   英業達股份有限公司	2
圖 2   連接器結構	8
圖 3   線對板連接器	9
圖 4   研究流程圖	15
圖 5   公端實物	16
圖 6   母端實物	17
圖 7   標準拉拔手法	17
圖 8   實際拉拔示意圖	18
圖 9   應力集中示意圖	19
圖 10  圖面公差	20
圖 11  公端卡合結構1尺寸	20
圖 12  公端卡合結構2尺寸	21
圖 13  母端卡合結構1尺寸	21
圖 14  母端卡合結構2尺寸	22
圖 15  Creo 3D試組示意圖	23
圖 16  Creo 3D卡合結構1間隙分析示意圖	23
圖 17  Creo 3D卡合結構2間隙分析示意圖(1)	24
圖 18  Creo 3D卡合結構2間隙分析示意圖(2)	24
圖 19  Creo 3D卡合結構2間隙分析示意圖(3)	25
圖 20  Creo 3D模擬拉拔示意圖	25
圖 21  Creo 3D模擬公端轉動15°示意圖	26
圖 22  Creo 3D模擬公端轉動20°示意圖	26
圖 23  Creo 3D模擬公端轉動25°示意圖	27
圖 24  Creo 3D模擬公端作動軌跡示意圖	27
圖 25  母端卡合結構1寬度調整示意圖	29
圖 26  公端卡合結構2厚度未調整轉動角度為16.5°示意圖	30
圖 27  公端卡合結構2厚度調整後轉動角度為16°示意圖	30
圖 28  公端卡合結構2厚度調整後轉動角度為15.5°示意圖	31
圖 29  母端卡合結構2倒圓角調整示意圖	31
圖 30  Ansys Workbench給予連接器施力示意圖	36
圖 31  Ansys Workbench第一組模擬端子L模擬結果	37
圖 32  Ansys Workbench第一組模擬端子R模擬結果	37
圖 33  Ansys Woekbench第二組模擬端子L模擬結果	38
圖 34  Ansys Workbench第二組模擬端子R模擬結果	38
圖 35  Ansys Workbench第三組模擬端子L模擬結果	38
圖 36  Ansys Workbench第三組模擬端子R模擬結果	39
圖 37  Ansys Workbench第四組模擬端子L模擬結果	39
圖 38  Ansys Workbench第四組模擬端子R模擬結果	39
圖 39  Ansys Workbench第五組模擬端子L模擬結果	40
圖 40  Ansys Workbench第五組模擬端子R模擬結果	40
圖 41  Ansys Workbench第六組模擬端子L模擬結果	40
圖 42  Ansys Workbench第六組模擬端子R模擬結果	41
圖 43  Ansys Workbench第七組模擬端子L模擬結果	41
圖 44  Ansys Workbench第七組模擬端子R模擬結果	41
圖 45  Ansys Workbench第八組模擬端子L模擬結果	42
圖 46  Ansys Workbench第八組模擬端子R模擬結果	42
圖 47  Ansys Workbench第九組模擬端子L模擬結果	42
圖 48  Ansys Workbench第九組模擬端子R模擬結果	43
圖 49  各控制因子S/N反應圖	44
圖 50  Ansys Workbench最佳化模擬端子L模擬結果	46
圖 51  Ansys Workbench最佳化模擬端子R模擬結果	46
圖 52  Ansys Workbench原始設計模擬端子L模擬結果	47
圖 53  Ansys Workbench原始設計模擬端子R模擬結果	47

表目錄
表 1   結構與設計優化相關歷年文獻回顧與分析分法與應力改善值比較	5
表 2   材料與接觸行為歷年文獻回顧與分析方法比較及改善效果	6
表 3   分析項目及結構優化比較	28
表 4   三種塑膠材料物性表	32
表 5   直交表L9(34)	33
表 6   控制因子級水準配置表	34
表 7   實驗數據統整表	43
表 8   直交表結合S/N	44
表 9   S/N平均值反應表	44
表 10  變異數分析表及貢獻度	45
表 11  最佳解與所有實驗組平均值及S/N比較	46
表 12  最佳化參數與原始設計之應力平均值及S/N比較	48

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