| Summary: | 碩士 === 國立虎尾科技大學 === 機械與電腦輔助工程系碩士班 === 100 === This study developed a continuous ultrasonic welding machine for solar plates that exceed 10 cm, and the adjustable machine design can fulfill processing for solar palates of various sizes. This machine mainly uses ultrasonic boosters to connect to the horns. Through the amplification displacement effects of the horns, the vibration energy is transferred to the processing aluminum bars, which rub against the welding surface of the solar plates causing friction and instantly generate diffusion bonding, thereby achieving ultrasonic welding.
In addition, the processing efficiency of ultrasonic welding depends on the horn design, the quality of which influences the processing effects. In this study, ANSYS finite element analysis software was used to analyze the horn data provided by manufacturers and to design new horns. Finite element analysis software was also used to perform model analysis to determine the natural frequency value distribution of the model. The Taguchi method was employed to determine a suitable target value for the design and to identify the optimal horn size parameters. Then, a simulation was conducted to compare these values. Finally, a frequency meter or measuring instrument was used to measure the optimized horn, obtaining a frequency of 34.8 kHz, which matched the simulation value. The results show that the new model effectively reduces the time spent correcting the horn size using trial-and-error methods and improves horn performance regarding horn processing.
A processing test for the new model was performed using an optical microscope and a tensile testing machine. Under various welding parameters, the effects of ultrasonic welding were investigated. The Taguchi method was employed to identify the optimal process parameters and processing element contribution rates to improve the processing quality.
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