本研究本著智慧製造 (Smart/Intelligent Manufacturing) 的觀念，進行高值化智能整平系統的開發，並提出一具網路雲端決策支援功能 (Cyber-Physical System) 之機台設計。根據現況與作業流程，提出適合之決策支援系統的參數設計與產能監控，且後續將就其系統之操作與顯示介面進行人機系統評估與改善，使產品之系統設計更貼近市場需求。本研究可根據此模擬系統，依現今市場的需求，自動調整內部經伺服化之關鍵元件之設定，以達到快速、彈性與大量客製化的目標，透過資訊整合，關鍵參數將被即時感測，並且透過網路進行即時產線機台參數以及監控製程品質，將大大促進產品之精度，提升並確保產出之品質與差異性。本研究開發之產線資訊與監控將可視化與人性化，將可提高人與機台間之配合，減少人為操作失誤，將可促進產能與產值。
目前線性測量系統廣泛應用於工業上，尤其在機械產業中更是達到精密定位控制之用。現今已有許多不同形式的線性測量系統如光學測量系統與磁性測量系統，然而磁性測量系統相較於光學測量系統，其優勢在於造價便宜、適合操作於有水、油脂和粉塵等嚴苛環境。但是在製作磁性測量系統過程中，磁性尺在捲收時會處於不同的彎曲半徑，而在捲料當下，殘留應力會在磁性尺當中逐漸累積，當鬆開時磁性尺表面會呈現殘留應力引起之彎曲變形。磁性尺的變形會影響磁場大小與磁通量密度大小使得磁性尺的充磁與測量品質跟著改變。本研究致力於研究與開發智能化滾輪矯直整平機台，以用於磁性尺上來達到去除磁性尺殘留應力造成之彎曲的效果，以複合磁性基材與彈塑性彎曲力學理論來分析，在不同的環境與操作參數下進行參數研究，以釐清如何將滾輪整平機最佳化整合到磁性尺的製造，以改善彎曲撓度、消除殘餘應力。

In smart manufacturing, machines are interconnected through cyber-physical system (CPS) to achieve efficient manufacturing production. Thus, the demands for seamless adjustment of machine setting has become a crucial issue. Likewise, manufacturing efficiency of precision magnetic scale has surfaced as an inevitable challenge. The manufacturing of precision magnetic scale requires precise flatness throughout production and handling processes. In the current technological shortcomings in magnetic scale manufacturing, any flatness defects in the scale would substantially influence its position sensing accuracy. Thus, with the proposed roller leveling machine for magnetic scales, the goal of this research is to develop and examine a hybrid flattening mechanics model used in the CPS to ensure the scale’s flatness during manufacturing. With this model, it is validated that accurate roller setting can be obtained prior to machine operation, which can significantly improve manufacturing efficiency. In this work, the proposed hybrid mechanics model is performed, validated, and compared to experimental and factory recommended results. The results have demonstrated its capability in predicting the optimal leveling roller settings under given parameters and conditions, suggesting the possibility of smart manufacturing for magnetic scales.

論文摘要 i
Abstract ii
Acknowledgement iii
Table of Contents iv
List of Figures viii
List of Tables xiv
1 Introduction 1
1.1 Magnetic Scale Technology and Development 1
1.2 Current Issues of Magnetic Scale 8
1.3 Known Methods for Accuracy Improvement of Magnetic Scale 13
1.4 Literature Review 17
1.4.1 Sheet metal stamping production line 17
1.4.2 Roller leveling machines 19
1.4.3 Analytical studies of roller leveling 25
1.4.4 Smart manufacturing 27
1.5 Research Objectives 30
1.5.1 Objective statements 30
1.5.2 Flowchart of approach and methods 32
1.6 Research Strategy 34
2 Mechatronics Integration of Intelligent Roller Leveling Machine 37
2.1 Smart Manufacturing Technology Implementation 38
2.2 Mechanical Design of Roller Leveling Machine 43
2.3 Implementation of Cyber-Physical System 46
2.4 Results and Discussion 48
3 Principles and Assumptions for Mechanics Modeling of Roller Leveling Process 49
3.1 Principles and Assumptions 49
3.2 Approach of Mechanics Modeling 56
4 Analytical Mechanics Modeling on Roller Leveling of Isotropic Magnetic Medium 58
4.1 Assumptions 58
4.2 Mechanics Modeling 61
4.2.1 Proposed hybrid flattening model 61
4.2.2 Curvature model 66
4.2.3 Stress model 69
5 Analytical Mechanics Modeling on Roller Leveling of Composite Magnetic Medium 72
5.1 Assumptions 72
5.2 Mechanics Modeling 76
5.2.1 Curvature model 76
5.2.2 Stress model 83
5.2.3 Proposed hybrid flattening model 85
6 Validation of Hybrid Flattening Model 87
6.1 Validation on Mechanics Modeling on Isotropic Magnetic Medium 88
6.1.1 Simulation and experimental setups 88
6.1.2 Results and discussions 90
6.1.3 Summary 94
6.2 Validation on Mechanics Modeling on Composite Magnetic Medium 95
6.2.1 Simulation and experimental setups 95
6.2.2 Validation of hybrid flattening model 98
6.2.3 Prediction of hybrid flattening model 104
6.2.4 Summary 107
6.3 Effect of Installation Error on Magnetic Characteristic of Magnetic Medium 108
6.3.1 Materials and methods 110
6.3.2 Results of effect of installation error 112
6.3.3 Summary 119
6.4 Effect of Roller Leveling on Reliability of Magnetic Medium 121
6.4.1 Materials and methods 122
6.4.2 Effect of roller leveling on crack formation 125
6.4.3 Effect of roller leveling on position accuracy 129
6.4.4 Summary 134
7 Conclusions, Contributions, and Directions for Future Work 135
7.1 Conclusions 135
7.2 Contributions 137
7.3 Directions for Future Work 138
References 139
Publications 146
Honors and Awards 148

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