應用閉迴路控制改善線纜絕緣製程之研究

Abstract

目前在線纜絕緣製程中，由於手動量測厚度的手續繁瑣，容易出錯的人工計算，調整厚度上也因個人判斷與手法不同而無法品質統一，且在規範上的不精確，經常成為索性調大製程厚度的理由，造成更浪費的惡性循環。為解決上述絕緣製程的問題，本研究嘗試以科技創新的角度將線纜絕緣製程自動化，研發出一套閉迴路控制系統，讓絕緣製程達到自動化與品質統一。相較傳統製程，本閉迴路控制系統利用感測器全時間對絕緣製程進行厚度的自動擷取與運算，並且透過本研究PID演算法能進行模擬人類的判斷標準並同時統一控制方法，經驗證能有效解決絕緣製程之問題，並期望創造一長期的競爭利基。本閉迴路控制絕緣製程相較於傳統絕緣控制有以下突破：一、能改善傳統絕緣製程上的人工量測、計算、判斷與調整繁瑣之問題。二、降低絕緣材料用量，以2022年度絕緣材料用量為例，每噸絕緣材料用量下降至97.5%，節省2.5%。三、操作自動化後，每月可降低三班人力約12萬新台幣。Currently in the cable insulation process, due to the cumbersome procedures of manual thickness measurement, manual calculations that are prone to errors, and the adjustment of thickness due to different personal judgments and methods, the quality cannot be unified. The inaccuracy often becomes a reason to simply increase the thickness of the process, resulting in a vicious circle of more waste.This research attempts to automate the cable insulation process from the perspective of technological innovation and develops a closed-loop control system to make the insulation process automatic and consistent in quality.The PID algorithm of this research, it can simulate human judgment standards and unify the control method at the same time. It has been verified It can effectively solve the problem of insulation process and expect to create a long-term competitive niche. Compared with the traditional insulation control, this closed-loop control has the following major breakthroughs in the insulation process:1.It can improve manual measurement, calculation, judgment and adjustment in the traditional insulation process.2.It can effectively reduce the amount of insulating materials (compared with manual adjustment, saving more than 13 tons of materials per year, down to 97.5%, saving 2.5%).3.After the operation is automated, the manpower of three shifts can be reduced by about NT$120,000 per month.