基於聲發射值判斷的主軸跑合系統

工具機智慧零組件關鍵技術開發應用暨性能驗證計畫

黃韋倫、許原昇、陳俊毅、呂東毅

主軸跑合是工具機在正式投入使用前的一個關鍵準備步驟，旨在通過控制主軸的轉軸與軸承暨相關驅動元件的低速運轉和逐步增加負載(轉速)的方式，使機械部件間達成良好磨合，有助於平滑機械的摩擦面，降低未來運行時的摩擦和磨損以提升其運行效能和延長使用壽命。主軸跑合過程通常分為數個階段，每個階段都以不同的速度運行，從而讓機械部件逐漸適應更高的工作壓力。這樣的階段性運行有助於檢測和調整任何製造或組裝上的不精確，確保部件均勻潤滑，減少局部過度磨損的風險。而目前應用的跑合方式主要是透過量測主軸溫度與速度來實施，由於可依循判斷的物理特徵較少，僅靠觀測溫度變化無法精確應對軸承潤滑的改變狀態，於各階段進行跑合參數調整時，容易誤判導致主軸跑合不足或過跑合現象，造成軸承潤滑不足導致損傷或產生過度磨損現象。

Spindle running-in is a critical preparatory step before machine tools are officially put into use. It aims to achieve optimal meshing of mechanical components by controlling the spindle's rotation and bearing-related driving elements' low-speed operation and gradually increasing the load (speed). This process helps to smooth the mechanical friction surfaces, reduce friction and wear during future
operation, thereby enhancing operational efficiency and extending service life. The running-in process is typically divided into several stages, each operating at different speeds, allowing the mechanical components to gradually adapt to higher working pressures. Such staged operation helps detect and adjust any manufacturing or assembly inaccuracies, ensuring uniform lubrication of components and reducing the risk of localized excessive wear. The current running-in methods primarily implement temperature and speed measurements of the spindle. Due to the limited physical characteristics available for judgment, relying solely on temperature changes cannot accurately respond to changes in bearing lubrication status. During parameter adjustments in various stages of running-in, misjudgments can easily occur, leading to insufficient or excessive spindle running-in, resulting in bearing damage due to inadequate lubrication or excessive wear. This patent proposes a spindle running-in mechanism and module based on multiple physical quantities. During the running-in process, it simultaneously monitors spindle temperature changes, the thermal elongation of the front-end test rod, and acoustic emission signals from the bearing end. By cross-interpreting these three physical quantities, a more effective and accurate evaluation of spindle running-in and bearing lubrication effects can be achieved. This serves as the basis for controlling and adjusting running-in parameters and proposing running-in methods tailored to high efficiency, energy-saving, or high stability requirements, thereby
improving the reliability and performance of spindle running-in.