以品質工程建構外轉子永磁無刷馬達應用商品化關鍵技術

彭美珠；劉陽光；楊堯斌；黃亮橋；張鈺炯

外轉子 ； 永磁無刷馬達 ； 振動 ； 溫度 ； PDCA ； QFD ； DFEMA ； ANOVA ； External Rotor ； Permanent Magnet Brushless Motor ； Vibration ； Temperature ； PDCA ； QFD ； DFEMA ； ANOVA

冷凍空調&能源科技

117期（2019 / 09 / 10）

64 - 70

繁體中文;英文

外轉子永磁無刷馬達（Brushless DC Motor，簡稱BLDCM）與配對的驅控器技術，是必須整合多項技術與人才的跨領域產品，其中包含永磁材料、永磁馬達構形、功率元件匹配、無感測變速驅動、智慧晶片控制，無線遙控通訊等，而且要具低成本與高性價比。與終端應用載具結合的案例之一，如吊扇，又須與燈控整合並滿足使用者的特殊需求。因此，吊扇產品要導入外轉子BLDCM模組，雖然是國內業界積極要投入的新產品方向，但也面臨了相當大的技術門檻。本研究以DMADV流程管理，結合品質工程落實執行。品質工程部份，則使用QFD、品質屋及客戶要求之品質指標為依據，從原本的超過50項檢驗指標挑選出優先檢驗的31項，利用相關係數分析找出：（1）與振動較相關的15項、（2）與散熱有關的6項因子作為優先考慮量測項目。最後輔小量試作及DOE ANOVA單因子三水準方法，利用p-value＜0.05的數值篩檢出在量產製程必須執行的檢驗項目，並建構：（1）吊扇用BLDCM商品振動商規的OK/NG判定準則，（2）示範量產出貨前之性能指標變異診斷與解決方案；以建立高良率之出貨與品管。另外亦對客戶端特別需求之品質項目：驅控器散熱及吊扇異音問題，導入CFD與NVH等技術加以解決而滿足量化指標成果，達成要求的品質目標。本研究實質建構具品質管理系統的示範生產線與制定各項品質關鍵技術及標準作業程序，並以示範量產商品持續協助國內業者進行實場之示範驗證。

The external rotor BLDCM and the associated controller technology were cross-disciplinary products that not only multiple technologies integration but human talents, including permanent magnetic materials, permanent magnetic motor configuration design, power components matching, senseless variable speed drives, smart chip control, and wireless remote control communication, etc., and low cost and high performance cost rate. The ceiling fan with the LED light control developed to meet the special needs for end-user. Therefore, the ceiling fan introduced the external rotor BLDCM drive control module. Although it was a new product direction that the domestic industry was actively investing in, it also faced a high technical threshold. The research adopted (Define, Measure, Analyze, Design and Verify) DMADV process management, and integrated with quality engineering. In the quality engineering part, the project used quality function deployment (QFD), quality of house, and quality indicators for customers' requests as the basis. From the original over 50 inspection indicators, we selected 31 priority inspections. Secondly, we identified much more vibration and cooling issues relevant by correlation coefficient analysis. We found 15 factors related to the vibration and six factors related to heat dissipation. Finally, we had trial production and used design of experiment (DOE) analysis of variance (ANOVA) with single factor, three level method was used, and the value of p-value<0.05 was used to screen the most-related check items. The OK/NG criteria for the commodity vibration regulation of the BLDC ceiling fan could be constructed. The performance index variation diagnosis and solution before demonstration mass products shipment could be constructed to establish high-yield rate shipment and quality control. At the same time, for the client special quality need items: the controller heat dissipation and the ceiling fan noise problem. This project introduced CFD and NVH technologies into quality tools with quantitative indicators and achieved the required quality goals. Lastly, the project had constructed a demonstration production line with a quality management system and developed quality key technologies and standard operating procedures. The demonstration mass production products substantially provided the cooperators demonstration verification for real marketing.

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