環保意識日趨受世人重視，能夠有效率的利用能源更是近年各車廠致力研發的目標方向，其中電池續續航能力或省油更視為為電動車或一般油車加值及吸引消費者的關鍵要素。碟式煞車系統在過去配置上，考量煞車效率及制動強度，在沒有煞車制動的情況下仍會有輕微的滑動阻力，其主要與碟式煞車卡鉗之活塞滾回量設計有關，且此滑動阻力事實上對電動機車及一般油車造成非必要的能源消耗。此問題更是逐漸受到各大車廠所詬病，並逐漸將此問題納入失效模式和效果分析中，被視為必須克服的課題。為了因應此情況，將針對碟式煞車系統的活塞滾回量進行新技術規格開發。在過去R&D設計在新產品開發上大多是依照過去經驗以及試誤法方式進行測試，但此方法卻造成傳統機械產業在新產品開發過程及驗證上缺乏一有系統性的開發過程，且開發成本的掌握時常不盡理想。 本研究將針對碟式煞車活塞滾回量進行新技術規格開發，由於碟式煞車活塞滾回量過小會造成煞車片持續與碟盤磨耗導致不必要的磨耗甚至造成滑動扭矩過緊；過大則會導致煞車系統制動力不足及無效行程過多。因此本研究目標將以克服失效模式分析中滑動阻力的問題為出發點，利用田口方法，將考量消費者使用過程所面臨無法避免的因素做為雜音因子，期望將此兩種失效模式發生的情況降低並選出最佳參數設計期望達到最小化雜音因子對產品的影響進而達到穩健設計，進而探討在此新的技術規格下實際的提升及對企業帶來的改善。 ;As Eco-conscious is taken more seriously by people, the effective use of fuel is gradually valued by the world. Among them, battery life of fuel saving is a key factor for adding value to automakers and attracting consumers. In the past configuration of the disc brake system, considering the braking efficiency and braking strength, there have slight residual resistance while the brakes are not activated. It is mainly related to the design of the piston retraction of the disc brake caliper. In addition, this residual resistance causes unnecessary fuel consumption for electric motor and general gasoline motor. This issue is gradually criticized by major automakers, and gradually included in the failure mode and effect analysis, which is regarded as a problem that must be overcome. To overcome this issue, new technology specification disc brake systems would be developed. In the past, R&D designers mostly developed new products based on past experienced and trial and error methods. However, this method has caused the traditional machinery industry to lack a systematic development process in the new product development process and verification, moreover, the development cost is often not control ideal. This study will develop new technology specification for retraction distance of disc brake pistons. Due to unique quality characteristics, too small or too large retraction distance of pistons would adversely affect the braking system. Therefore, the goal of this research is to overcome the issue-Residual resistance in failure mode and effect analysis(FMEA) as a starting point, using Taguchi method to overcome the problem of sliding resistance in failure mode analysis. And expected to reduce the occurrence of two seriously failure modes and select the best parameter design. The impact of the product will then achieve a robust design. Finally, discuss the improvements and contribution of the Taguchi Method experiment and results to the enterprise.
