• Journal of the Korea Academia-Industrial cooperation Society
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• v.8 no.2
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• pp.173-178
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• 2007

Improvement of welding property of seat fiame is necessary for safety because seat frame is a unique connecting structural part between the rider and vehicle. Generally the robot and jig system for own use is used for welding of seat frame and unwelded zone can be inspected because of the geometrical interference between robot and jig system. In this study the unwelded zone of the conventional welding jig system is analysed and the 3D modeling and design change to solve the problem is discussed. As a result the weldability of system is improved and the manual welding jig is unnecessary because of the optimal jig system.

• Journal of the Korean Society of Mechanical Technology
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• v.13 no.4
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• pp.131-136
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• 2011

In commercial vehicle, sub-frame which equipped in main frame supporting dump deck and oil tanker. This is the main structure for all equipment which including joint function. Sub-frame is made by welding process, this susceptible to deform and crack by its longitudinal size. Also various kind of sub-frame make it difficult to standardization in manufacturing process and exclusive jig is not adapted yet. Frame size is over 6~8m and weight is more than 300kg this make re-work more difficult. If manufacturing company made precise sub-frame, this is not only convenient for customers but also save the company money by reducing the working time. In this study manufacture the sub-frame be suitable for its main function and develop exclusive welding jig for obtain checking fixture function as well.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2010.05a
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• pp.393-394
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• 2010

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.14 no.1
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• pp.51-56
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• 2015

This paper presents an investigation of abnormal wear of a contact jig between a nail and a nail fixture in electric resistance welding. To perform an analysis on the abnormal wear phenomenon, several methods are provided. Based on the theory of electric resistance welding, are analyzed. Using microscopic analysis, surface craters are observed. In the measurement of the electric current flow in the nail fixture, the current flow distribution is measured. From several analyses, the cause of abnormal wear in the contact jig is measured using the electric discharge of high current density at the inflow point of the electric supply to the nail fixture. An alternative shape for normal wear is proposed.

• Proceedings of the KWS Conference
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• 2009.11a
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• pp.62-62
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• 2009

석탄화력발전소의 CO2배출량 감소와 고효율, 대용량화로 인해 초초임계압(USC:Ultra Super Critical) 화력발전소의 건설이 증가하고 있다. USC 발전소는 효율향상을 위한 증기온도와 압력의 상승 때문에 보일러 고온고압부에 기존의 소재에 비해 고온강도와 내산화성의 재료물성이 향상된 신소재 적용이 불가피하다. 특히 사용된 신소재 중에서 보일러 본체를 구성하는 수냉벽관(Water wall), 과열기와, 재열기용 튜브 및 후육부인 헤더와 배관재로 기존의 2.25Cr-1Mo강을 개량한 2.25Cr-1.6W계 내열강이 적용되고 있다. 2.25Cr-1.6W강은 SMI와 MHI가 공동개발한 소재로 1995년 튜브제품이, 1999년에 단조, 파이프재, 플레이트제품이 ASME code case로 등재되었고, 2009년 ASME code case 2199-4로 개정되어 사용 중이다. 이 소재는 2.25Cr-1Mo강에 고온강도 개선을 위해 석출강화효과가 있는 V과 Nb을 첨가하였고, 탄화물의 열적안정성과 고용강화효과 증대를 위해 W을 첨가하였다. 그리고 제작성과 용접성 및 재료의 인성 향상을 위해 B첨가와 C함량을 낮추었다. 합금성분의 첨가와 조정에 의해 고온강도는 개선되었지만, 보일러 설치 및 보수를 위한 용접과정에서 용접금속과 CGHAZ(Coarse Grain HAZ)에서 용접균열이 발생하였다. 대부분의 용접균열은 용접결함이나 고온 혹은 저온균열이 아닌 2.25Cr-1.6W계강의 강도 개선을 위해 첨가한 V과 Nb이 용접후열처리 도중 입내에 MX형태의 미세석출로 입내를 강화시킴으로서 발생한 재열균열 민감성 증대에 기인된 것으로 판단된다. 이에 본 연구에서 용접 및 후열처리 과정에서 용접금속과 HAZ에서 발생하는 용접금속의 응력분포를 전산해석을 통해 확인하고 실제 후육파이프 용접부에서 잔류응력을 측정해 비교하였다. 용접부 응력분포는 SYSWELD 프로그램을 사용해 해석을 수행하였고, 발전소 실배관재의 용접부 응력측정은 수평부 측정이 용이하도록 지그를 부착한 Potable 잔류응력측정기를 사용해 Hole Drilling Method(HDM)를 적용하여 잔류응력을 측정하였다. 해석 결과 CGHAZ부위의 잔류응력이 용접금속과 기타 부위에 비해 높은 응력분포를 나타냈으며, 이는 CGHAZ와 용접용융선 부근에서 균열이 발생하는 실제값과 일치하는 결과를 보였다. 실제 배관재 용접부에서 측정한 잔류응력값은 항복응력의 약 50% 이하 응력값을 나타냈다. 배관 구조에 기인한 시스템응력의 영향을 제거하기 위해 배관재 용접부를 중심으로 양끝단을 절단 후 용접부에서 측정한 응력은 항복응력 대비 25%수준의 낮은값을 보였다. 그러나 배관재가 장기간 고온환경에 노출되었고 용접금속 내부의 균열이 발생한 상태에서 측정하였기 때문에 용접잔류응력은 상당부분 해소되어 상대적으로 낮은 응력값이 얻어진 것으로 판단된다.

• Journal of the Korean Society of Fisheries and Ocean Technology
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• v.36 no.4
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• pp.329-336
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• 2000

Welding is a important technological method in mechanical engineering. $CO_2$MAG(metal active gas) welding means that metal part in double capstan drum for the inshore and costal vessels are joined by melting(with or without a filler material) or that new material is added to a metal part by melting. The thermal stresses appear due to a non-uniform temperature field, inhomogeneous material properties, external restraint and volume changes during phase transformations. In this study analysis the elasto-plastic thermal stresses distribution of welding part in double capstan drum for the inshore and costal vessels using finite element method (FBM). Therefore it calculates the numerical value that can be applied to the optimum design of welding parts and the shapes. The significant results obtained in this study are summarized as fellows. At early stage of the cooling after welding process, the abrupt thermal stresses gradient has been shown in the vicinity of welding part. In the thermal stresses analysis due to temperature gradient and heat shocking maximum stress was occurred of welding part and stresses were distributed from 54MPa~48MPa.

• Journal of the Korea Institute of Information and Communication Engineering
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• v.26 no.4
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• pp.556-561
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• 2022

In this paper, we present a block media communication (BMC) system which employs powerline communication to the equipments used in the welding process for ship-assembly and uses metal block as a communication medium. Inductive couplers are installed on digital feeder and pin jig. Information signal is added to the current generated by the welding gun, and applied to the block. When the welding operation starts, information generated in the field is transmitted to the monitoring server in real-time. The field test on the BMC system confirms that the transmitted data are correctly received at the server. Since the proposed system can be built without any changes to the existing welding process, it is helpful to increase competitiveness of the shipbuilding industry through smart factory of shipyards. It is also possible to quickly respond to emergency situations that may occur to workers in an electromagnetic wave shielding environment or a closed space, the effect of preventing industrial accidents will be great.

• Journal of the Korean Society for Railway
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• v.2 no.2
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• pp.1-5
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• 1999

Based on the development of designed technology for aluminum carbody. the prototype aluminum carbody has been constructed. All extrusion profiles required for the carbody has been produced and their quality has also been proven. For sound construction. welding technology to join aluminum extrusion profiles has been developed and jigs for precise assembly of blocks have been made. The aluminum carbody for urban subway train has been completed with the required chamber being set and the welding deformations being constrained by jigs. The safety of the carbody structure has also been proven by the static load test. And also, painting technology has been developed and the surface of the carbody has been pre-treated and painted. The developed technology to construct the aluminum carbody can be used in mass production of aluminum cars ordered by domestic and foreign customers.

• Korean Journal of Computational Design and Engineering
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• v.8 no.3
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• pp.189-200
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• 2003

This paper introduces the development of a three-dimensional jig design system for automotive body welding assembly. Recently, three-dimensional CAD systems have been introduced in the jig design area, because they reduce errors in design process and the design result can be used readily for virtual manufacturing simulation. However, to facilitate three-dimensional jig design, it is essential to customize three-dimensional CAD system for this specific design area. To accomplish this object, we first standardized the parts and units in a jig assembly, and then built the standard part library. We also developed the dedicated 3D design capabilities of jig units and a jig base. By using this system, design can be performed more intuitively, and verification and simulation of design results can be done more easily. The proposed system has been implemented using the UG/Open API of the Unigraphics system.

• Journal of the Korea Institute of Information and Communication Engineering
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• v.25 no.3
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• pp.433-439
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• 2021

In this paper, we propose a method to implement an IoT-based sensor network for each workplace of a shipyard. Here, at the most common welding workplace in shipyards, the shipbuilding blocks are used as a communication medium to transmit information such as the worker's location, welding progress, and working hour to a server using LoRa and powerline communication. To achieve the data communication, inductive couplers and hybrid modems have been manufactured and installed on wire feeders and pin jigs to establish a sensor network. As a result of field test, the proposed system shows a success rate of data transmission and a rate of successful recognition of worker's location of about 98% or more. In addition, the process management system platform can record and display the work process data generated at the field in real time. The proposed system can be a starting point for enhancing the competitiveness of Korean shipbuilding industry through the establishment of a smart shipyard.