• Journal of Korean Society of Industrial and Systems Engineering
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• v.41 no.4
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• pp.91-100
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• 2018

The setting of values on door hinge mounting compensation for door assembly tolerance is a constant quality issue in vehicle production. Generally, heuristic methods are used in satisfying appropriate door gap and level difference, flushness to improve quality. However, these methods are influenced by the engineer's skills and working environment and result an increasement of development costs. In order to solve these problems, the system which suggests hinge mounting compensation value using CAE (Computer Aided Engineering) analysis is proposed in this study. A structural analysis model was constructed to predict the door gap and level difference, flushness through CAE based on CAD (Computer Aided Design) data. The deformations of 6-degrees of freedom which can occur in real vehicle doors was considered using a stiffness model which utilize an analysis model. The analysis model was verified using 3D scanning of real vehicle door hinge deformation. Then, system model which applying the structural analysis model suggested the final adjustment amount of the hinge mounting to obtain the target door gap and the level difference by inputting the measured value. The proposed system was validated using the simulation and showed a reliability in vehicle hinge mounting compensation process. This study suggests the possibility of using the CAE analysis for setting values of hinge mounting compensation in actual vehicle production.

• Proceedings of the Korean Society For Composite Materials Conference
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• 2002.05a
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• pp.163-166
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• 2002

For the development of an all composite unmanned aerial vehicle (UAV), manufacturing consideration in design phase, works for composite parts fabrication, subassembly and final assembly are summarized. In design phase, to maximize the advantage of composite material, manufacturing processes such as cocuring, cobonding and secondary bonding are introduced. For the curing of designed parts, composite tools are designed and manufactured. Assembly jigs are designed to satisfy dimensional tolerance of the structure. Inspection criteria are established and applied to the manufacturing. Technical data about inspection items and methods are summarized as manufacturing specifications for the mass production of the UAV structure.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2006.05a
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• pp.353-358
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• 2006

A three-dimensional finite element approach to process analysis and design for joining the socket with the ball by a kind of the rotary forging processes is presented in this paper. The rigid-plastic finite element method is employed and its results are used to reduce the number of process design tryouts. The approach is applied to developing a concave piston assembly for a high pressure hydraulic pump. Experiments show that the developed piston assembly satisfies the quality requirement on geometrical tolerance.

• Journal of the Korea Society for Simulation
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• v.25 no.2
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• pp.83-92
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• 2016

Tolerances are defined as the allowable variations in the geometry and positioning of parts in a mechanical assembly for assuring its proper functionality. Tolerance analysis is the activity related to estimating the potential accumulated variation in assemblies. If the estimated variances go out of the specified ranges, it causes the quality problem. Thus, we should adjust the tolerances and this activity is called as tolerance design. In this paper, a case study on the accumulated tolerance analysis and design using Monte Carlo simulation is introduced, which is applied for developing a portable medical device. Using the simulation study, we can improve the assemblability and functionality of the product.

• Proceedings of the KIPE Conference
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• 2004.07b
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• pp.874-877
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• 2004

This paper presents the bus controller analysis of a power control unit of GEO satellite with 3kW power output. The sensing error of bus voltage produce control signal of the shunt switch assembly and the battery power converter, and the tolerance of error signal generated decide the stability of proposed system. The worst case analysis considered for the initial tolerance, temperature effect, tolerance of end of life is peformed to verify a designed bus controller. And also, the stability of system proposed according to moving of zero and pole values by some component failures is analyzed.

• Transactions of Materials Processing
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• v.16 no.2 s.92
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• pp.132-137
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• 2007

A double roll rotary forming equipment is presented in this paper. The equipment is developed for joining the socket with the ball of a concave piston assembly with its geometrical tolerance requirements satisfied. The equipment is composed of a lathe, a double roll system and a roll pressing unit driven by the hydraulic system. The workpiece rotates by spindle chuck of the lathe while the double roll system approaches perpendicularly to the central line of the workpiece. The equipment is successfully applied to precision joining of the ball and the socket fur the concave piston assembly of a high pressure hydraulic pump.

• Journal of Korean Society for Quality Management
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• v.22 no.4
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• pp.79-101
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• 1994

In modern manufacturing, a product consists of many components created by different processes. Variations in the individual component dimensions and in the processes may result in unacceptable final assemblies. Thus, engineers have increased pressure to properly set tolerance specifications for individual components and to control manufacturing processes. When a proper variation stack-up analysis is not performed for all of the components in a functional system, all component parts can be within specifications, but the final assembly may not be functional. Thus, in order to improve the performance of the final assembly, a proper variation stack-up analysis is essential for specifying dimensional tolerances and process control. This research provides a detailed case example of the use of variation stack-up analysis using a Monte Carlo simulation method to improve the defect rate of a complex process, which is the commutator brush track undercut process of an armature assembly of a small motor. Variations in individual component dimensions and process mean shifts cause high defect rate, Since some dimensional characteristics have non-normal distributions and the stack-up function is non-linear, the Monte Carlo simulation method is used.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.27 no.9
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• pp.1597-1606
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• 2003

Static analysis using hybrid finite element(FE) method has been applied to characterize the influence of position, runout and thickness errors of the sun, ring and planet on the bearing forces and critical tooth stress. Some guidelines for tolerance control to manage critical stress and bearing forces are deduced from the results. Carrier indexing error planet assembly and planet tooth thickness error are most critical to reduce planet bearing force and maximize load sharing as well as to reduce critical stresses. Sun and carrier bearing forces due to errors increase several times more than those of normal condition.

• Journal of the Korean Society of Industry Convergence
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• v.25 no.6_1
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• pp.953-959
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• 2022

In this paper, the design result of robotic tools and the development of robot control system for chemical coupler assembly are presented. This research aims to eliminate the risk of chemicals exposed to human operators by developing the robotic tools and robot automation system for chemical tank lorry unloading that were done manually. Due to tight tolerance between couplers, even small pose error may result in very large internal force. In order to resolve the problem, the 6-axis compliance device is employed, which can provide not only enough compliance between couplers but also F/T sensing. The 6-axis compliance device having large force and moment capacity is designed. A simple linear gripper with rack-and-pinion is designed to grasp two sizes of couplers. The proposed robot automation system consists of 6-DOF collaborative robot with offset wrist, 6-axis compliance device with F/T sensing, linear gripper, and two robot visions.

• Transactions of the Korean Society of Automotive Engineers
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• v.14 no.2
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• pp.23-31
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• 2006

Tolerance analysis of auto body requires the consideration of its compliance because of potentially significant deformation during the spot-weld assembly process. In this paper, a relatively recent method for such analyses is briefly introduced as one can find in the literature. In this method, it is important to take into account of the covariance between the sources of variation as they are closely located, which is the case in most auto body assembly. However, it is often impossible to know such covariance, for example, when a new car is being developed. Therefore, a mechanics-based method is proposed in this paper to estimate the covariance among the sources of variation by finite element analyses and simple statistical computations. The proposed method is illustrated by applying it to a three-dimensional model of real front wheel housing.