• Design & Manufacturing
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• v.14 no.1
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• pp.8-14
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• 2020

In general, auto parts production assembly line is assembled and produced by automatic mounting by an automated robot. In such a production site, quality problems such as misalignment of parts (doors, trunks, roofs, etc.) to be assembled with the vehicle body or collision between assembly robots and components are often caused. In order to solve such a problem, the quality of parts is manually inspected by using mechanical jig devices outside the automated production line. Automotive inspection technology is the most commonly used field of vision, which includes surface inspection such as mounting hole spacing and defect detection, body panel dents and bends. It is used for guiding, providing location information to the robot controller to adjust the robot's path to improve process productivity and manufacturing flexibility. The most difficult weighing and measuring technology is to calibrate the surface analysis and position and characteristics between parts by storing images of the part to be measured that enters the camera's field of view mounted on the side or top of the part. The problem of the machine vision device applied to the automobile production line is that the lighting conditions inside the factory are severely changed due to various weather changes such as morning-evening, rainy days and sunny days through the exterior window of the assembly production plant. In addition, since the material of the vehicle body parts is a steel sheet, the reflection of light is very severe, which causes a problem in that the quality of the captured image is greatly changed even with a small light change. In this study, the distance between the car body and the door part and the door are acquired by the measuring device combining the laser slit light source and the LED pattern light source. The result is transferred to the joint robot for assembling parts at the optimum position between parts, and the assembly is done at the optimal position by changing the angle and step.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.24 no.4 s.175
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• pp.811-823
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• 2000

In design and manufacturing airframe structures which are composed of a lot of sub-assemblies and large complex profile shapes it is difficult to reduce so called hardware variations. Accordingly cost increasing factors for manufacturing airframe parts are much more than other machine parts because of the variability of fabricated details and assemlies. To improve cost and quality, accurate assembly methods and DPD techniques are proposed in this paper which are based upon using CAD/CAM techniques, the concept of KC's and the coordinated datum and index throughout the design, tooling, manufacturing and inspection. The proposed methods are applied to produce fuselage frame assemblies and related engineering aspects are described regarding the design of parts and tools in the context of concurrent digital definition. First articles and consequent mass production of frame assemblies shows a great improvement of the process capability ratio from 0.7 by the past processes to 1.0 by the proposed methods in addition to the cost reduction due to the less number of tools, reduced total assembly times and the space compaction needed by massive inventory. The need to achieve better Cpk, however, and future studies to be investigated will be addressed briefly.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.8 no.4
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• pp.930-937
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• 2007

In this paper, we address a design problem and a case study of a K-stage inspection system, which is composed of K stages, each of which includes an inspection process and a rework process. Assuming the type I and II errors of inspectors and the re-inspection policy for items classified as good, we determine the smallest integer of K which can achieve a given target defective rate. If K does not exist, holding the current values of the type I, II errors, we search reversely a new vector, (the defective rate of an assembly line, the defective rate of a rework process), which can give the target defective rate. Our formulas and methodology based on our K-stage inspection system could be applied and extended to similar situations with slight modifications.

• Journal of Korea Society of Industrial Information Systems
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• v.26 no.6
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• pp.11-16
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• 2021

In this paper, a quality inspection system was developed to identify the defective assembly of connectors used in automobile wiring. For waterproof connectors, an internal seal must be inserted for waterproofing. However, there are cases where it is omitted or double-inserted during production. An automatic inspection jig was designed using photosensors and touch switches to classify good and bad connector components. In the case of the existing visual inspection, 6,400 connectors were inspected when 5 people inspected for 8 hours. However, when using the inspection jig developed under the same conditions, 20,000 pieces were inspected. In other words, the productivity is greatly improved compared to the conventional visual inspection.

• Proceedings of the Korean Society for Noise and Vibration Engineering Conference
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• 2007.11a
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• pp.1231-1236
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• 2007

Balance Shaft Module is module parts that is installed to vehicles engine to reduce noise and vibration of vehicles engine. Balance Shaft Module's performance exerts important influence on performance of engine. Therefore, must be able to warrant quality and performance of Balance Shaft Module. Existing product found and revised error at continuous process of production, and estimated failure mode in Balance Shaft Module. Previous method hard to secure product that performance is excellent, and bring a lot of damages economically. Therefore, development of inspectin system for quality inspection of parts and performance test of assembly is essential in Balance Shaft Module. In this study, represented development process of automatic dynamic inspection system to test performance and detect breakdown of Balance Shaft Module that is producing in Dongbo.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 1994.10a
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• pp.543-548
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• 1994

This is the paper on the development of assemnly automation and visual inspection system for smart card reader connector. The automation consists of 3 main process injection, assembly and inspection. During the injection, the main pin of a reel. transferred under uniform tension, is cut with an injection interval and positioned precisely to an injection mold by roll feeder after injection. The main base is stacked to a magazine for main pin's exact positionning to a mold . For last effective production, The turn table and pick & place are driver with gears and came by a single monter. We developed the small parts handling technigue for stable supply of micro ist pin and 2nd pin and could determine the orientation and position of those pins. For reliable inspection, We used the vision system which examins the guality of arranged pins with a CCD camera. The connector models which can be manufactured with this system are 8 pin and 10 pin type. The user can select the connector model for production and adjust the torerable error range during the inspection of arranged pins.

• Nuclear Engineering and Technology
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• v.46 no.3
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• pp.439-446
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• 2014

An amphibious inspection robot system (hereafter AIROS) is being developed to visually inspect the in-containment refueling storage water tank (hereafter IRWST) strainer in APR1400 instead of a human diver. Four IRWST strainers are located in the IRWST, which is filled with boric acid water. Each strainer has 108 sub-assembly strainer fin modules that should be inspected with the VT-3 method according to Reg. guide 1.82 and the operation manual. AIROS has 6 thrusters for submarine voyage and 4 legs for walking on the top of the strainer. An inverse kinematic algorithm was implemented in the robot controller for exact walking on the top of the IRWST strainer. The IRWST strainer has several top cross braces that are extruded on the top of the strainer, which can be obstacles of walking on the strainer, to maintain the frame of the strainer. Therefore, a robot leg should arrive at the position beside the top cross brace. For this reason, we used an image processing technique to find the top cross brace in the sole camera image. The sole camera image is processed to find the existence of the top cross brace using the cross edge detection algorithm in real time. A 5-DOF robot arm that has multiple camera modules for simultaneous inspection of both sides can penetrate narrow gaps. For intuitive presentation of inspection results and for management of inspection data, inspection images are stored in the control PC with camera angles and positions to synthesize and merge the images. The synthesized images are then mapped in a 3D CAD model of the IRWST strainer with the location information. An IRWST strainer mock-up was fabricated to teach the robot arm scanning and gaiting. It is important to arrive at the designated position for inserting the robot arm into all of the gaps. Exact position control without anchor under the water is not easy. Therefore, we designed the multi leg robot for the role of anchoring and positioning. Quadruped robot design of installing sole cameras was a new approach for the exact and stable position control on the IRWST strainer, unlike a traditional robot for underwater facility inspection. The developed robot will be practically used to enhance the efficiency and reliability of the inspection of nuclear power plant components.

• Journal of Korean Institute of Industrial Engineers
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• v.27 no.4
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• pp.366-373
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• 2001

Economic component screening procedures for multi-component assembly products supplied with warranty are proposed. It is assumed that the screening variable is continuous and the performance variable is dichotomous. Logistic and normal models are considered; the proportion of conforming items is a logistic function of the screening variable in the logistic model and the screening variable given the performance variable is normally distributed in the normal model. Cost models are constructed which involve three cost components; screening inspection cost for each component, cost due to disposing a rejected component, and warranty cost for an assembly product. Methods of finding the optimal screening procedures are presented and numerical examples are given.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.3 no.4
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• pp.7-12
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• 2004

Inspection and analysis are essential process to determine whether a completed product is in given specification or not. Analysis of products with very complicated shape is difficult to carry out direct comparison between inspected coordinate and designed coordinates. So process called as matching or registrations is needed to solve this problem. By defining error between two coordinates and minimizing the error, registration is done. Registration consists of translation, rotation and scale transformations. Error must be defined to express feature of inspected product. In this paper, registration algorithm is developed to determine pose of sub-frame at assembly with body of automobile by defining error between two coordinates considering geometric feature of sub-frame.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2010.05a
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• pp.355-356
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• 2010