• Steel and Composite Structures
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• v.24 no.3
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• pp.351-358
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• 2017

Due to the increasing competition, automotive manufacturers have to manufacture highly safe and light vehicles. The parts which make up the body of the vehicle and absorb the energy in case of a crash, are usually manufactured with sheet metal forming methods such as deep drawing, bending, trimming and spinning. The part may get thinner, thicker, folded, teared, wrinkled and spring back based on the manufacturing conditions during manufacturing and the type of application methods. Transferring these effects which originate from the forming process to the crash simulations that are performed for vehicle safety simulations, makes accurate and reliable results possible. As a part of this study, firstly, the one-step and incremental sheet metal forming analysis (deep drawing + trimming + spring back) of vehicle front bumper beam and crash boxes were conducted. Then, crash performances for cases with and without the effects of sheet metal forming were assessed in the crash analysis of vehicle front bumper beam and crash box. It was detected that the parts absorbed 12.89% more energy in total in cases where the effect of the forming process was included. It was revealed that forming history has a significant effect on the crash performance of the vehicle parts.

• Journal of Power System Engineering
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• v.19 no.3
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• pp.75-80
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• 2015

Typically, robot system configured by articulated robot manipulator with 1 DOF transfer unit is being applied in automotive manufacturing automation process. Especially, 1 DOF transfer unit is necessary to extend workspace of robot manipulator. In this configuration, because transfer unit works only one direction, robot manipulator only works in one side in case of car body painting or sealing automation process. it is necessary three robot manipulator system at least. In this paper, in order to robot manipulator works effectively in car body sealing automation application, we are suggested omni-directional manipulator system and conducted studying on redundancy resolution method to solve manipulability-optimal problem.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.21 no.4
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• pp.60-69
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• 2022

To keep pace with Industry 4.0, it is imperative for companies to redesign their working environments by adopting robotic automation systems. Automation lines are facilitating the latest cutting-edge technologies, such as 3D vision and industrial robots, to outdo competitors by reducing costs. Considering the nature of the manufacturing industry, a time-saving workflow and smooth linkwork between processes is vital. At Dellics, without any additional new installation in the automation lines, only a few improvements to the working process could raise productivity. Three requirements are the development of gripping technology by utilizing a 3D vision system for the recognition of the material shape and location, research on lighting projectors to target long distances and high illumination, and testing of algorithms/software to improve measurement accuracy and identify products. With some of the functional requisites mentioned above, improved robotic automation systems should provide an improved working environment to maximize overall production efficiency. In this article, the ways in which such a system can become the groundwork for establishing an unmanned working infrastructure are discussed.

• Transactions of the Korean Society of Automotive Engineers
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• v.13 no.5
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• pp.142-151
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• 2005

To predict the fatigue life of the Hub Bearing Unit(HBU), preload effect and initial axial clearance have to be considered. Various theory and equations for the HBU design used in the passenger car are well developed in many literatures. But most design hand book for bearings or bearing catalogues do not consider the initial axial clearance and preload effect. So there are limits and difficulties to use those data in actual bearing design. To consider the preload effect and initial axial clearance, complex elliptic integrals and nonlinear equations are involved. These equations are difficult to solve during the design process. In order to solve these problems effectively, a program is developed to solve these equations reliably and to help the designer in obtaining the performance data of the HBU such as load distribution, maximum contact stress and fatigue life. The preprocessor of the program helps users to prepare the input data through a dialog box and the post processor makes graphical presentation of the result. In this paper, theoretical and numerical background for the prediction of the fatigue life of the HBU is explained. A simple example is presented to show the usefulness of developed program.

• Journal of Adhesion and Interface
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• v.12 no.3
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• pp.81-87
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• 2011

In this study, UV curing and crosslinking process was introduced for synthesis of acrylic foam tape that can be applied to the the automotive assembly process. Polymerized adhesive are laminated to baseform and varying the thickness of specimens were prepared. To measure basic mechanical properties, stainless steel was used. And in the test peel, dynamic shear and t-block were used. The acrylform adhesive show better results compare with typical adhesive and the properties depand on external factors - thick, wetting time -. To analysis functions of acrylic foam adhesive used to automobile production, evaluate the adhesive properties on the various plastic substrate. In PP and PE are categorized low surface energy materials, their properties have not been expressed. But dynamic shear tests show that some properties could be expressed by the difference break mechanism.

• Fire Science and Engineering
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• v.33 no.5
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• pp.7-12
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• 2019

To investigate the influence of the char layer formed during the combustion process on the pyrolysis of wood combustibles, ISO 5660-1 cone calorimetry experiments and Fire dynamics simulator (FDS) simulations were performed, and the results from these two methods were compared. The wood combustible selected as the fuel for this study, Douglas fir, has been widely used for the production of building materials, furniture, etc. The heat release rate (HRR) measured from the cone calorimetry experiment was in good agreement with the result predicted by the FDS simulation. However, the FDS simulation failed to predict the heat released by the smoldering combustion process, due to the absence of the char surface reaction in the model. The FDS simulation results clearly indicate that the char layer formed on the surface of combustibles produces a thermal barrier which prevents heat transfer to the interior, thickening the thermal depth and thus reducing the pyrolysis rate of combustibles.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.11 no.6
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• pp.130-138
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• 2012

There are increasing demands from the industry for intelligent robot-calibration solutions, which can be tightly integrated to the manufacturing process. A proposed solution can simplify conventional robot-calibration and teaching methods without tedious procedures and lengthy training time. iGPS(Indoor GPS) system is a laser based real-time dynamic tracking/measurement system. The key element is acquiring and reporting three-dimensional(3D) information, which can be accomplished as an integrated system or as manual contact based measurements by a user. A 3D probe is introduced as the user holds the probe in his hand and moves the probe tip over the object. The X, Y, and Z coordinates of the probe tip are measured in real-time with high accuracy. In this paper, a new approach of robot-calibration and teaching system is introduced by implementing a 3D measurement system for measuring and tracking an object with motions in up to six degrees of freedom. The general concept and kinematics of the metrology system as well as the derivations of an error budget for the general device are described. Several experimental results of geometry and its related error identification for an easy compensation / teaching method on an industrial robot will also be included.

• Journal of the Korean Applied Science and Technology
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• v.29 no.3
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• pp.450-458
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• 2012

In order to reduce the effects of greenhouse gas (GHG) emissions, the South Korean government has announced a special platform of technologies as part of an effort to minimize global climate change. To further this effort, the Korean government has pledged to increase low-carbon and carbon neutral resources for biofuel derived from biomass to replace fossil and to decrease levels of carbon dioxide. In general, second generation biofuel produced form woody biomass is expected to be an effective avenue for reducing fossil fuel consumption and greenhouse gas (GHG) emissions in road transport. It is important that under the new Korean initiative, pilot scale studies evolve practices to produce biomass-to-liquid (BTL) fuel. This study reports the quality characteristics of F-T(Fischer-Tropsch) diesel for production of BTL fuel. Synthetic F-Tdiesel fuel can be used in automotive diesel engines, pure or blended with automotive diesel, due to its similar physical properties to diesel. F-T diesel fuel was synthesized by Fischer-Tropsch (F-T) process with syngas($H_2$/CO), Fe basedcatalyst in low temperature condition($240^{\circ}C$). Synthetic F-T diesel with diesel compositions after distillation process is consisted of $C_{12}{\sim}C_{23+}$ mixture as a kerosine, diesel compositions of n-paraffin and iso-paraffin compounds. Synthetic F-T diesel investigated a very high cetane number, low aromatic composition and sulfur free level compared to automotive diesel. Synthetic F-T diesel also show The wear scar of synthetic F-T diesel show poor lubricity due to low content of sulfur and aromatic compounds compared to automotive diesel.

• Journal of Welding and Joining
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• v.34 no.3
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• pp.6-11
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• 2016

Joining Al/Fe dissimilar metals is becoming a subject of special interest in the assembly of automotive parts as a trade-off between the weight lightening and the cost reduction. Although various studies have been introduced to join Al alloy with the steel sheet by fusion welding, weak joint strength and galvanic corrosion still remained as problems to be solved. As a solid state welding, friction stir welding has been preferred to fusion welding processes in the dissimilar metal joints. This study investigated friction stir spot welding (FSSW) of Al alloy to the thin steel sheet with a thickness of 0.65 mm. The conventional FSSW is a stationary spot welding process but new approach adopted an additional circumferential movement in company with high speed tool rotation. A full factorial experimental design was implemented, and the main and interaction effects of parameters were analysed on the failure load in the tensile shear test. The direction and radius of rotation were statistically significant parameters and these two parameters affected the joint width and the shape of the hook.

• Journal of Electrical Engineering and Technology
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• v.9 no.6
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• pp.1944-1953
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• 2014

This paper shows the design and control methods of the bidirectional DC-DC converter to generate the proper DC-link voltage of a PMSM drive. Conventionally, because the controllable power of the PWM based voltage source inverter is limited by its DC-link voltage, the DC-DC converter is used for boosted DC-link voltage if the inverter source cannot generate enough operating voltage for the PMSM drive. In this paper, to obtain more utilization of this DC-DC converter, optimal DC-link voltage control for PMSM drive will be explained. First, the process and current path of the DC-DC converter will be illustrated, and a control method of this converter for variable DC-link voltage will then be explained. Finally, an improvement analysis of the optimal DC-link voltage control method, especially on the deadtime effect, will be explained. The DC-DC converter of the proposed control method is verified by the experiments by comparing with the conventional constant voltage control method.