• Transactions of the Korean Society of Automotive Engineers
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• v.18 no.1
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• pp.1-7
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• 2010

The paper proposes a multi-body dynamic simulation to numerically evaluate the generated axial force(G.A.F) and plunging resistant force(P.R.F) practically related to the shudder and idling vibration of an automobile. A numerical analysis of two plunging types of CV joints, tripod joint(TJ) and very low axial tripod joint(VTJ), is conducted using the commercial program DAFUL. User-defined subroutines of a friction model illustrating the contacted parts of the outboard and inboard joint are subsequently developed to overcome the numerical instability and improve the solution performance. The Coulomb friction effect is applied to describe the contact models of the lubricated parts in the rolling and sliding mechanisms. The numerical results, in accordance with the joint articulation angle variation, are validated with experimentation. The offset between spider and tulip housing is demonstrated to be the critical role in producing the 3rd order component of the axial force that potentially causes the noise and vibration in vehicle. The VTJ shows an excellent behavior for the shudder when compared with TJ. In addition, a flexible nonlinear contact analysis coupled with rigid multi-body dynamics is also performed to show the dynamic strength characteristics of the rollers, housing, and spider.

• International Journal of Automotive Technology
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• v.7 no.5
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• pp.547-554
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• 2006

This paper is concerned with an optimal control suspension system using the preview information of road input based on a quarter car model. The main purpose of the control is to combine good vibration isolation characteristics with improved attitude control. The optimal control law is derived with the use of calculus of variation, consisting of three parts. The first part is a full state feedback term that includes integral control acting on the suspension deflection to ensure zero steady-state deflection in response to static body forces and ramp road inputs. The second part is a feed-forward term which compensates for the body forces when they can be detected, and the third part depends on previewed road input. The performance of the suspension is evaluated in terms of frequency domain characteristics and time responses to ramp road input and cornering forces. The effects of each part of the suspension controller on the system behavior are examined.

• Transactions of the Korean Society of Automotive Engineers
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• v.22 no.2
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• pp.175-181
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• 2014

A four-link mechanism consisting of torsion bars is used for opening the trunk lid in most midsize sedans. When the weight of the lid is in equilibrium with the spring force exerted by torsion bars, the lid stops opening at a pop-up height. However, the actual pop-up height has large deviations from the specified height even with the same parts in the same car model, which leads to quality issues. Automotive manufacturers have experienced this deviation problem despite much effort to resolve it. In this research, we developed a multi-body dynamics model for the analysis of pop-up deviation of a trunk lid with torsion bars, which can simulate the actual pop-up motion of the trunk lid by considering kinematic constraints of the motion and friction forces in joints. We could also determine the most important factor that governs the pop-up height by sensitivity analysis of all parts. The developed system can be used for the analysis of other trunk lid systems to control the tolerance of parts.

• Journal of Sensor Science and Technology
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• v.32 no.5
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• pp.320-327
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• 2023

In this study, an FPGA-based sealer inspection system was developed to inspect the sealer applied to install vehicle glass on a car body. The sealer is a liquid or paste-like material that promotes adhesion such as sealing and waterproofing for mounting and assembling vehicle parts to a car body. The system installed in the existing vehicle design parts line does not detect the sealer in the glass rotation section and takes a long time to process. This study developed a line laser camera sensor and an FPGA vision signal processing module to solve this problem. The line laser camera sensor was developed such that the resolution and speed of the camera for data acquisition could be modified according to the irradiation angle of the laser. Furthermore, it was developed considering the mountability of the entire system to prevent interference with the sealer ejection machine. In addition, a vision signal processing module was developed using the Zynq-7020 FPGA chip to improve the processing speed of the algorithm that converted the profile to the sealer shape image acquired from a 2D camera and calculated the width and height of the sealer using the converted profile. The performance of the developed sealer application inspection system was verified by establishing an experimental environment identical to that of an actual automobile production line. The experimental results confirmed the performance of the sealer application inspection at a level that satisfied the requirements of automotive field standards.

• Journal of the Korean Society of Safety
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• v.30 no.3
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• pp.1-6
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• 2015

Self-piercing riveting (SPR) is receiving more recognition as a possible and effective solution for joining automotive body panels and structures, particularly for aluminum parts and dissimilar parts. In this study, static strength and fatigue tests were conducted using coach-peel and cross-tension specimens with Al-5052 plates for evaluation of fatigue strength of the SPR joints. For the static experiment results, the fracture modes are classified into pull-out fracture due to influence of plastic deformation of joining area. During the fatigue tests for the coach-peel and cross-tension specimens with Al-5052, interface failure mode occurred on the top substrate close to the rivet head in the most cycle region. There were relationship between applied load amplitude $P_{amp}$ and life time of cycle N, $P_{amp}=715.5{\times}N^{-0.166}$ and $P_{amp}=1967.3{\times}N^{-0.162}$ were for the coach-peel and cross- tension specimens, respectively. The finite element analysis results for specimens were adopted for the parameters of fatigue lifetime prediction. The relation between SWT fatigue parameter and number of cycles was found to be $SWT=192.8N_f^{-0.44}$.

• 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 Automotive Engineers
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• v.25 no.2
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• pp.257-265
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• 2017

In this work, the effect of field-degradation of automotive polymeric interior parts on the squeak characteristics was studied for a number of used vehicles with various mileages and years of service. The purpose of this study was to characterize the squeak noise related with long-term degradation in service life. The characteristics of field-degraded polymeric samples are analyzed using Fourier transform infrared(FT-IR) spectroscopy and scanning electron microscopy(SEM). Complicated carbonyl spectra from FT-IR were deconvoluted into various carbonyls to trace field-degradation phenomenon. In addition, various mechanical tests, i.e. tensile test, hardness test as well as coefficient of friction test, were performed to analyze the variation in mechanical properties due to field-degradation. Squeak noise was measured and analyzed by frequency analysis. It was shown that the changes in the chemical structures of polymer due to field-degradation influenced the variation in mechanical properties, and squeak noise may worsen by increasing the squeak noise level in the wide frequency range. The results indicated that customer complaints regarding the squeak noise coming from used vehicles might be one of the important reliability issues because the increase in sound pressure level especially in the high frequency range could annoy drivers and passengers.

• Proceedings of the Materials Research Society of Korea Conference
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• 2010.05a
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• pp.40.1-40.1
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• 2010

Recently high strength steel sheets with high formability for automotive parts have been being developed to meet the demands for passenger safety and weight reduction of car body. Among these high strength steels, dual-phase steels are regarded as one of the attractive steels due to their excellent mechanical properties including high strength and ductility. However, to be successfully applied to automotive parts they should be corrosion resistant enough to satisfy the required quality of car maker. This also requires their feasibility for galvannealed production including hot dip galvanizability. In this study has been placed on understanding the effects of heat-treatment(austenizing and isothermal treatment) on the microstructures and mechanical properties of a 0.06C-0.03Si-2.0Mn high strength steel for cold forming. The microstructure and phase distribution were examined with eth aids of SEM, EBSD, TEM etc.. Through the study the production of 590MPa grade DP GA steels with good formability and galvaniability were shown to be possible.

• Transactions of the Korean Society of Automotive Engineers
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• v.20 no.5
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• pp.26-35
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• 2012

This paper investigates the influence on the aerodynamic performance of a passenger cruising very fast by some specific car body parts such as side mirrors, wheel arches and wheels designed hardly regarding aerodynamics. The magnitude of the contribution of each part is analyzed via on the CFD simulations. YF SONATA, a sedan of Hyundai Motors Company, plays a major role as the baseline car in this research, representing all passenger car. The CFD analysis condition consists of 6 different cases depending on whether each part exists or not. According to the CFD results, there were confirmed that additionally to the body parts' own drag, the car body went through somewhat the consequential increment of the drag by them. Among the 3 parts, wheel is the magnate that not only has the maximal drag but drives the drag of the passenger car to increase most steeply and the next is the side mirror.

• Transactions of Materials Processing
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• v.32 no.6
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• pp.311-320
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• 2023

Recently, lightweight of automotive parts has been required to solve environmental problems caused by global warming. Accordingly, research and development are proceeded on manufacturing of parts using aluminum that can replace steel for lightweight of the automotive parts. In addition, high strength aluminum can be applied to body parts in order to meet both requirements of lightening and improving crash safety of vehicle. In this study, hot blow forming of roof side rail is employed to manufacturing of the automotive parts with high strength aluminum tube. In hot blow forming, longer forming times and excessive thinning can be occurred as compared with conventional manufacturing processes. So optimization of process conditions is required to prevent excessive thinning and to uniformize thickness distribution with fast forming time. Mechanical properties of high strength aluminum are obtained from tensile test at high temperature. These properties are used for finite element(FE) analysis to investigate the effect of strain rate on thinning and thickness distribution. Variation of thickness was firstly investigated from the result of FE analysis according to tube diameter, where the shapes at cross section of roof side rail are compared with allowable dimensional tolerance. Effective tube diameter is determined when fracture and wrinkle are not occurred during hot blow forming. Also FE analysis with various pressure-time profiles is performed to investigate the their effects on thinning and thickness distribution which is quantitatively verified with thinning factor. As a results, optimal process conditions can be determined for the manufacturing of roof side rail using high strength aluminum.