• Journal of the Korean Society of Manufacturing Process Engineers
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• v.7 no.3
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• pp.12-16
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• 2008

The state of deformation and stress and the structural safety are studied at the main frame composed with car body by the impact of front, offset and overturn in this study. The values of maximum deformation and von-Mises stress in case of offset impact are 2 to 3 times as high as those in case of front or offset impact at the parts of front and middle legs of roll cage. The case of front impact is of the greatest safety as compared with the case of offset or overturn impact. As there is a great stress on the side in case of overturn impact, this value is more than 2 times as low as that in case of offset impact. But there is a great possibility of overturn by the buckling on both sides in case of overturn impact.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.35 no.2
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• pp.213-221
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• 2011

In this study, we discussed the weight reducing of a urban railway-car body, in particular, of the Korean EMU, by optimizing topology and size of aluminum extrusion profiles. The heaviest parts of aluminum railway-car bodies, i.e., the base plate of underframe and side panels of side frame composed of double skin structures are considered for optimization. Topology optimization process is applied to obtain get an optimized rib structure for the base plate. The thickness of ribs and plates of the topologically optimized base plate and the existing side panel are also optimized by employing the size optimization process. The results are verified by comparing the maximum von Mises stresses and maximum deformation in the case of the existing design with those in the case of the optimized design. It is shown that the weight of a base plate and side panel can be reduced by 12% and that the weight of the whole car body can be reduced by 8.5%.

• 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 Welding and Joining
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• v.34 no.1
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• pp.21-25
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• 2016

The automotive vehicle is made through the following processes such as press shop, welding shop, paint shop, and general assembly. Among them, the most important process to determine the quality of the car body is the welding process. Generally, more than 400 pressed panels are welded to make BIW (Body In White) by using the RSW (Resistance Spot Welding) and GMAW (Gas Metal Arc Welding). Recently, as the needs of light-weight material due to the $CO_2$ emission issue and fuel efficiency, new joining technologies for aluminum, CFRP (Carbon Fiber Reinforced Plastic) and etc. are needed. Aluminum parts are assembled by the spot welding, clinching, and SPR (Self Piercing Rivet) and friction stir welding process. Structural adhesive boning is another main joining method for light-weight materials. For example, one piece aluminum shock absorber housing part is made by die casting process and is assembled with conventional steel part by SPR and adhesive bond. Another way to reduce the amount of the car body weight is to use AHSS (Advanced High Strength Steel) panel including hot stamping boron alloyed steel. As the new materials are introduced to car body joining, productivity and quality have become more critical. Productivity improvement technology and adaptive welding control are essential technology for the future manufacturing environment.

• Proceedings of the Korean Society for Noise and Vibration Engineering Conference
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• 2014.04a
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• pp.466-471
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• 2014

The interior vehicle noise due to the exterior aerodynamic field is an important topic in the acoustic design of a car. The air flow detached from the A-pillar and impacting the side windows are of particular interest as they are located close to the driver / passenger and provides a lower insulation index than the trimmed car body parts. This paper presents a numerical analysis method for a simplified vehicle model. The internal air cavity including trim component are included in the simulation. The car body includes the windshield and two side windows. The body is made of aluminum and trimmed with porous layers. The methodology proposed in this paper relies on two steps: the first step involves the computation of the exterior flow and turbulence induced non-linear acoustic field using PowerFlow. The second step consists in the computation of the vibro-acoustic transmission through the window using the finite element vibro-acoustic solver Actran. Additionally in order to validate the numerical process, an experimental set-up has been created based on the simplified vehicle. The vibration of the windshield and windows, the total wind noise level results and the relative contributions of the different windows are then presented and compared to measurements. The influence of the flow yaw angle (different wind orientation) is also assessed.

• Journal of the Korean Society for Precision Engineering
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• v.22 no.5 s.170
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• pp.130-137
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• 2005

Recently, the importance of CAE research is growing with the advances of the automotive and computer industry. In addition, multi-body dynamics and powertrain analysis are the most important factors in improving the vehicle design. Since engine torque with curve-data was used for analyzing full car simulation in the multi-body dynamics system for many years, it is impossible to assess the concurrent analysis of the engine and powertrain element included in a real full car system. In powertrain, since vehicle are usually modeled as a simple mass and a inertia, they can not be seen as real cars. Moreover, it is hard to obtain additional dynamics data other than the longitudinal velocity value in movement. Because of the reason that was previously discussed, it is necessary to consolidate the two parts as one routine program for design and development through the coordinate system connectivity, and presented here is a program named O-DYN. Using an object-oriented language C++, this program has a good structure with the valuable characteristics of objectivity, inheritance, and reusability. The reliability of this multi-body dynamics program is examined by DADS, which is the general dynamics program, using DAE solver and PECE integral function with the common coordinator separation method. As a result, we can obtain a better solution and total dynamics data in either area through this process. This program will be useful for analyzing full car simulation with powertrain.

• Journal of Sensor Science and Technology
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• v.33 no.3
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• pp.179-184
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• 2024

In the car industry, welding is a fundamental linking technique used for joining components, such as steel, molds, and automobile parts. However, accurate inspection is required to test the reliability of the welding components. In this study, we investigate the detection of weld beads using 2D image processing in an automatic recognition system. The sample image is obtained using a 2D vision camera embedded in a lighting system, from where a portion of the bead is successfully extracted after image processing. In this process, the soot removal algorithm plays an important role in accurate weld bead detection, and adopts adaptive local gamma correction and gray color coordinates. Using this automatic recognition system, geometric parameters of the weld bead, such as its length, width, angle, and defect size can also be defined. Finally, on comparing the obtained data with the industrial standards, we can determine whether the weld bead is at an acceptable level or not.

• Proceedings of the Korean Society for Noise and Vibration Engineering Conference
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• 2005.11b
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• pp.140-143
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• 2005

The hybrid CAE/CAT methods are widely applied to product development in various fields because this method can predict the response of the whole system when a part of the system is changed. Especially, the hybrid CAE/CAT method is very useful to predict tile vehicle NVH characteristics after changing some parts of the vehicle. Target parts can be established on the basis of test models and FE models of the prototype constructed in the planning stage of car development. In this study, the topic was focused on the proper test-based FBS application process to predict vehicle NVH characteristic. First, the test-based FBS method was apply to vehicle substructure and car-body. And then the test-based model was replaced with FE model to apply hybrid CAE/CAT method. The replaced FE model was modified through the optimization process. The interior noise in vehicle during the drive was predicted with Modified FE model, then the predicted results were verified by experimenting with actual modified model.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1998.06a
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• pp.110-120
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• 1998

Tailor-welded blanks are made of two or more different blanks in thickness or material. So car body with tailor-welded blanks need not reinforcement panels. However in order to make stamping tools for tailor-welded blanks, die engineers should know about the exact position of the welding line after the part is drawn. The necessity of knowledge about the position of welding line needs forming simulation methodology as a prior step in tooling. Therefor some parts of the simulation methodology are proposed and compared with the experimental results.

• Proceedings of the KSR Conference
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• 2004.10a
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• pp.616-621
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• 2004

In this paper, the crush characteristics of a tilting train express (TTX) M-car design are evaluated with a head-on collision scenario. Its body shell is divided into three parts - front end, middle section, and rear end. For each part, crush-force relation is evaluated numerically through 3-dimensional shell element analysis with LS-DYNA. TTX's embody structure is a hybrid type structure made of steel and composite materials. Composite sandwich panels are modeled as layered shells whose layers have different material properties. And a damage material model is used to consider the effect of stiffness degradation during deformation. The crush characteristics obtained from these calculations will be used as material modeling data of full-rake collision analyses.