• Journal of the Korean Society of Manufacturing Process Engineers
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• v.21 no.7
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• pp.84-90
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• 2022

The purpose of the cover housing component of a car door is to protect the terminals of the plug housing that connects the electric control unit on the door side to the car body. Therefore, for a smooth assembly with the plug housing and to prevent contaminants from penetrating into the gaps that occur after assembly, the warpage of the cover housing should be minimized. In this study, to minimize the warpage of the cover housing, optimization was performed for design factors related to the mold and processes based on the injection molding simulation. These design factors include gate location, gate diameter, injection time, resin temperature, mold temperature, and packing pressure. To optimize the design factors, Taguchi's approach to the design of experiments was adopted. The optimal combination of the design factors and levels that minimize warpage was predicted through L₁₈-orthogonal array experiments and main effects analysis. Moreover, the warpage under the optimal design was estimated by the additive model, and it was confirmed through the simulation experiment that the estimated result was quite consistent with the experimental result. Additionally, it was found that the warpage under the optimal design was significantly improved compared to both the warpage under the initial design and the best warpage among the orthogonal array experimental results, which numerically decreased by 36.9% and 23.4%, respectively.

• Transactions of the Korean Society for Noise and Vibration Engineering
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• v.17 no.9
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• pp.853-861
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• 2007

Currently, automotive industries improve the vehicle performance and reduce the development period of vehicle using each module part for the high quality and performance of vehicles. However each component part doesn't generate the noise and vibration problems, sometime these problems are generated on the assembly status between vehicle chassis frame and each module part. On this study, in order to analysis the dynamic characteristics of a shield door module that is a typical module part of vehicles, the acquisition and evaluation process about the vibration and noise of shield door module is developed. Also the possibility to apply to shield door module of the developed process is verified by the comparison with the dynamic characteristics between plastic and steel module plate.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2004.10a
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• pp.295-298
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• 2004

Automobile door-handle is assembled with three parts that are base, skin and cover. Over-molding processing makes assembly of the base and skin. The skin part that was made by PVC polymer has various thickness. Plastic injection molding simulation of part including significant changed thickness as skin is an inaccuracy comparing with real injection molding. To solve this problem, two commercial flow prediction software that are Moldflow MPI and MAPS 3D were used in this study. Simulations were conducted for three types mesh. Taguchi method was applied for simulation experiments. It will be need to compare with simulation results and real over-molding behavior in the near future.

• Journal of Korean Society of Industrial and Systems Engineering
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• v.34 no.4
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• pp.138-144
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• 2011

The design flexibility and robustness have become key factors to handle various sources of uncertainties at the early phase of design. Even though designers are uncertain about which single values to specify, they usually have a preference for certain values over others. In the first and second reports of a four-part paper, a set-based design approach has been proposed for achieving design flexibility and robustness while capturing designer's preference, and its effectiveness has been illustrated with a simple vehicle side-door impact beam design problem. This report presents the applicability of the proposed design approach to the large-scale multi-objective design optimization with a successful implementation of real vehicle side-door structure design.

• Journal of the Korean Society for Precision Engineering
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• v.13 no.3
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• pp.34-41
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• 1996

This work deals with finding a suitable position correction algorithm of industrial robot based on measuring particular points, which calculates two dimensional correction quantities and the must allow visually acceptable door-chassis assembly task. Three optimizing algorithms corresponding to three differ- ent error based performance indices are compared and selected to the best one, in terms of the predefined total uniformity, line uniformity and computational time. The selected algorithm(Total Error Minimization) is implemented for a simple door-chassis model to show its effectiveness.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.19 no.6
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• pp.80-87
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• 2020

The currently observed trend in car manufacturing is to increase energy-efficiency by producing lighter cars. This study examines the replacement of particular parts, specifically around the impact beam, with material composites 30% lighter than conventional steel currently used. The shape of the impact beam was determined as the trapezoidal cross-sectional area with central reinforcement, using three-point bending analysis. A prototype was fabricated based on the findings of our study and its performance was evaluated by the three-point bending analysis; 2 ply of aramid applied for its displacement. The performance of the final prototype for the door assembly was evaluated using a side-door strength test, which resulted to measured initial strength of 10.5 KN and intermediate strength of 15.6 KN. This research provides a promising solution for better impact beam manufacturing.

• Proceedings of the Korean Society for Noise and Vibration Engineering Conference
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• 2007.11a
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• pp.291-296
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• 2007

This study presents the evaluation process for door module. Its objective evades the resonance generated at module plate due to the operation of window regulator motor. For this study, the design improvement process is composed of experimental methods having three steps. First step is modal analysis at door assembly status for acquisition of dynamic characteristics which are modal frequency and damping. Second step is a vibration experiment to get the test mode considered an efficiency of window regulator motor. Last step is a vibration measurement by the form of $6{\times}6$ array on module plate. A vibration measurement of 6x6 array form can be got to three analysis results which are a transfer path of vibration using cross correlation function, a vibration map using OA level and a contribution by frequency band using coherent output power spectrum on module plate. These results are applied to SDM(structural dynamic modification) for design improvement to get around the resonance on module plate by the excitation of window regulator motor.

• Transactions of the Korean Society for Noise and Vibration Engineering
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• v.17 no.11
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• pp.1093-1101
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• 2007

This study presents the design improvement process for door module. Its objective evades the resonance generated at module plate due to the operation of window regulator motor. For this study, the design improvement process is composed of experimental methods having three steps. First step is modal analysis at door assembly status for acquisition of dynamic characteristics which are modal frequency and damping. Second step is a vibration experiment to get the test mode considered an efficiency of window regulator motor. Last step is a vibration measurement by the form of $6{\times}6$ array on module plate. A vibration measurement of $6{\times}6$ array form can be got to three analysis results which are a transfer path of vibration using cross correlation function, a vibration map using OA level and a contribution by frequency band using coherent output power spectrum on module plate. These results are applied to SDM(structural dynamic modification) for design improvement to get around the resonance on module plate by the excitation of window regulator motor.

• Journal of the Korean Society for Precision Engineering
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• v.31 no.1
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• pp.59-66
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• 2014

The central seam, the vertical 'line' between doors, in the front view of a refrigerator must have its gap and flush within certain ranges to meet functional and aesthetic requirements. The conventional criteria for gap and flush control in the industry are to keep the gap and flush within certain ranges at each of various points along the seam. For aesthetics, however, the uniformity of the gap is also as important because a 'tapered' seam is negatively perceived by human eyes. This paper shows a case study of tolerance design for a refrigerator door system. It presents a step-by-step procedure, which consists of datum flow chain analysis, identification of assembly features, computer modeling of feature tolerances, assembly operations and measurements, tolerance simulation, and tolerance adjustments based on the simulation results. It is found that extra care may need to be used to satisfy the aesthetical criterion for gap uniformity.

• Transactions of the Korean Society of Automotive Engineers
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• v.24 no.5
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• pp.527-537
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• 2016

Recent automakers are trying to be more precise with the dimension check and moving parts to guarantee high quality and satisfy customer requirements. The aim of this paper is to investigate the design tolerance suitability of door operating mechanism linked arms, lever, and cam-shaft in a mobile air handling unit. These parts are complicated because doors, arms, lever and cam-shaft are connected nonlinearly in 3D. The current tolerance analysis method poses problems in design analysis because the moving doors are reasonably suitable for the AHU function. The 3-DCS analysis method provided useful results not only in establishing the inspection criteria for the quality control of products but also in enabling economical production. As a result, the vent door had $1.62^{\circ}{\sim}1.72^{\circ}$ and the defrost door had $0.84^{\circ}{\sim}0.9^{\circ}$ for the directly connected arms operating-type. For the lever connected arm operating-type, the foot door had $2.0^{\circ}{\sim}2.24^{\circ}$ tolerance, while the tolerance values satisfied the air flow volume distribution rate criteria in the AHU. Finally, the results have confirmed the design's tolerance suitability by using 3-DCS analysis at the early design stages. Reliability can be achieved by analyzing accumulated tolerance during the sub-parts assembly process and the moving mechanism linked especially by arms, lever, and cam-shaft.