• Proceedings of the KSR Conference
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• 2002.05a
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• pp.386-391
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• 2002

Stainless rolling stocks are usually fabricated by spot welding process without painting. Indentation on the surface of the car body after spot welding injures the beauty of the stainless rolling stocks. In this study, electrode tips to reduce the indentation are developed and applied to the actual spot welding works. The developed tips are composed of head, nut hole far cooling water, body and resistance material. They provide large surface contact area with the base materials during spot welding and enhance the current density by necking. Experimental results using the developed tips show that small indentation and sufficient tensile shear strength is produced due to large contact area and enhanced current density.

• Proceedings of the KSME Conference
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• 2003.11a
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• pp.1757-1762
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• 2003

For coping with various ship types easily, welding automation using CAD/CAM is demanded and and developed. In this paper we propose a dedicated CAM system which generates MACRO files to control robot manipulators. The paper contains CAD interface, virtual simulation, macro generation and job schedulling. At first, it defines and extracts weldline from CAD data, and generates proper MACRO programs. And it obtains optimum job schedules. This system removes the manual work, and consequently reduces the overall lead time. And it reduces costs and time for developing robot welding programs. This can be expanded to virtual factory simulation technology. Moreover, it is possible to apply this system for automation of Cutting and Painting

• Proceedings of the KWS Conference
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• 2005.06a
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• pp.188-190
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• 2005

• Journal of Power System Engineering
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• v.21 no.1
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• pp.30-36
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• 2017

In robot industries, the request to obtain a high efficiency and accurately controlled electric actuator has been growing. Nevertheless, the effectiveness of electric actuators is significantly affected by the presence of factors such as nonlinearity, uncertain disturbance and unknown dynamics. Therefore, it makes difficult to derive an exact mathematical model of the controlled system. In this paper, a new method for easily recognizing and regenerating robot motions used in small size industries such as painting and welding parts is proposed. Instead of modeling the entire dynamic motion of the robot system, this method is based on the procedure of modeling and controller design for every arm individually. The proposed method does not require complex model and control system such that it gives easy working process to the small size industries. Based on this fact, in this research, the model and PID controller for every arm of the 3 DOF robot system are obtained separately. Some experimental results are implemented to validate the effectiveness of the proposed method.

• Journal of Welding and Joining
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• v.34 no.1
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• pp.59-67
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• 2016

The automotive manufactures increase their use of lightweight materials to improve fuel economy and energy usage has a significant influence on the choice of developing materials. To meet this requirements manufacturers are replacing individual body parts with lightweight metals, for these the process treating and painting surfaces is changing. The pre-coated steels are newly developed to avoid the conventional complex and non-environmental painting process in the body-in-white car manufacturing. The development of new joining techniques is critically needed for pre-coated steel sheets, which are electrically non-conductive materials. In the present study, dissimilar combination of pre-coated steel and galvanized steel sheets were joined by the self-piercing rivet, adhesive bonding and hybrid joining techniques. The tensile shear test and free falling high speed crash test were conducted to evaluate the mechanical properties of the joints. The highest tensile peak load with large deformation was observed for the hybrid joining process which has attained 48% higher than the self-piercing rivet. Moreover, the hybrid and adhesive joints were observed better strain energy compared to self-piercing rivet. The fractography analyses were revealed that the mixed mode of cohesive and interfacial fracture for both the hybrid and adhesive bonding joints.

• Journal of the Korean Society of Industry Convergence
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• v.25 no.5
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• pp.799-810
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• 2022

Welding work is a production work method widely used throughout the industry, and various types of welding technologies exist. In addition, many methods are being studied to automate these welding operations using robots, but in the ship manufacturing field, welding such as painting, cutting, and grinding is also the most common operation, but the manual operation ratio is higher than in other industries. Such a high manual labor ratio in the field of ship manufacturing not only causes quality problems and production delays according to the skill of workers, but also causes problems in the supply and demand of manpower. Therefore, this paper analyzed the reason why the automation rate is low in welding work at ship manufacturing sites compared to other industries, and analyzed the production process and field environment for small and medium-sized ship manufacturing companies that repeatedly manufactured with a small quantity production method. Based on the analysis results, it is intended to propose a robot system that can easily move between workplaces and secure uniform welding quality and productivity by collaborating simple welding tasks with humans. Finally, the simulation environment is constructed and analyzed to secure the suitability of robot system application to current production site environment, work process, and productivity, rather than to develop and apply the proposed robot system. Through such pre-simulation and robot system suitability analysis, it is expected to reduce trial and error that may occur in actual field installation and operation, and to improve the possibility of robot application and positive perception of robot system at ship manufacturing sites.

• Journal of Korean Society of Occupational and Environmental Hygiene
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• v.16 no.4
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• pp.398-412
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• 2006

The purpose of this study is to investigate the relationship between the acceleration of vibration by the powered hand tools used in the shipbuilding industry, and to develop the prospective prevalence model for the hand-arm vibration syndrome among the shipbuilding workers.The acceleration levels and frequencies of six types of grinder were measured using the ISO5349 method along with the time of exposure to the vibration from the powered hand tools. Medical examination for 114 workers were performed using the cold provocation test. Comparisons were made between the estimated prevalence of hand-arm vibration syndrome from ISO5349 and the observed values from the medical examinations. By multiple regression, we developed the prospective prevalence model of hand-arm vibration syndrome produced by the hand tools used in the shipbuilding industry. 4 hour-energy-equivalent frequency-weighted accelerations were $6.23m/s^2$ in the grinding job done after welding, and $13.39m/s^2$ in the grinding job done before painting. The mean exposure time while holding powered hand tools was 4.64 hours. Prevalence rates of Raynaud's Phenomenon were 12.04% in the grinding after soldering, and 42.9% in the grinding before painting measured using the ISO5349 method. After exposure to vibration for 10.79 years, about a half of the workers in the grinding after welding could developed Raynaud's Phenomenon. For the workers in the grinding before painting, the latency was 5.02 years. The ISO equation for dose response relationship was not significantly correlated with observed recovery rates of finger skin temperatures, blood flows and amplitudes of nerve conduction velocities. A multiple regression model for dose-response relationship was proposed from the results. Recovery rate of the skin temperatures = -0.668+ 0.337 ${\times}$ 4 hour energy equivalent frequency-weighted accelerations + 0.767 ${\times}$ duration of vibration exposure(years) The validity was proved by multiple regression analysis after correlation transformation and regression results based on model-building data and validation data.

• Corrosion Science and Technology
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• v.18 no.1
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• pp.16-23
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• 2019

Steels for automotive fuel tank require unique properties such as corrosion resistance for fuel, welding for joining, forming for press, and painting for exterior. Recently, automakers have been requiring excellent seam weldable steels to enhance manufacturing productivity of fuel tank. Thus, POSCO developed a new type of functional steels coated with nano-composite thin layer on Zn-Ni plating steels. The nano-composite coating solution was prepared by mechanical fine dispersion of solutions consisting of polymeric resin and nano-composite materials in aqueous media. The composite solution was coated on the plating steel surface by using roll coater and cured through induction furnace. These new developed plating steels were evaluated for quality performances such as seam and spot weldability, press formability, and corrosion resistance. These new functional steels coated with nano-composite layer exhibited excellent seam weldability and press formability. Detailed discussion of coating solution and experimental results suggest that nano-sized composite dispersion as coating layer plays a key role in enhancing the quality performance.

• Proceedings of the Korea Committee for Ocean Resources and Engineering Conference
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• 2006.11a
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• pp.281-284
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• 2006

After building a ship in a shipyard, there are so many repeated inspection of welding seam defects and painting status before delivering to the ship's owner. An inspection on the bottom part of a ship in commercial service should be done in every two years for the purpose of safety and for the prevention of ship speed deterioration. conventional welding seam inspection systems are rely on the visual inspection by human or the ultrasonic inspection for the selective part of a ship. This paper suggests a remote controlled inspection system for the examination of large ships or steel structures. The proposed system moves in contact with the ship under inspection and have a CCD camera to provide visual-guidance information to a remotely located human worker. Additionally this system utilizes a weld line tracking algorithm for an optimal position control. We verified the effectiveness of the inspection system by experimental data.

• Journal of the Ergonomics Society of Korea
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• v.31 no.1
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• pp.177-183
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• 2012

Objectives: The objectives of this study are to discuss the importance of job stress and to introduce a model of job stress at the shipbuilding industry considering the characteristics of the shipbuilding works. Background: Shipbuilding works consist of grinding, painting, interior works, welding, and assembling and using heavy equipment in narrow space or work at outside or at high and dangerous places. The working environments aggravate the stress to the workers. Methods: Studies of job stress in industries including shipbuilding industries were reviewed and the characteristics of jobs of shipbuilding were analyzed to find causes of job stress. Results: A model was constructed based upon these findings and reviews. Conclusions: Job stress of shipbuilding workers are very high and thus job and working conditions need to be improved to attenuate the level of job stress of shipbuilding workers. Applications: This model can be used to identify the highly stressed workers and sources of stress.