• The Transactions of The Korean Institute of Electrical Engineers
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• v.60 no.6
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• pp.1274-1279
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• 2011

The purpose of this paper is to present the manufacturing defect and damage pattern of a 3 phase 22.9/3.3kV oil immersed transformer, as well as to present an objective basis for the prevention of a similar accident and to secure data for the settlement of PL related disputes. It was found that in order to prevent the occurrence of accidents to transformers, insulating oil analysis, thermal image measurement, and corona discharge diagnosis, etc., were performed by establishing relevant regulation. The result of analysis performed on the external appearance of a transformer to which an accident occurred, the internal insulation resistance and protection system, etc., showed that most of the analysis items were judged to be acceptable. However, it was found that the insulation characteristics between the primary winding and the enclosure, those between the ground and the secondary winding, and those between the primary and secondary windings were inappropriate due to an insulating oil leak caused by damage to the pressure relief valve. From the analysis of the acidity values measured over the past 5 years, it is thought that an increase in carbon dioxide (CO2) caused an increase in the temperature inside the transformer and the increase in the ethylene gas increased the possibility of ignition. Even though 17 years have passed since the transformer was installed, it was found that the system's design, manufacture, maintenance and management have been performed well and the insulating paper was in good condition, and that there was no trace of public access or vandalism. However, in the case of transformers to which accidents have occurred, a melted area between the upper and the intermediate bobbins of the W-phase secondary winding as well as between its intermediate and lower bobbins. It can be seen that a V-pattern was formed at the carbonized area of the transformer and that the depth of the carbonization is deeper at the upper side than the lower side. In addition, it was found that physical bending and deformation occurred inside the secondary winding due to non-uniform pressure while performing transformer winding work. Therefore, since it is obvious that the accident occurred due to a manufacturing defect (winding work defect), it is thought that the manufacturer of the transformer is responsible for the accident and that it is lawful for the manufacture to investigate and prove the concrete cause of the accident according to the Product Liability Law (PLL).

• Transactions of the Korean Society of Mechanical Engineers A
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• v.37 no.10
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• pp.1201-1206
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• 2013

Defects that occur during the manufacturing process or operation of a wind turbine blade have a great influence on its life and safety. Typically, defects such as delamination, pore, wrinkle and matrix crack are found in a blade. In this study, the detectability of the pores, a type of defect that frequently occur during manufacturing, was examined from the full field strain distribution determined with the image correlation technique. Pore defects were artificially introduced in four-ply laminated GFRP composites with $0^{\circ}/{\pm}45^{\circ}$ fiber direction. The artificial pores were introduced in consideration of their size and location. Three different-sized pores with diameter of 1, 2 and 3 mm were located on the top and bottom surface and embedded. By applying static loads of 0-200 MPa, the strain distributions over the specimen with the pore defects were determined using image correlation technique. It was found the pores with diameter exceeding 2 mm can be detected in diameter.

• Journal of Korean Society of Industrial and Systems Engineering
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• v.39 no.1
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• pp.130-139
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• 2016

The purpose of this paper is to analyze the problems and the sources of defective products and draw improvement plans in a small plastic boat manufacturing process using TOC (Theory Of Constraints) and statistical analysis. TOC is a methodology to present a scheme for optimization of production process by finding the CCR (Capacity Constraints Resource) in the organization or the all production process through the concentration improvement activity. In this paper, we found and reformed constraints and bottlenecks in plastic boat manufacturing process in the target company for less defect ratio and production cost by applying DBR (Drum, Buffer, Rope) scheduling. And we set the threshold values for the critical process variables using statistical analysis. The result can be summarized as follows. First, CCRs in inventory control, material mix, and oven setting were found and solutions were suggested by applying DBR method. Second, the logical thinking process was utilized to find core conflict factors and draw solutions. Third, to specify the solution plan, experiment data were statistically analyzed. Data were collected from the daily journal addressing the details of 96 products such as temperature, humidity, duration and temperature of heating process, rotation speed, duration time of cooling, and the temperature of removal process. Basic statistics and logistic regression analysis were conducted with the defection as the dependent variable. Finally, critical values for major processes were proposed based on the analysis. This paper has a practical importance in contribution to the quality level of the target company through theoretical approach, TOC, and statistical analysis. However, limited number of data might depreciate the significance of the analysis and therefore it will be interesting further research direction to specify the significant manufacturing conditions across different products and processes.

• Journal of IKEEE
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• v.19 no.1
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• pp.64-72
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• 2015

In this paper, we have developed the gantry automation system via information technology (IT) to improve the productivity of fuel filter manufacturing process. The monitoring system of manufacturing process plays an important role in analyzing the defective products as well as improving the production yield rate. The experimental results of 3 months with 10000 samples validate that the error rate is decreased from 0.65 % to 0.45 %. Also, the defect of raw material is decreased via monitoring of material tools which can notify the time for replacement and accurate insertion of raw materials to the loader. The productivity is increased by reducing the process time from 94.7 sec to 78.8 sec per raw material through comparing the whole manufacturing courses : from inserting of raw material to outcome of product. The process time is decreased by 20.2 % by automation of inserting and outcome course. Moreover, safety of worker as well as reduction of transfer time are highly related with increase of productivity.

• Journal of the Korea Institute of Military Science and Technology
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• v.22 no.3
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• pp.299-310
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• 2019

Increase of combat capability through the lightweighting of vehicles has been internationally issued. One of the methods for lightening is applying high hardness armor(HHA) steel which is outstanding ballistic performance and protection performance compared to weight. Development of HHA steel is currently completed in America, United Kingdom, Australia and Germany. It is used for not only combat vehicle, but also various combat device. Korea is developing new material of HHA steel according to this trend. When such HHA steel is applied to structure, welding process is used for connection of the structure. Cracks from hydrogen embrittlement and cold cracking are easily generated in welds of HHA steel and it greatly affects the strength of all structure. Decrease of strength from welding defect is critical to combat capability. Therefore, welding process optimization is important for performing the role of structure. In this study, international welding technology is reviewed through scientific research paper and patent.

• Design & Manufacturing
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• v.14 no.4
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• pp.65-70
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• 2020

Partial reinforcement of sheet metal parts with CFRP patch is a technology that can realize ultra-lightweight body parts while overcoming the high material cost of carbon fiber. Performing these patchworks with highly productive press equipment solves another issue of CFRP: high process costs. The A-pillar is the main body part and has an undercut shape for fastening with other parts such as roof panels and doors. Therefore, it is difficult to bond CFRP patches to the A-pillar with a general press forming tool. In this paper, a flexible system that applies uniform pressure to complex shapes using ceramic particles and silicone rubber is proposed. By benchmarking various A-pillars, a reference model with an undercut shape was designed, and the system was configured to realize a uniform pressure distribution in the model. The ceramic spherical particles failed to realize the uniform distribution of high pressure due to their high hardness and point contact characteristics, which caused damage to the CFRP patch. Compression equipment made of silicone rubber was able to achieve the required pressure level for curing the epoxy. Non-adhesion defects between the metal and the CFRP patch were confirmed in the area where the bending deformation occurred. This defect could be eliminated by optimizing the process conditions suitable for the newly developed flexible system.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.18 no.6
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• pp.375-380
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• 2017

This study assessed the technology to minimize the discoloration to reduce the defect rate and penetrate the curing solution through the egg shells to produce quality smoked eggs that meet the preference of consumers. The discoloration refers to the defects on the colors of egg shells due to overheated smoking fluids, causing the eggs to be discarded. The manufacturing process was prepared by the manufacturer of the regular smoked egg manufacturing process. A preliminary study found that the preferred salinity of smoked eggs was 1.67~2.00% and the major processing factors have been set to maintain the optimal salinity of smoked eggs and an industrially attainable minimum defect rate below 3%. When the eggs were aged at $50^{\circ}C$ for 96 hours to produce the smoked eggs, the discoloration rate was 0%. When the circulatory dipping method was applied, 3.00% salinity was achieved after 8 hours. When the eggs were smoked at that time, the salinity was 1.67%. With a $2.07kg/cm^2$ pressure, 3.33% salinity was achieved after 4 hours and 2.00% salinity was achieved when the smoked eggs were produced. To identify the most efficient pressurizing method, 0.52, 1.55, 1.86, 2.07, 2.38, 2.58, and $3.62kg/cm^2$ were applied, the discoloration rate was 2.2% after 4 hours under a $2.07kg/cm^2$ pressure. The aging and pressurized method is considered to be the basis for reducing the manufacturing time and decreasing the rate of error during the smoked eggs process.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.14 no.6
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• pp.14-20
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• 2015

A high-speed reduction transfer case is usually employed by an excavator, wheel loader, or bulldozer. When powerful torque is required in the case of climbing steep roads or towing heavy equipment, the high-speed reduction mode of the gearbox is used. Generally, a transfer case using a spur gear type with a speed reduction system has a speed reduction ratio of 1 to 1 or 2 to 1. However, the structure of a transfer case achieved at a high speed of 1 to 1 and a low speed of 4.5 or under 5.5 to 1 with the speed reduction by use of a planetary gear type with a speed reduction system was proposed in this study. By employing a planetary gear type with a speed reduction system, the compact structure of the transfer case was achieved, and the impact or the partial defect of gear teeth was eliminated.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.6 no.2
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• pp.34-40
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• 2007

Antifatigue failure technology take an important part of current industries. Currently, the shot peening is used for removing the defect from the surface of steel and improving the fatigue strength on surface. Therefore, this paper the effect of compressive residual stress and corrosion of spring steel(SAE 5155)by shot-peening on fatigue crack growth characteristics in stress ratio(R=0.05)was investigated with considering fracture mechanics. By using the methods mentioned above, We arrived at the following conclusions. The fatigue crack growth rate(da/dN) of the shot-peening material was lower than that of the un-peening material. And in stage I, ${\Delta}Kth$, the threshold stress intensity factor, of the shot-peen processed material is high in critical parts unlike the un-peening material. Also m, fatigue crack growth exponent and number of cycle of the shot-peening material was higher than that of the un-peening material. That is concluded from effect of da/dN. Finally fracture of shot-peening material and un-peening material was identified and discussed in this study.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.9 no.5
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• pp.135-143
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• 2000

The vision system is easy to use the exclusive use as a independent computer system but it is not much popularization by reason of expensive and difficult to adapt to the various fields, because it is easy to the existed computer system, the price is cheap and also it can use to the various measurement purpose which user wanted and programed. The measurement method of the vehicle axle casing nut welding part is that measure the value of the welding part to adapt the actual operation program from using the ratio between the actual length of the standard specimen and the length of image, to measure the ratio between the actual product and the camera image. A defect is found by the assembled visual inspection system. The inspection algorithm which estimates the quality of welded product is developed and also, the software program which processes the automatic test function of the inspection system. We make the foundation of the inspection automatic system and we will help to apply other welding machine.