We introduce FEST (Flight Environment Simulation Test) procedures for precise guided missiles to reliably improve systems. Flight vibration specification was established based on power spectral density curves calculated from flight test data of a high speed precise guided missile. A FEST pre-profile was developed according to flight vibration specification and delivered to a precise guided missile assembly. Vibration responses were measured by installing accelerometers on electronic components vulnerable to dynamic forces. The FEST profile was adjusted by comparing the vibration responses and the flight vibration specification. Subsequently, the FEST profile was repeatedly modified through trial and error, because the responses were similar to the flight environment. The modified FEST profile enabled performance testing of assembled precise guided missiles under simulated flight conditions on the ground, where unexpected errors could be corrected before the flight tests, leading to cost and risk reduction in the development of the precise guided missile system.

The weight of an antenna system pointing satellite on the mobile platform is restricted by the weight limit of the mobile platform. The maximum power of the actuator driving the antenna system is thus limited because a high power actuator needs a heavier weight. Thus, a drive system is designed to have a low torque requirement by reducing the gravitational torque depending on gravity or acceleration of the mobile platform, including vibration, shock, and accelerated motion. To reduce the gravitational torque, the mathematical model of the gravitational torque is preferentially obtained. However, the method to directly estimate the mathematical model in an antenna system has not previously been reported. In this paper, a method is proposed to estimate the gravitational torque as a mathematical model in the antenna system. Additionally, a method is also proposed to calculate the optimal weight of the balancing weight to compensate for the gravitational torque.

The vehicle-mounted radar system (VMRS) including its electronic parts must be designed so that its performance is maintained under varying environmental conditions. The important aspects are typically weight and safety. Since many rotating VMRSs have been developed, discussion about the vibration and shock requirements for the transportation conditions has occurred: in addition, the dynamic unpaved, paved, and off-road effects have been emphasized with respect to lightweight designs. A lightweight-design VMRS should be capable of operating stably under the wind condition with the support of the vehicle structure. In this paper, a structural analysis regarding the support of the VMRS is performed, whereby the real-load conditions for three types of road and pressure were employed in terms of the wind condition. The structural analysis for the safety of the VMRS is performed, and the structural-integrity analytical processes of the VMRS are presented for different load conditions.

Prior to installation in a navy ship, shipboard equipment should be qualified by shock test requirements. The multi-function console mounted on the elastic platform of the ship should also withstand given shock loads. In this study, both real shock test methods, as well as numerical computer simulations using the finite element method were used to verify structural durability under shock load conditions. First, we used domestic test facilities to perform possible shock tests, including an impact hammer test, a drop table test and a shaker shock test. Full model tests satisfying the shock response spectrum level were performed. Thereafter, an analytical model of the complex console structure was built by the finite element method. Finally, numerical results were verified by modal test results of the real product and an FEA analysis was also performed with a full model transient response analysis.

Hybrid Electric Vehicles (HEVs) are developed to be operated with two kinds of power source (Diesel Engine and Electric Motor with Rechargeable High Voltage Battery Pack). HEVs for military vehicle require high reliability to provide stable powers under serious environment such as vibration and shock. To ensure normal operation of battery pack under serious environment such as vibration and shock, the high voltage battery pack needs to have appropriate dynamic characteristics. This paper presents a design procedure for high voltage battery pack with such characteristics. An isolator design is proposed to reduce vibration and shock. Associated random vibration and shock response of the high voltage battery pack are simulated under conditions suggested by MIL specifications. Its dynamic characteristics and vibration and shock responses are validated with experiments.

Recently, the use of composite materials in the defense system has grown dramatically. The strength/weight and stiffness/weight ratios of composite structures are normally higher than of metals. Woven composites, especially, are increasingly considered for a variety of applications, because they offer good workability for complicated structures. HPW193/RS1222 is one of the most famous woven composites and has been used in many types of Korean military equipment, such as antenna pedestals and radar systems. In this study, we predicted the elastic modulus of HPW193/RS1222 using the principles of unidirectional composite stiffness predictions, such as ROM (Rule of Mixture), HSR (Hart Smith 10% Rule), CLA (Classical Laminate Analysis) and LAP (Laminate Analysis Program). We compared the dynamic characteristics with the experimental predictions and finite-element analysis (FEA). From our results we concluded that transversely isotropic materials are similar to isotropic materials when the shape of the composite structure is complicated.

Electro-Mechanical Actuator installed on the aircraft plays a key role in an aircraft’s flight control through flight control computer. Reliable prediction of the actuator is important for the aircraft. To estimate the lifetime of a product, it is necessary to test full target life. However, it is very difficult to perform it due to the long life time of actuator but short period of development time with increasing cost. Therefore, accelerated life test has been used to reduce the test time for various reasons such as reducing product’s development cycle and cost. In this paper, to predict the lifetime of the actuator, we analyzed the flight profile of aircraft and adapted the method of accelerated life test in order to accelerate failure modes that might occur under user conditions. We also set up an endurance test equipment for validating the demanded lifetime of an actuator and performed accelerated life test.

This paper presents a position control strategy for a pump-controlled electro-hydrostatic actuator (EHA) using feedforward control with disturbance compensation. As the disturbance observer is used to estimate nonlinear dynamics of EHA, which has valve-opening conditionals, as well as external disturbances, an additional feedforward control is adopted to achieve rapid response. The effectiveness of the proposed control strategy is verified through experiment using an EHA test bench. The proposed controller shows better tracking performance compared with a conventional PID controller.

A direct laser lithography system is widely used to fabricate various types of DOEs (Diffractive Optical Elements) including lenses made as CGH (Computer Generated Hologram). However, a parametric study that uniformly and precisely fabricates the diffractive patterns on a large area (up to 200 mm X 200 mm) has not yet been reported. In this paper, four parameters (Focal Position Error, Intensity Variation of the Lithographic Beam, Patterning Speed, and Etching Time) were considered for stabilization of the direct laser lithography system, and the experimental results were presented.

Planetary gear systems have several advantages over traditional gearboxes with parallel axis gear shafts. The planetary gearbox arrangement also creates greater stability due to the even distribution of mass and increased rotational stiffness. However, gears in planetary gear systems occasionally have a short-life due to wear and breakage by repetitive load during operation time. In this study, we evaluated variables of the strength design for each part and conducted structural analysis of seven cases of the planetary gear system. The result of structural analysis was applied to shape optimization method and obtaining the weight lightening designed value. Subsequently, the planetary gear system was performed to ensure the durability of gears during operation time with miner’s rule.

In this study, we proposed a novel concept of electric sun visor comprising a dark, see-through sun shade material that ensures unimpaired driver’s vision with continuous control of the shade position. The shade extending from the windshield base along its surface may be subjected to severe vibration during driving unless the design parameters are carefully selected. A prototype was tested to collect acceleration data during driving. Based on the test data, an ADAMS dynamics model was validated. The mechanism of sun visor was optimized to minimize vibration based on the dynamics model, experimental design, and response surface method.

The aim of this study was to examine the validity of fracture criterion for PMMA plates that have a V-notch with an end hole. The predicted stress intensity factors and crack initiation angles by the fracture criterion based on the maximum circumferential stress and the novozhilov’s criteria were compared with the experimental results. By increasing the radius of end hole, the differences of predicted stress intensity factors and experimental results increased, possibly due to the plastic zone size. The results indicated that when the radius of end hole is ＜ 1 ㎜, the fracture criterion would be useful.

In this study, we proposed an effective and simple way to directly generate wrinkle patterns on a curved surface. A curved surface was prepared using a 3D printer and an UV (Ultraviolet)-lighting system was utilized to weakly polymerize the UV-curable thin resin layer coated on the surface, resulting in a gradient of material properties in the layer thickness. Subsequently, a thermal curing process was conducted to generate microscale wrinkles by compressive forces that were generated during complete curing. Wrinkle shapes from 5, 15, 25 sec of UV-light exposure were compared. With increasing UV-exposure, the line-width of wrinkles became thicker due to much higher strength of skin zone. The results indicated that the proposed fabrication process could be utilized for surface modification in diverse research fields.