This paper deals with the aspects of die design for the multistage fine tooth hub gear in the cold forging process. In order to manufacture the cold forged product for the precision hub gear used as the ARD 370 system of bicycle, it examines the influences of different designs on the metal flow through experiments and FE-simulation. To find the combination of design parameters which minimize the damage value, the low gear length, upper gear length and inner diameter as design parameters are considered. An orthogonal fraction factorial experiment is employed to study the influence of each parameter on the objective function or characteristics. The optimal punch shape of fine tooth hub gear is designed using the results of FE-simulation and the artificial neural network. To verify the optimal punch shape, the experiments of the cold forging of the hub gear are executed.

Punching tools like an electrodes are made by milling or etching or EDM. These methods had time consuming, low efficiency and air pollution. So, we have developed a shearing device which counter punching method for burr less cutting of micro wire. Using the straightened SUS304 wire with 200 ㎛ diameter, we confirmed the tendency of the shear plane for punch tools. It was impossible to completely remove the burr in the shearing process. In order to minimize the burr size and fine shear plane, we have accomplished the various experiment conditions such as the U-groove, the effect of the counter punch, shear angle and clearance. The results of the experiments show that indentation, slip plane and bent shape were related to the shear angle and clearance.

Gravitational centers of precise spinning components must coincide with the rotational centers of those to reduce noise and vibration and to extend those life as well. Therefore quality control should be performed in the manufacturing process, in which the unbalance moments are accurately measured. In this paper 3-point weighing method is adopted to measure the unbalance moment of small-sized precision spinning elements using electronic scales with 0.1 ㎎ resolution. Firstly methods to eliminate the fixture error and to reduce the effects of frictional force that is known as side effect, are proposed. A measuring system is developed and various experiments are performed to verify the proposed approach. The measured and calculated values are analysed in statistical methods, and this provides the errors of the measuring system. The results show that the proposed theory and test procedures gives reliable unbalance moments and gravitational centers.

A target of this paper is to study on the usefulness of the adaptive piezoelectric energy harvesting device as a wireless electrical power supply when it is driven by mechanical vibrations of low frequency. For this purpose, an adaptive control technique and a step-down converter are used. A THUNDER series a piezoelectric material(TH7-R), which has been developed by a NASA engineer is selected for this study. In order to provide a mechanical energy to the piezoelectric material, a mechanical motion vibrator is designed. The adaptive controller is implemented using a dSPACE DS1104 controller board. The de-dc converter with an adaptive control technique harvests energy at over five times the rate of direct charging without a converter.

Electric Power Steering(EPS) mechanism has become widely equipped in passenger vehicle due to the increasing environmental concerns and higher fuel efficiency. This paper describes the development of concurrent simulation technique and simulation integration technique of EPS control system with a dynamic vehicle system. A full vehicle model interacting with EPS control algorithm was concurrently simulated on a single bump road condition. The dynamic responses of vehicle chassis and steering system resulting from road surface impact were evaluated and compared with proving ground experimental data. The comparisons show reasonable agreement on tie-rod load, rack displacement, steering wheel torque and tire center acceleration. This concurrent simulation capability was employed for EPS performance evaluation and calibration as well as for vehicle handling performance integration and synthesis.

A new gain-scheduled control design is proposed to improve disturbance attenuation for systems with bounded control input. The state feedback controller is scheduled according to the proximity to the origin of the state of the plant. The controllers is derived in the framework of linear matrix inequality(LMI) optimization. This procedure yields a linear time varying control structure that allows higher gain and hence higher performance controllers as the state move closer to the origin. The main results give sufficient conditions for the satisfaction of a parameter-dependent performance measure, without violating the bounded control input condition.

In this paper, the gain-scheduled control design proposed in the previous paper has been applied to a target tracking system. In such system, it is needed to attenuate disturbance effectively as long as control input satisfies the given constraint on its magnitude. The scheduled gains are derived in the framework of linear matrix inequality(LMI) optimization by means of the MatLab toolbox. Its effectiveness is verified along with the simulation results compared with the conventional optimum constant gain and the scheduled gain control with constant Q matrix cases.

To establish of standard technique of nano-length measurement in 2D plane, new AFM system has been designed. In the long range (about several tens of ㎛), measurement uncertainty is dominantly affected by the Abbe error of XY scanning stage. No linear stage is perfectly straight; in other words, every scanning stage is subject to tilting, pitch and yaw motion. In this paper, an AFM system with minimum offset of XY sensing is designed. And XY scanning stage is designed to minimize rotation angle because Abbe errors occur through the multiply of offset and rotation angle. To minimize the rotation angle optimal design has performed by maximizing the stiffness ratio of motion direction to the parasitic motion direction of each stage.
This paper describes the design scheme of full AFM system, especially about XY stage. Full range of fabricated XY scanner is 100㎛×100㎛. And tilting, pitch and yaw motion are measured by autocollimator to evaluate the performance of XY stage. As a result, XY scanner can have good performance.
Using this AFM system, 3um pitch specimen was measured. The uncertainty of total system has been evaluated. X and Y direction performance is different. X-direction measuring performance is better. So to evaluate only ID pitch length, X-direction scanning is preferable. Its expanded uncertainty(k=2) is √(3.96)²+(4.10×10??×p)², where p is the measured length in ㎚.

A design and control of electrostatic suspension system for flexible objects is presented. A number of electrode pairs of which the number depends on the object flexibility are positioned above the object and the voltages applied to each electrode pair are controlled, independently on the others, on the basis of the gap length. To implement the system with low cost and compactness, switched-voltage control scheme that is based on the relay feedback control is utilized. Relay feedback control method deploys only a single high-voltage power supply that can deliver a DC voltage of positive and/or negative polarity and thus high voltage amplifiers that are costly and bulky are not needed any more. It is shown that despite the inherent limit cycle property of the relay feedback based control, an excellent performance in vibration suppression is attained due to the presence of a relatively large squeeze film damping originating from the electrodes and levitated object. Employing fourteen electrode pairs, a thin aluminum plate with a thickness of 0.1 ㎜ has been suspended at a gap length of 0.75㎜.

Recently, the reliability evaluation and analysis are applied for many industrial products which are required to guarantee in quality and efficiency. The purpose of this paper is to present some of reliability evaluation methodologies that are applicable to machine tools. Especially ATC(Automatic Tool Changer), which is a core component of line center, was chosen as the target of the reliability evaluation and analysis. The scope of research is reliability prediction, reliability test and evaluates their results. The results of reliability evaluation have shown the failure rates, MTBF (Mean Time Between Failure), reliability for those components of ATC and real tests reliability through the constructed reliability test-bed. It is expected that proposed methodologies would increase reliability for a high-speed line center.