With rapid growth of the global electric vehicle market, interest in the development of secondary batteries such as lithium batteries is also increasing. Core functional parts of secondary batteries are known to determine the performance of these batteries. Micro cracks, scratches, and markings that may occur during the manufacturing process must be checked in advance. As part of developing an automated inspection system based on machine vision, this study optimized the design of a linear feeder exposed to an environment with a specific operating frequency continuously to transfer parts at a constant supply speed. Resonance can occur when the natural frequency and the operating frequency of the linear feeder are within a similar range. It can negatively affect stable supply and the process of finding good or defective products during subsequent vision tests. In this study, vibration characteristics of the linear feeder were analyzed using mode analysis, frequency response analysis, and finite element analysis. An optimal design plan was derived based on this. After evaluating effects on vibration characteristics for structures in which vibrations or periodic loads such as mass and rails were continuously applied, the shape of the optimal linear feeder was presented using RSM.
In the heating and drying system using microwaves, an optimal design method was presented to effectively shield microwaves leakage between the door and the cylindrical applicator. In order to protect the human body from leaking microwaves, it is necessary to keep the intensity of microwaves below 5 mW/cm². The door part adopts a choke structure and includes a number of design factors, such as, fin shape, slit shape, and a gap between the applicator and the door. The geometry was optimized by design of experiments, applying full factorial design and response surface method in a 4-factor, 2-level design. The results obtained by ANSYS HFSS analysis were applied to the intensity of microwave leakage according to the change of the design factors. The shape of the choke structure was optimized using Minitab, a statistical program. The microwave heating and drying system was manufactured based on optimal design value and the leakage of microwaves between the door and the applicator was measured. We confirmed that the experimental values were consistent with the simulation values.
An optimal design was developed for housing of a 50-ton hydraulic breaker. A four-factor, two-level design was created using the full factorial design, and it was confirmed that the safety factor, the response value, exhibited a curvature. As the curvature was confirmed, a higher-order experiment, a response surface analysis was performed. Based on the Minitab"s optimized prediction of the safety factor and weight, the actual analysis was performed using ANSYS Workbench, the finite element analysis program. As a result, the safety factor was 2.03 and the weight was 3222.2 kg, which was almost consistent with the Minitab’s prediction. The safety factor decreased from 2.33 to 2.03 compared to that in the initial model, but the optimization model can also be judged as being safe because the safety factor was set to 2.00. The weight was reduced by 119.1 kg, from 3341.3 to 3222.2 kg.
Additive manufacturing (AM) had a significant influence on the geometry design of products. It became possible to replace the full solid material with cellular structures for the optimal design of AM parts. Various types of cellular structures have been developed and studied for different purposes. However, many studies have focused on an optimal design using cellular structures having near-isotropic properties, such as cube or honeycomb structures. This paper presents the effect of the anisotropic material property on the optimal design by generating cellular structure with anisotropic material property induced by internal void geometry. Kriging metamodel-based material property model is proposed for modeling anisotropy induced by the rotation of internal void. This material model is then applied to the optimal design process. Three types of void geometry, circular, non-rotating, and rotating elliptical void, are considered to demonstrate the effect of anisotropic cellular structure on the optimal design. Due to the anisotropy induced by complex internal void geometry, Kriging metamodel-based material property models are utilized as the material property model. The effect of the anisotropic property and the material property model on the optimized structures is confirmed through two numerical examples in the perspectives of structure performance and density distribution.
In Korea, water spraying to suppress the dust during building dismantling operations has been done manually by human laborers, considered extremely dangerous since it often causes fatal accidents. Abroad, however, water spraying machines have been developed and used in construction sites instead of workers to prevent such serious industrial accidents. In this study, the first domestic water spraying machine is suggested. Since the spraying machine should have a novel dust tracking function, an optimal structure and mechanism should be designed to guarantee its motion performance. The motion for target tracking is achieved by the 2 DOF (Degrees of Freedom) structure comprising a linear and a rotary actuator. Then, the geometric analysis was performed to provide a sufficient kinematic workspace. Through the dynamic performance simulation, the optimal actuator capacities could be selected to generate an appropriate acceleration. The geometric and dynamic performance was evaluated by the extensive motion experiments. With this study, it is expected that an advanced water spraying machine can be developed only with domestic technologies to protect construction laborers from potentially dangerous accidents.
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For the teleoperation of dual-arm robots with various tasks, the existence of a controller with a high degree of freedom is indispensable. Especially when precise work is required, additional information such as force feedback is very helpful for the operator. In transmitting such force information, a control device of exoskeleton-type with many points of contact with the human body can be one of the solutions. This paper proposes an optimal design method for the 7 degrees of freedom (DOF) exoskeleton systems. The proposed method optimizes the kinematic parameters by using kinematic performance indices related to the dexterity of the human and exoskeleton system. The manipulability ellipsoid is a representative index that can confirm the dexterity of the robot. In this study, we derived the objective function considering the human body model and then optimized it using a genetic algorithm. Unlike other HRI (Human-Robot Interaction) systems, exoskeleton robots share the end-effector as well as the base of the robot with the wearer. Therefore, it is hypothesized that the proposed performance index will be highly suitable for exoskeleton systems.
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In this paper, the boom structure of a telescopic boom-type forklift truck was analyzed using ANSYS, a finite element analysis program. As a result, 494.22 MPa exceeded 456.08 MPa, allowable stress of the material, in the second boom. Thus, structural analysis was performed by reinforcing the thickness of the boom and stress was reduced. The experiment was conducted by selecting four factors of the thickness of the boom T1, T2, T3, and T4. Through response surface analysis, the curvature of the factors for stress was confirmed, and T1 was the most influential factor. Through regression equations from the variance analysis of each response, response maximization was performed to optimize mass and stress. As a result, 467.65 MPa was predicted. This exceeded allowable stress of 456.08 MPa. To obtain the result that does not exceed allowable stress, the mass was fixed at 118 kg, the initial value, and multiple response optimization was performed to limit target value and minimize stress. As a result, 432.96 MPa was expected to occur, and structural analysis resulted in 428.87 MPa stress demonstrating 13.22% reduction of stress compared to the existing model, and it is safe because allowable stress was less than 456.08 MPa.
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The sanding device support bracket is part of the axle box and is one of the railway vehicles parts that must withstand extremely harsh environments. Conventional welded structure type brackets were cracked at welds during operation, requiring design changes. To minimize harsh environments and manufacturing errors, this review was conducted from the design stage, and design changes were made through several trial and error. In this paper, the optimal design was derived by performing topology optimization on the model designed and manufactured through trial and error and applied to the actual vehicle. The comparison of the existing model with the empirically designed model confirmed the improvement of the optimal design using the topology optimization. The optimized design was verified by the analysis and the vibration test of IEC 61373 was satisfied. The test parts based on the optimal design were applied to the actual vehicle and the performance was verified. In the optimum design process, the shape and material as well as the weight analysis were performed and finally the brackets were designed to be light in weight and improved in strength.
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In this study, the sensitivity of the power generation effect of the applied linear generator of the energy harvesting suspension system under various input conditions was analyzed. The energy-harvesting suspension generates electric energy through energy harvesting using the road surface vibration energy during driving. Before analyzing the power generation effect, we analyzed the structure of the eight-pole Outer PM (Permanent Magnet) linear generator model using the electromagnetic suspension system to design the efficient generator, PIANO (Process Integration and Design Optimization). The ANSYS MAXWELL program was used to perform electromagnetic simulations of a linear generator model installed inside an energy-harvesting suspension to determine the power generation of the linear generator under various input conditions. The sensitivity of each input variable was compared by comparing the power generation effect of the energy-harvesting suspension device according to road displacement, frequency, and vehicle speed. The sensitivity to the road surface frequency was 1.9451, the sensitivity to the road surface amplitude was 1.0502, and the sensitivity to the vehicle speed was 0.6258. It is confirmed that the maximum sensitivity to the road surface displacement was demonstrated.
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Due to urbanization, it is difficult to secure a large knuckle crane workspace. To solve this problem, we developed a small knuckle crane combined with a one-ton truck. In this study, the safety of small knuckle cranes is evaluated through Finite Element Analysis. Shape optimization was performed using the Design of Experiment for parts speculated to have failed from fatigue. As a result, maximum equivalent stress of a plate in link speculated to have failed from fatigue was reduced by approximately 84.2%.
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Due to urbanization, parameters such as large size and height constrain the workspace of aerial lift truck. An aerial lift truck with reduced height was developed to decrease the telescopic boom. Based on FEM Analysis, the failure was localized to the shaft of the boom joint. Shape optimization was performed using the Design of Experiment based on three design factors. As a result, the maximum equivalent stress of boom joint was reduced by about 32.33%.
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Due to the characteristics of domestic mountainous terrain, the tunnels are increasing. Therefore, an increased budget and more advanced equipment are required to maintain the tunnels cleanliness. As a study on shape optimization using the design of experiment, this paper assessed the design parameters affecting the maximum stress of an articulated hydraulic crane boom. As a result, the maximum stress of an optimized boom was 223.94 MPa at optimal factors. It showed an accuracy of 99.38% compared with the finite element analysis.
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Optimal Design of 50 ton Hydraulic Breaker Housing Jai Hak Lee, Dong Ju Lee, Jun Young Choi Journal of the Korean Society for Precision Engineering.2022; 39(4): 269. CrossRef
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