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.
As advanced driver-assistance systems become more common in commercial vehicles, there is a growing need for evaluating safety of vehicles. Low platform target robot systems play a crucial role in this evaluation process as they can assess safety performances of autonomous vehicles. Driving stability of a target robot during real vehicle tests depends significantly on its suspension system. Therefore, developing an appropriate suspension device for the target robot is of utmost importance. This study aimed to improve driving stability by comparing two different suspension configurations: a single rocker and a double rocker, both incorporating a crank rocker mechanism. Initially, a two-dimensional model that met constraints of the suspension device was developed, followed by an analysis of reaction forces. Subsequently, an optimal design was determined using design of experiments principles based on parameters of a 2D model. The manufactured suspension system model based on the optimal design underwent multi-body dynamics simulation to evaluate driving stability. Comparative analysis of driving stability for both configurations was performed using MBD simulation, offering insights into the superior suspension design for the target robot.
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.
Electric kickboards provide personal mobility with a simple structure and easy operation. With these advantages, the number of users is increasing annually. However, as the number of users of electric kickboards increases, related accidents are also increasing. To prevent accidents, this study proposes the topological optimization of an electric kickboard connecting part to improve structural strength during a front collision. The results confirmed that as the volume fraction increased, the structure connecting the board and the bottom of the handle support changed to a toroidal shape, thereby lowering the maximum stress and improving the uniformity of the stress distribution. In addition, the topological optimization was safer than the connecting parts of two typical electric kickboards sold in the Korean market. These findings can contribute to improving the safety and optimizing the design direction of electric kickboards.
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Two-Dimensional Topology Optimization of Headtube in Electric Scooter Considering Multiple Loads Min Gyu Kim, Jun Won Choi, Jung Jin Kim Applied Sciences.2025; 15(5): 2829. CrossRef
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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.
As global warming is rapidly emerging as one of the inherently global issues, one of the renewable energies, i.e. thermo-electric generation, has received attention. In order to increase the efficiency of thermo-electric generation, a maximum temperature difference in plain fins in a heat exchanger is needed, and an appropriate pressure drop is required to ensure stable flow of high temperature fluid. In the present study, the characteristics of the temperature difference and pressure difference for the 2 kW-class thermo-electric generator installed in exhaust pipes of a cogeneration plant were investigated numerically via thermal fluid analysis using ANSYS CFX. Then, size optimization for plain fins of a heat exchanger was carried out using SAS JMP, in which the temperature difference was maximized while meeting the requirement of a given pressure drop condition. A meta-model was generated by using the response surface model, and individual desirability functions were defined to derive the optimal solution that provided the maximal overall desirability function. The result obtained by size optimization showed that the temperature difference of the optimized plain fins of a heat exchanger increased by approximately 27% in comparison with the original model under the given pressure drop condition.
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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Development of a Realistic Simulator for Driving Education of a Disaster-Responding Special Purpose Machinery Hyo-Gon Kim, Jung-Woo Park, Hyo-Jun Lee, Sung-Ho Park, Young-Ho Choi, Byeong-Kyu Lee, Jin-Ho Suh Journal of Power System Engineering.2021; 25(2): 86. CrossRef
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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Research on Key Issues of Consistency Analysis of Vehicle Steering Characteristics Yanhua Liu, Xin Guan, Pingping Lu, Rui Guo Chinese Journal of Mechanical Engineering.2021;[Epub] CrossRef
Shock-Absorber Rotary Generator for Automotive Vibration Energy Harvesting Tae Dong Kim, Jin Ho Kim Applied Sciences.2020; 10(18): 6599. CrossRef
The production method of round wire used in conventional high-grade fabric production requires an additional step of cutting the side portion after cold rolling. However, after the additional cutting process, the performance of the round side portion was not improved. To solve these problems, the shape of the side portion is improved by replacing the process of wire cutting by the shape rolling. The rolling is done six times in total, and four flat rolling and two shape rolling are performed. There are three types of shape rolling: square, box and oval. The total number of cases of rolling analysis was analyzed nine times according to the kind of 3,5th shape rolling. Efficient shape rolling was selected by comparing deformation of wire thickness and width after final rolling, residual stress of the wire and the shape of the side part. The above study was conducted through LS-DYNA, a simulation program that can analyze material behavior of materials.
Gears are rotating mechanical parts with excellent power transmission efficiency and are widely used in machine tools, automobile, industrial machinery, and aviation industries. To enhance the performance of the gear, optimized design of the gear geometry is paramount. In this paper, we optimize the geometric tooth profile of helical gears which are among the gears of the transfer case gearbox by using the finite element program, Romax Designer to model and analyze the load and gear teeth of the gearbox power transmission system. The optimized gears were fabricated and compared to the results of the gear tests.
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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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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
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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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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to Design Parameters of a Fire Ladder Vehicle Hoon Jung, Cheol-Jung Kim, Hong-Gun Kim Journal of the Korean Society of Manufacturing Process Engineers.2020; 19(8): 64. CrossRef
Optimal Design of Boom for Telescopic Boom Type Forklift Truck Jai Hak Lee, Kang Su Kim Journal of the Korean Society for Precision Engineering.2020; 37(6): 457. CrossRef
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
Recently, a high-precision ball screw is an essential part of high-speed machines. However, producing high-precision ball screws has been costly and time-consuming. Nowadays, a whirling machine is used to produce high-precision ball screws efficiently. Rotating multi-tips are used to turn the ball screw in the whirling machine. In this study, a structural analysis was performed by a finite-element method to develop a whirling machine. An improved model of the whirling machine was proposed by the analysis. In addition, a thermal analysis was performed to confirm the thermal stability. The results of the analysis can be applied in order to further develop the whirling machine.
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Heat Generation Characteristics of Whirling Spindle for Ball Screw Machining Hong-Man Moon, Sang-Won Kim, Ho-In Jeong, Choon-Man Lee Journal of the Korean Society of Manufacturing Process Engineers.2020; 19(10): 44. CrossRef
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