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가변 곡률 제품의 TRIZ 기반 설계 개선

한재영1, 김권희2,#

Design Improvement of a Product with Variable Curvature Based on TRIZ

Jae Young Han1, Kwon Hee Kim2,#
Journal of the Korean Society for Precision Engineering 2017;34(10):715-721.
Published online: October 1, 2017

1 고려대학교 대학원 기계공학과

2 고려대학교 기계공학부

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#E-mail: kwonhkim@korea.ac.kr, TEL: +82-2-3290-3360, FAX: +82-2-929-6947
• Received: November 28, 2016   • Revised: May 15, 2017   • Accepted: June 10, 2017

Copyright © The Korean Society for Precision Engineering

This is an Open-Access article distributed under the terms of the Creative Commons Attribution Non-Commercial License (http://creativecommons.org/licenses/by-nc/3.0) which permits unrestricted non-commercial use, distribution, and reproduction in any medium, provided the original work is properly cited.

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  • In this work, a new design for mobiles proposes a flexible display that can be switched between flat and curved surfaces. After a few unsuccessful attempts, a noble conversion scheme between the two configurations was obtained after application of the TRIZ contradiction analysis. For physical embodiment of flat display, effects of design parameters are investigated experimentally using the Taguchi method and response surface methodology. It is suggested that a finite element model might be useful for future applications after proper experimental validation.
  • KEYWORDS: Flexible, Variable curvature, Design improvement, TRIZ
  • KEYWORDS: 플랙서블, 가변곡률, 설계개선, 트리즈
최초의 OLED (Organic Light-Emitting Diode)에 대한 연구1 이후, 디스플레이 서브스트레이트(Display Substrate)로 얇은 유리나 금속박판, 플라스틱 필름 등 유연한 소재를 사용하는 방법에 대한 연구,2 플라스틱 필름의 롤투롤(Roll-to-Roll) 대량생산 방법에 대한 연구3 등이 수행되고 있다. 유연 디스플레이의 발전에 따라 제품들도 휘거나 부분적으로 구부러진 형태로 개발 된 사례가 있으며4-9 디스플레이를 완전히 접거나 두루마리처럼 말아 휴대성을 높이는 연구도 수행되고 있다.10-16 본 연구에서는 평면 디스플레이에서 영화감상이나 가상현실(Virtual Reality) 체험 시 곡률 화면으로 전환 가능한 제품의 개념을 제안하였다. 기존에 TV 등 대형 디스플레이 분야에서 모터 등의 동력원을 이용한 가변 곡률 구조는 연구된 사례가 있으나,17-19 공간상의 제약과 구조의 복잡도로 인하여 모바일 분야에 적용하기는 어렵다. 본 연구에서는 TRIZ를 통하여 구조가 단순하면서도 수동으로 원활하게 작동되는 새로운 방식의 가변곡률 구조를 도출하고, 이를 기반으로 새로운 제품을 디자인 하였다. 평면 모드에서 디스플레이 평탄도(Flatness)를 높이기 위하여 다구찌 실험계획법 및 반응표면법을 이용하여 최종 설계를 확정하였다. 또한 본 연구에서 제안한 설계가 향후 실용화 될 것을 전제로, 평면-곡면 전환 구조의 거동을 모사하는 유한요소 모델을 제안하고 검증하였다.
2.1 구조 및 작동 방법
Fig. 1은 본 연구에서 구현하고자 하는 가변 곡률 구조의 기본 컨셉을 나타낸다. 사용 씬에 따라 평면과 곡면 두가지 모드 전환을 수동으로 손쉽게 할 수 있고 명확하게 두 상태가 전환되는 구조를 목표로 하였다.
Fig. 1

Device with variable curvature display

KSPE_2017_v34n10_715_f001.jpg
2.2 초기 구조의 문제점
Fig. 2는 이러한 컨셉을 구현하기 위한 초기 구조를 나태낸다. 기존 구조는 장치를 상, 중, 하로 나누어 3단으로 분리한 후 Fig. 3에서와 같이 내측의 메탈 프레임에 힌지 구조를 추가하여 가변 곡률을 구현하는 방식이다. 이 구조는 3단으로 나누어져 있어 미려하지 않다는 디자인적 문제점 외에 복잡한 구조로 인한 부품단가 상승 및 생산성 저하로 제조 원가가 상승되는 문제가 있다. 또한, 힌지의 가동 구간이 너무 작아서 모드 변환시의 단단한 고정 및 구분감 있는 동작 피드백을 내기 어렵다는 기술적인 문제가 있다.
Fig. 2

A design with locally bendable display

KSPE_2017_v34n10_715_f002.jpg
Fig. 3

Hinge structure in Fig. 2

KSPE_2017_v34n10_715_f003.jpg
3.1 기술적 모순 해석
본 연구에서는 주어진 문제를 기술적 모순(Technical Contradiction)으로 정의 하였다.20-22 가변 곡률 구조의 개선목표는 기존구조의 복잡도를 개선하는 문제와 고정이 확실하지 않은 문제의 해결 및 동작구간을 늘려 동작시의 구분감을 높이는데 있다. 복잡도를 개선하는 문제와 관련된 개선변수는 ‘장치의 복잡성(36)’으로 볼 수 있고 동작구간을 늘려서 구분감을 늘리는 부분과 관련된 개선변수는 ‘움직이는 물체의 면적(5)’ 로 볼 수 있다. 각각에 대한 상반변수로는 ‘모양(12)’, ‘움직이는 물체의 길이(3)로 볼 수 있다. 위에서 정의한 개선변수와 상반 변수를 모순 행렬표에 적용하면 Table 1과 같이 모순 해결의 원리들을 찾을 수 있다. Table 1의 각 해결 원리들을 발생빈도에 따라 Table 2에 정리하였다. 빈도수가 높은 해결원리로 ‘자유도 증가(15)’가 나왔으며, 다른 해결 원리들 중 수동으로 작동시킨다는 초기 설계 컨셉에 맞지 않는 원리들은 제외하였다. ‘곡선화(14)’ 는 기존 설계에 적용되지 않았으며 새로운 설계에 적용이 가능하다고 판단되어 선택하였다. 이렇게 도출 된 원리를 바탕으로 새로운 구조를 고안 하였다.
Table 1

Contradiction analysis for variable curvature mechanism

Table 1
Feature to improve Worsening features Inventive principles
Device complexity(36) Shape(12) 29, 13, 28, 15
Area of moving object(5) Length of moving object(3) 14, 15, 18, 4
Table 2

Frequency of inventive principles in Table 1

Table 2
Feature to improve Inventive principles Frequency
Device complexity(36)
Area of moving
object(5)		 15 Dynamicity 2
14 Curvature increase 1
3.2 모순해석을 통한 설계 개선
Table 2에서 도출된 해결 원리인 ‘자유도 증가(15)’, ‘곡선화(14)’ 를 통해서 문제의 해결 방안을 모색하였다.
자유도 증가는 “부분, 단계마다 자유롭게 움직이기” 이며, 곡선화는 “직선을 곡선으로 바꾸어 본다” 이다. 자유도 증가의 원리에 착안하여 기존의 3분할로 되어 있던 케이스 구조를 Fig. 4와 같이 수많은 마디를 갖는 일체형 케이스 형태로 변경하였고, 곡선화의 원리에 따라 기존 3단으로 구분되어 동작하는 프레임을 하나의 큰 곡선을 이루는 좌굴을 이용한 구조로 변경 하였다. Fig. 5(a)는 이러한 원리를 통해 새롭게 고안한 가변 곡률 구동부의 구상도 이다. 스냅 스프링(Snap Spring)은 내측의 프레임(Frame)에 응력이 가해진 상태로 조립된다. 프레임의 조립부보다 길이가 긴 스프링은 프레임에 조립될 때 응력이 가해지며, 곡선형의 형태를 띄게 된다. Figs. 5(b)는 5(a)의 프레임 어셈블리가 바디(Body)에 체결되어 있는 상태를 나타낸다. Fig. 6와 같이 외부에서 수동으로 힘을 가하면 스냅 스프링이 위 방향으로 좌굴되어 세트는 평면 모드로 전환되며, 다시 반대방향으로 힘을 가하면 스냅 스프링이 좌굴되어 초기 상태인 곡면 모드로 변환 되는 구조이다.
Fig. 4

Structure of deformable main body

KSPE_2017_v34n10_715_f004.jpg
Fig. 5

Concept of a conversion structure

KSPE_2017_v34n10_715_f005.jpg
Fig. 6

Manual operation the conversion structure

KSPE_2017_v34n10_715_f006.jpg
Fig. 7에서 나타낸 바와 같이 기존 삼단 프레임 조립구조에서 하나의 프레임으로 구조를 단순화하였고, 곡면형의 외골격 바디와 좌굴을 이용한 동작 메커니즘을 가지는 구조를 적용함으로써 기존대비 구조적으로 단순하고 확실한 작동 구분감을 갖는 기존과 전혀 다른 형태의 구조로 설계 할 수 있었다.23
Fig. 7

Conversion structure with variable curvature23 (Adapted from Ref. 23 with permission)

KSPE_2017_v34n10_715_f007.jpg
4.1 주요 해결 과제
모순 해석을 통해 새로운 구동방식의 간단하면서도 안정적인 동작이 가능한 구조가 개발되었다. Fig. 8과 같이 샘플을 제작하여 시험해 본 결과 수동으로 손쉽고 원할하게 작동함을 알 수 있었다. 그러나, 형태 유지 측면에 있어 곡면 모드에서의 형태는 안정적으로 유지되었으나, 평면 모드에서의 전면 부 평탄도는 개선이 필요하다고 판단 되었다. 따라서 평탄도에 영향을 주는 주요 설계 인자들을 선정하여 개선하는 것을 목표로 하였다.
Fig. 8

Prototype of a structure with variable curvature

KSPE_2017_v34n10_715_f008.jpg
4.2 설계 변수 선정
표면의 평탄도에 영향을 주는 주요 인자들을 선정하기 위해 기기의 몸체와 Fig. 9와 같이 스프링의 형상에 변화를 주어 사전 시험을 시행하였다. 시험결과 Fig. 10과 같이 스프링의 중간 마디를 일정 부분 두껍게 처리하는 것이 평탄도 향상에 도움을 준다는 것을 확인하였으며, 이러한 사전시험을 바탕으로 평탄도에 영향을 주는 7가지 인자를 각 2수준으로 정리하여 Fig. 11과 Table 3에 정리 하였다. 각 인자의 수준 값은 제작될 시제품을 기준으로 결정 하였다.
Fig. 9

Snap spring prototypes

KSPE_2017_v34n10_715_f009.jpg
Fig. 10

Snap spring and frame assembly

KSPE_2017_v34n10_715_f010.jpg
Fig. 11

Design parameters

KSPE_2017_v34n10_715_f011.jpg
Table 3

Design parameters in 2 levels

Table 3
Design parameter Level 1 Level 2
A Thickness of window (mm) 1.4 1.6
B Length of mid-block (mm) 8.0 10.0
C Interval of blocks (mm) 8.0 10.0
D Radius of curvature (R) 600 800
E Thickness of spring (mm) 1.5 2.0
F Length of middle portion of spring (mm) 25.0 30.0
G Thickness of middle portion of spring (mm) 3.2 3.5
4.3 평탄도 분석
Table 3의 주요 설계 인자들의 영향을 분석하고 최적 조합을 찾기 위하여 ‘Taguchi’ 실험계획법을 통해 Table 4에 보인것과 같이 L8(27) 직교배열표를 작성하였다. 이를 활용하여 7개의 2수준 인자들에 대한 8종류의 시료를 제작하였으며, 두세트를 제작 측정후 평균값을 취하였다. Fig. 12과 같이 비접촉, 비젼 방식의 평탄도 측정 장비(KEYENCE사 VR3200)를 이용하여 Fig. 13에서 나타낸 바와 같이 전면부(해칭영역)의 평탄도를 측정하였으며, 각 측정값은 Table 4에 나타내었다. 측정결과 각 시료별 평탄도 프로파일은 Fig. 13에 나타낸 바와 같이 세트의 중앙부가 주변부 대비 볼록하게 솟아 오르는 일정한 경향을 나타내었고, 중심선 상의 Rz 값 분포로 시료 간의 평탄도 차이를 비교할 수 있음을 확인하였다.
Table 4

L8(27) orthogonal array for the parameters in Table 3

Table 4
Run A B C D E F G Rz (mm)
1 1 1 1 1 1 1 1 0.662
2 1 1 1 2 2 2 2 0.702
3 1 2 2 1 1 2 2 0.786
4 1 2 2 2 2 1 1 0.641
5 2 1 2 1 2 1 2 0.669
6 2 1 2 2 1 2 1 0.692
7 2 2 1 1 2 2 1 0.545
8 2 2 1 2 1 1 2 0.506
Fig. 12

Measurement setup for flatness

KSPE_2017_v34n10_715_f012.jpg
Fig. 13

Measurement area and central profile

KSPE_2017_v34n10_715_f013.jpg
Fig. 14

Analysis of means for the test results in Table 4

KSPE_2017_v34n10_715_f014.jpg
4.4 1차 최적화
Fig. 15는 평탄도에 영향을 주는 7가지 인자에 대한 주효과 분석 결과를 나타낸다. 바디부에서는 윈도우부의 두께와 마디의 간격의 영향이 컸으며, 스프링부의 인자 세가지 역시 영향력이 적지 않아 변수들의 적절한 조합이 중요함을 판단할 수 있었다. 주효과 분석 결과 가장 이상적인 조합인 A2, B2, C1, D2, E2, F1, G1 은 기존 제작한 시료에 없는 조합이기 때문에 새로 제작하여 측정 하였다. 측정결과 개선 전 0.65 mm에서 개선 후 0.20 mm로 약 69%의 평탄도 향상이 있었다.
Fig. 15

Local minimum of Rz

KSPE_2017_v34n10_715_f015.jpg
4.5 반응 표면법을 이용한 추가 최적화
반응표면법을 통해 스프링의 두께 E와 스프링 중앙부의 두께 F를 추가로 최적화 하였다.24-26 MINITAB을 이용하였으며, 반응 표면을 생성하기 위한 2인자 2수준의 실험 조건 13개와 평탄도 측정값을 Table 5에 나타내었다. 예측 모형은 식(1)과 같이 계산되었고, 표면도는 Fig. 15에 나타내었다. 이에 따라 E와 F의 최적값은 각각 1.8, 26.3 mm로 선정 하였고, 시료 제작 후 측정결과 평탄도는 1차 최적 결과인 Rz = 0.20 mm에서 Rz = 0.13 mm로 35% 개선되었다.
(1)
Rz=12.83-5.04X1-0.621X2+1.450X12+0.01206X22-0.0072X1X2
Table 5

Test matrix and results for the 2nd order response surface

Table 5
Test No. X1 (mm) X2 (mm) Rz (mm)
1 2.00 30.00 0.328
2 1.50 30.00 0.395
3 1.40 27.50 0.397
4 1.75 23.96 0.147
5 2.00 25.00 0.248
6 1.75 27.50 0.146
7 1.50 25.00 0.297
8 1.75 27.50 0.149
9 2.10 27.50 0.249
10 1.75 27.50 0.146
11 1.75 31.04 0.438
12 1.75 27.50 0.145
13 1.75 27.50 0.146
5.1 유한 요소 모델 생성
Fig. 16은 스냅 스프링(Snap Spring), 프레임(Frame), 바디(Body)에 대한 유한 요소 모델을 나타낸다. 모델 생성에는 Altair사의 HyperMesh를 이용하였으며, 각 부품의 요소 개수는 Table 6에 물성치는 Table 7에 나타내었다. 감쇠 효과를 주기위해 식(2)의 Rayleigh Damping 매트릭스27-28에서 질량 비례 감쇠 계수인 α는 0.1/msec로 하였고, β는 해석의 단순화를 위해 0으로 하였다.
(2)
C=αM+βK
Fig. 16

Finite element model of a structure with variable curvature

KSPE_2017_v34n10_715_f016.jpg
Table 6

Number and type of elements

Table 6
Part name Snap spring Frame Body
Number 6446 29776 67386
Type 10-Node tetrahedral elements
Table 7

Material properties

Table 7
Material Density,
ρ (kg/mm3)		 Young’s
modulus,
E (GPa)		 Poisson’s
ratio, ν 		Yield stress,
σy (MPa)
PC+ABS 1.14E-6 2.0 0.39 54
5.2 유한 요소 해석
유한 요소 해석은 LS-DYNA 971R7버전으로 수행하였으며, 크게 두 단계로 나누어 진행하였다. 1차로 스냅 스프링을 프레임에 넣는 해석을 진행하였다. 실제 조립하는 과정과 같도록 Fig. 17(a)와 같이 한쪽 끝을 프레임에 걸고 Fig. 17(b)와 같이 반대쪽 끝은 X축으로 5 mm, Z축으로 -5 mm 이동시켜 스프링에 변형을 가하였다. 마지막으로 Fig. 17(c)와 같이 프레임의 반대쪽 홈에 맞추어 가해진 하중을 제거함으로써 스프링을 프레임에 조립하였다. 두번째 과정으로 Fig. 17에서 해석된 프레임 어셈블리 데이터에 Fig. 18과 같이 바디를 조립하였고, 곡면에서 평면모드로의 수동전환을 재현하기 위해 3 포인트 벤딩 해석을 진행하고 평탄도를 측정하였다.
Fig. 17

Simulation step 1 (Snap spring-frame assembly)

KSPE_2017_v34n10_715_f017.jpg
Fig. 18

Simulation step 2 (3 point bending)

KSPE_2017_v34n10_715_f018.jpg
5.3 해석 결과
반응표면법을 통한 최적화 전과 후의 해석모델을 가지고 3 포인트 벤딩 해석 진행 후 각각의 평탄도를 비교해 보았다. 비교결과 최적화 전, 후 각각 0.12, 0.07 mm로 약 42% 개선됨을 확인하였다. 이는 앞선 개선시료의 실측결과와 비교해 볼 때 개선의 경향은 유사하나 측정값 자체로는 실측결과 대비 더 좋은 경향을 나타내었다. 제작 시료보다 해석결과가 더 나은 평탄도를 보이는 가장 큰 이유는 3D 프린터로 제작한 샘플이 기본적으로 가지고 있는 표면 거칠기가 해석 모델에서는 반영되지 않기 때문에 나온 결과라고 판단 되었고, 이를 감안할 경우 해석상의 검증 또한 의미가 있다고 판단된다.
TRIZ 모순해석을 통하여 수동으로 평면-곡면 전환이 가능한 가변 곡률 구조를 도출하고, 새로운 컨셉의 제품을 제안하였다. 평면 모드에서 디스플레이 평탄도를 높이기 위하여 다구찌 실험 계획법 및 반응표면법을 이용하여 주요 설계 변수들의 최적값을 도출하였다. 평탄도는 Rz 값 기준으로 최초 설계시의 0.65 mm에서 최종 0.13 mm로 약 80% 개선을 이룰 수 있었다. 향후 유사구조 개발 시 반복 실험을 최소화 하고 해석을 통한 개선이 이루어질 수 있도록 유한요소 모델을 만들고 실험을 통하여 검증하였다.
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Design Improvement of a Product with Variable Curvature Based on TRIZ
J. Korean Soc. Precis. Eng.. 2017;34(10):715-721.   Published online October 1, 2017
DOI: https://doi.org/10.7736/KSPE.2017.34.10.715
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Design Improvement of a Product with Variable Curvature Based on TRIZ
J. Korean Soc. Precis. Eng.. 2017;34(10):715-721.   Published online October 1, 2017
DOI: https://doi.org/10.7736/KSPE.2017.34.10.715
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Design Improvement of a Product with Variable Curvature Based on TRIZ
Image Image Image Image Image Image Image Image Image Image Image Image Image Image Image Image Image Image
Fig. 1 Device with variable curvature display
Fig. 2 A design with locally bendable display
Fig. 3 Hinge structure in Fig. 2
Fig. 4 Structure of deformable main body
Fig. 5 Concept of a conversion structure
Fig. 6 Manual operation the conversion structure
Fig. 7 Conversion structure with variable curvature23 (Adapted from Ref. 23 with permission)
Fig. 8 Prototype of a structure with variable curvature
Fig. 9 Snap spring prototypes
Fig. 10 Snap spring and frame assembly
Fig. 11 Design parameters
Fig. 12 Measurement setup for flatness
Fig. 13 Measurement area and central profile
Fig. 14 Analysis of means for the test results in Table 4
Fig. 15 Local minimum of Rz
Fig. 16 Finite element model of a structure with variable curvature
Fig. 17 Simulation step 1 (Snap spring-frame assembly)
Fig. 18 Simulation step 2 (3 point bending)

Fig. 1

Fig. 2

Fig. 3

Fig. 4

Fig. 5

Fig. 6

Fig. 7

Fig. 8

Fig. 9

Fig. 10

Fig. 11

Fig. 12

Fig. 13

Fig. 14

Fig. 15

Fig. 16

Fig. 17

Fig. 18

Design Improvement of a Product with Variable Curvature Based on TRIZ
Feature to improve Worsening features Inventive principles
Device complexity(36) Shape(12) 29, 13, 28, 15
Area of moving object(5) Length of moving object(3) 14, 15, 18, 4
Feature to improve Inventive principles Frequency
Device complexity(36)
Area of moving
object(5)		 15 Dynamicity 2
14 Curvature increase 1
Design parameter Level 1 Level 2
A Thickness of window (mm) 1.4 1.6
B Length of mid-block (mm) 8.0 10.0
C Interval of blocks (mm) 8.0 10.0
D Radius of curvature (R) 600 800
E Thickness of spring (mm) 1.5 2.0
F Length of middle portion of spring (mm) 25.0 30.0
G Thickness of middle portion of spring (mm) 3.2 3.5
Run A B C D E F G Rz (mm)
1 1 1 1 1 1 1 1 0.662
2 1 1 1 2 2 2 2 0.702
3 1 2 2 1 1 2 2 0.786
4 1 2 2 2 2 1 1 0.641
5 2 1 2 1 2 1 2 0.669
6 2 1 2 2 1 2 1 0.692
7 2 2 1 1 2 2 1 0.545
8 2 2 1 2 1 1 2 0.506
Test No. X1 (mm) X2 (mm) Rz (mm)
1 2.00 30.00 0.328
2 1.50 30.00 0.395
3 1.40 27.50 0.397
4 1.75 23.96 0.147
5 2.00 25.00 0.248
6 1.75 27.50 0.146
7 1.50 25.00 0.297
8 1.75 27.50 0.149
9 2.10 27.50 0.249
10 1.75 27.50 0.146
11 1.75 31.04 0.438
12 1.75 27.50 0.145
13 1.75 27.50 0.146
Part name Snap spring Frame Body
Number 6446 29776 67386
Type 10-Node tetrahedral elements
Material Density,
ρ (kg/mm3)		 Young’s
modulus,
E (GPa)		 Poisson’s
ratio, ν		 Yield stress,
σy (MPa)
PC+ABS 1.14E-6 2.0 0.39 54
Table 1 Contradiction analysis for variable curvature mechanism
Table 2 Frequency of inventive principles in Table 1
Table 3 Design parameters in 2 levels
Table 4 L8(27) orthogonal array for the parameters in Table 3
Table 5 Test matrix and results for the 2nd order response surface
Table 6 Number and type of elements
Table 7 Material properties

Table 1

Table 2

Table 3

Table 4

Table 5

Table 6

Table 7

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