Weld Quality Monitoring System Development Applying A design Optimization Approach Collaborating QFD and Risk Management Methods

품질 기능 전개법과 위험 부담 관리법을 조합한 설계 최적화 기법의 용접 품질 감시 시스템 개발 응용

  • Son, Joong-Soo (Design Technology Research Center, Institute for Advanced Engineering) ;
  • Park, Young-Won (Design Technology Research Center, Institute for Advanced Engineering)
  • 손중수 (고등기술연구원 설계기술연구실) ;
  • 박영원 (고등기술연구원 설계기술연구실)
  • Published : 2000.02.01

Abstract

This paper introduces an effective system design method to develop a customer oriented product using a design optimization process and to select a set of critical design paramenters,. The process results in the development of a successful product satisfying customer needs and reducing development risk. The proposed scheme adopted a five step QFD(Quality Function Deployment) in order to extract design parameters from customer needs and evaluated their priority using risk factors for extracted design parameters. In this process we determine critical design parameters and allocate them to subsystem designers. Subsequently design engineers develop and test the product based on these parameters. These design parameters capture the characteristics of customer needs in terms of performance cost and schedule in the process of QFD, The subsequent risk management task ensures the minimum risk approach in the presence of design parameter uncertainty. An application of this approach was demonstrated in the development of weld quality monitoring system. Dominant design parameters affect linearity characteristics of weld defect feature vectors. Therefore it simplifies the algorithm for adopting pattern classification of feature vectors and improves the accuracy of recognition rate of weld defect and the real time response of the defect detection in the performance. Additionally the development cost decreases by using DSP board for low speed because of reducing CPU's load adopting algorithm in classifying weld defects. It also reduces the cost by using the single sensor to measure weld defects. Furthermore the synergy effect derived from the critical design parameters improves the detection rate of weld defects by 15% when compared with the implementation using the non-critical design parameters. It also result in 30% saving in development cost./ The overall results are close to 95% customer level showing the effectiveness of the proposed development approach.

Keywords

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