• 한국정밀공학회지
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• 제30권3호
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• pp.324-330
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• 2013

This paper describes a novel method to surface large optics mirror with an extremely high hardness, which could replace the high cost of the repetitive off-line measurement steps and the large ultra-precision grinding machine with ultra-positioning control of 10 nm resolution. A lot of diamond pellet to be attached on the convex aluminum base consists of a grinding tool for the concave large mirror, and the tool was pressured down on the large mirror blank. The tool motion at an interval on the spiral path was controlled with each feed rate as the dwell time in the conventional computer-controlled polishing. The shape to be surfaced was measured directly by a touch probe on the machine without any separation of the mirror blank. Total 40 iterative steps of the surfacing and measurement could demonstrate the form error of RMS $7.8{\mu}m$, surface roughness of Ra $0.2{\mu}m$ for the mirror blank with diameter of 1 m and spherical radius of curvature of 5400 mm.

• 한국안전학회지
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• 제36권5호
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• pp.71-78
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• 2021

There are regularly planned overhaul periods in thermal power plants, which involve the maintenance of the boiler of the power plants. However, thermal power plants workers are always exposed to risk during overhaul periods owing to the narrow space and significant dust inside the boiler. Therefore, it is essential to develop a safety monitoring system that is suitable for operating in this type of environment. In this study, we developed not only a worker three-dimensional (3D)-location monitoring system that can monitor and record the entry/exit of workers, their 3D-location, and fall accidents but also a method to secure the working environment and operation efficiency. This system comprises of a worker tag, which was equipped with an inertial measurement unit, a barometric pressure sensor, and a Bluetooth low energy (BLE), and the tags were given to each worker. In addition, the location of workers inside the boiler was measured using a pedestrian dead reckoning (PDR) method and BLE beacons. The location data of the workers tag were transmitted to the integrated database (DB) server through a gateway, and to the administrator monitoring system. The performance of the system was demonstrated inside an actual thermal power plant boiler, and the accuracy and reliability of the system were verified through a number of repeated tests. These results provide insights on designing a new system for monitoring enclosed spaces.

• 한국정밀공학회지
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• 제32권5호
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• pp.423-429
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• 2015

Linear motion (LM) ball guides have good accuracy and high efficiency. They are widely applied for precision machinery such as machine tools, semiconductor fabrication machines and robots. However, friction force incurs heat between the balls and grooves. Thermal expansion due to the heat deteriorates stiffness and accuracy of the LM ball guides. For accurate estimation of stiffness and accuracy during the linear motion, friction models of LM ball guides are required. To formulate accurate frictional models of LM ball guides according to load and preload conditions, rolling and viscous frictional analyses have been performed in this paper. Contact loads between balls and grooves are derived from Hertzian contact analysis. Contact angle variation is incorporated for the precision modeling. Viscous friction model is formulated from the shear stress of lubricant and the contact area between balls and grooves. Experiments confirm validity of the developed friction model for various external load and feedrate conditions.

• 한국정밀공학회지
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• 제31권7호
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• pp.561-567
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• 2014

Precision injection mold is an essential element in order to manufacture small and precision plastic lenses used for phone camera. There are many critical factors to meet the requested specifications of high quality plastic lenses. One of the main issues to realize high quality is minimizing decenter value, which becomes more critical as pixel numbers increases. This study suggests the method to minimize decenter value by modifying ejecting structure of the mold. Decenter value of injection-molded lens decreased to 1 ${\mu}m$ level from 5 ${\mu}m$ by applying suggested ejecting method. Also, we also developed BIS (Built-in Sensor) based smart mold system, which has pressure and temperature sensors inside of the mold. Pressure and temperature profiles from cavities are obtained and can be used for deduction of optimal injection molding condition, filling imbalance evaluation, status monitoring of injection molding and prediction of lens quality.

• 한국정밀공학회지
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• 제30권12호
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• pp.1303-1312
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• 2013

We report an ultra-precision lathe designed to machine micron-scale features on a large-area roll mold. The lathe can machine rolls up to 600 mm in diameter and 2,500 mm in length. All axes use hydrostatic oil bearings to exploit the high-precision, stiffness, and damping characteristics. The headstock spindle and rotary tooling table are driven by frameless direct drive motors, while coreless linear motors are used for the two linear axes. Finite element method modeling reveals that the effects of structural deformation on the machining accuracy are less than $1{\mu}m$. The results of thermal testing show that the maximum temperature rise at the spindle outer surface is approximately $0.5^{\circ}C$. Finally, performance evaluations of the error motion, micro-positioning capability, and fine-pitch machining demonstrate that the lathe is capable of producing optical-quality surfaces with micron-scale patterns with feature sizes as small as $20{\mu}m$ on a large-area roll mold.

• 한국정밀공학회지
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• 제25권10호
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• pp.115-121
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• 2008

This paper presents bisymmetric dual iron core lineal motor stage for heavy-duty high precision applications such as large area micro-grooving machines or high precision roll die machines. In this stage, two iron core linear motors are installed in laterally symmetric way to cancel out the attractive forces. Main focus was given to analyzing the effect of cogging force and moment for two different layouts, which are symmetric and half-pitch shifted ones. Experimental results showed that the symmetric layout is more adequate for high precision applications because of its clear moment cancellation effect. It was also verified that the effect of the residual cogging moment can be suppressed further by increasing the bearing stiffness. One problem of the symmetric layout is added cogging force which hinders smooth motion, but its effect was relatively small compared with that of moment cancellation.

• 한국정밀공학회지
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• 제9권3호
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• pp.67-72
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• 1992

This paper presents the process of manufacturing technology of ceramics ferrule for opitcal fiber connector. Precision zirconia ceramic ferrules is widely for high performance and low cost single mode optical fiber connectors. To polish the hole of the zirconia ceramic ferrule, the wire lapping instrument is developed and the machining experiment is conducted. Through the centerless grinding using diamond wheel the surface roughness of zirconia ceramics ferrule is below the 1$\mu$m Rmax.

• 한국정밀공학회:학술대회논문집
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• 한국정밀공학회 2005년도 춘계학술대회 논문집
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• pp.1862-1865
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• 2005

We have a plan to design a controller for electron beam manufacturing system. At first, we designed a controller for SEM. The controller consists of five parts (power source, beam controller, scanning controller, optic controller and main controller). Beam controller supplies pulse wave for generating high voltage and can monitor the status of high voltage instrument through emission current. Optic controller controls focus, spot size and image shift. Main controller transmits variables from operating program to each part and monitors the status of peripheral device.

• 전기학회논문지
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• 제67권1호
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• pp.87-95
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• 2018

The high-precision magnetic levitation transport system is a transport device applying the principle of magnetic levitation. So it is preferable for manufactory process of semiconductor and display industries. In this system, the gap sensors are arranged discontinuously and turned on or off when the tray moves in the running direction. Therefore, precise gap data is important for precise control of the carrier. However, a slight error occurs in the process of installing the gap sensor. So, in this paper, we introduce the high-precision magnetic levitation transport system for OLED evaporation process. Also, we propose a strategy for stable flight control and an offset algorithm for tracking installation errors transport system. The performances of the proposed algorithm are validated through simulation.

• International Journal of Precision Engineering and Manufacturing
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• 제6권2호
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• pp.19-25
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• 2005

In this paper, the feedforward control with least mean square (LMS) adaptive algorithm is proposed and examined to reduce rotating error by runout of an active magnetic bearing system. Using eddy-current type gap sensors for control, the electrical runout caused by non-uniform material properties of sensor target produces rotational error amplified in feedback control loop, so this runout should be eliminated to increase rotating accuracy. The adaptive feedforward controller is designed and examined its tracking performances and stability numerically with established frequency response function. The designed feedforward controller was applied to a grinding spindle system which is manufactured with a 5.5 kW internal motor and 5-axis active magnetic bearing system including 5 eddy current gap sensors which have approximately 15∼30㎛ of electrical runout. According to the experimental results, the error signal in radial bearings is reduced to less than 5 ,Urn when it is rotating up to 50,000 rpm due to applying the feedforward control for first order harmonic frequency, and corresponding vibration of the spindle is also removed.