• Journal of the Korean Society of Manufacturing Process Engineers
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• v.21 no.7
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• pp.43-52
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• 2022

Design of a controller for a high-precision servo control system has been a popular topic while finding optimal parameters for multiple controllers is still a challenging subject. In this paper, we propose a practical scheme to optimize multi-parameters for the robust servo controller design by introducing a new cost function and optimization scheme. The proposed design method provides a simple and practical tool for the systematic servo design to reduce the control error with guaranteeing robust stability of the overall system. The reduction of the position error by 24% along with a faster convergence rate is demonstrated using a typical hard disk drive servo controller with 41 parameters.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.20 no.5
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• pp.35-46
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• 2021

The purpose of this study is to establish effective quality control activities to maintain proper operation rates and improve the performance of research and development weapon systems. Quality control improvement measures suitable for the actual conditions of our military were identified by comparing the operational methods and advantages/disadvantages of the domestic quality control systems Defense Quality Management System and Defense Quality mark with those of the systems employed in the US(QPL and QML). In order to ensure the reliability of the weapon system, it is imperative to operate a design-oriented self-quality management system through manufacturing-oriented government-led inspection and to expand and reorganize the certification system divided into manufacturing items and companies.

• IE interfaces
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• v.21 no.3
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• pp.294-301
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• 2008

Agile and flexible manufacturing systems make it mandatory that a control program should have features such as agility, flexibility, and reusability in order to run manufacturing unit smoothly. PLCs are the most frequently used control program in manufacturing systems. PLC programs are mostly programmed by subcontraction, which makes correction of code very difficult. As a result, it may cause delay during down time and ramp up time which leads to big loss of revenue and goodwill. To prevent delay during the times, this paper proposes systematic process analysis and application method for programmable logic controller like LLD (Ladder Logic Diagram). The proposed method uses modified human-error investing techniques for documentation and transforming technique to program LLD from the documentation. Furthermore, this paper demonstrates an example of piston mechanism to explain the proposed method.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.12 no.6
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• pp.69-76
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• 2013

This paper presents the development of the FCF method for the manufacturing of final products using numbers related to the minimum amount of work. The utilized product is a drum clutch, which is part of the transmission of an automobile. A double acting press is secured first and a prediction of the forming load on the practical material is made through an experiment with a plasticine model. Also, a finite element simulation using product shape and properties is performed, as well as a press experiment. A double acting press is manufactured that is suitable for a double acting experiment with a conventional hydraulic press(200 tons). A peripheral device for the press is additionally designed for experimental purposes. And, the press has as its essential points the drive speed, stroke control, etc., all of which influence the forming and is modified. Especially, a laser system is used for velocity measurement of two punches. The forming load of a practical material is predicted in order to derive a forming load formula for cold conditions on the basis of approximate similarity theory. Finite element analysis of the relative velocity ratio(RVR), etc., for most suitable flow defect(unfilling, etc.) prevention is achieved as well. The results are verified through a press experiment.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.12 no.2
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• pp.852-857
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• 2011

The shipbuilding industry needs automation and mechanization to solve reduction of skilled workers and labor shortage. Ship manufacturing process is the lack of automation than standardized manufacturing field. In this paper, we design and development an process automation system for hand rail production. Mechanical parts of the cutting process was designed with efficiency, productivity and reliability, CATIA and ANSYS, the stability of the mechanical structure was confirmed. System control using a PCNC controller to provide an open and scalable, and operate using touch-screen display control and monitoring of the system was performed. The automatic system successfully passed the driving test and processing test, and it showed an excellent performance.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.12 no.3
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• pp.28-35
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• 2013

Micro electrical discharge machining (EDM) as a non-contact machining process is very effective for micromachining with a thin electrode because of its low machining reaction force. The micro-electrode machining device has the advantage of maintaining high precision through the whole processes and uses a feeding wire in the thin electrode tool manufacturing process. This study describes the design and evaluation of a micro-electrode machining device using optical photo-interrupter. The electrode was fabricated by reverse electrical discharge machining. The performance of designed system was evaluated to measure tension force according to feed speed of wire. This system for micro electrode fabrication proves the feasibility in the micro-EDM process of the micro holes and parts for industrial applications.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.8 no.4
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• pp.76-82
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• 2009

A worm screw is widely used in a geared motor unit for motion conversion from rotation to linear motion. For mass production of a high quality worm, the current roll forming process is substituted with the milling cutter process. Since the milling cutter process enables the integration of all machining operations of worm manufacturing on a CNC(Computer Numerical Control) lathe, productivity can be remarkably improved. The tooling system for side milling cutter on the CNC lathe to improve machinability is developed. However, the runout of spindle and cutting tips are important factors to be considered for producing high quality worms because the tooling system has multiple tips. In this study, surface roughness variations accuracy according to runout was investigated in side milling cutter for worm screw. The result shows by simulation and experiment.

• Journal of Korean Society of Industrial and Systems Engineering
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• v.22 no.52
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• pp.347-354
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• 1999

Statistical Process Control(SPC) which uses control charts is widely used to inspect and improve manufacturing process as a effective method. A parametric method is the most common in statistical process control. Shewhart chart was made under the assumption that measurements are independent and normal distribution. In practice, this assumption is often excluded, for example, in case of (equation omitted) chart, when the subgroup sample is small or correlation, it happens that measured data have bias or rejection of the normality test. A bootstrap method can be used in such a situation, which is calculated by resampling procedure without pre-distribution assumption. In this study, applying bootstrap percentile method to (equation omitted) chart, it is compared and evaluated standard process control limit with bootstrap percentile control limit. Also, under the normal and non-normal distributions, where parameter is 0.5, using computer simulation, it is compared standard parametric with bootstrap method which is used to decide process control limits in process quality.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.16 no.5
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• pp.78-84
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• 2017

Compared to other types of power, hydraulic energy is the most commonly used for heavy vehicles and ships because it has fewer location and space constraints, and its controllability can be maintained even under adverse conditions. Operators have controlled a main control valve of ship winches by pushing or pulling the lever, which is directly connected to the spool. However, because of the spatial arrangement, the importance of remote control valves has emerged. In this paper, experiments of the hysteresis characteristics were performed by analyzing the remote-control valve using a valve tester and RA2300. The validity was verified by comparing with the analytical model using SimulationX as the hydraulic analysis program. This study examined the effects of the spool's notch (Non, End-mill, and Spherical) and the effects of stiffness and pre-load of the spool spring on Spool stroke, open area, and hysteresis characteristics. It is considered possible to reduce the cost and the, trial and error process in designing remote-control valves in the future.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.20 no.11
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• pp.43-51
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• 2021

A robust tracking controller design was developed for a rotary motion control system. The friction force versus the angular velocity was measured and modeled as a combination of linear and nonlinear components. By adding a model-based friction compensator to a nominal proportional-integral-derivative controller, it was possible to build a simulated control system model that agreed well with the experimental results. A zero-phase error tracking controller was selected as the feedforward tracking controller and implemented based on the estimated closed-loop transfer function. To provide robustness against external disturbances and modeling uncertainties, a disturbance observer was added in the position feedback loop. The performance improvement of the overall tracking controller structure was verified through simulations and experiments.