• Journal of Welding and Joining
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• 제28권5호
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• pp.75-79
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• 2010

The Remote welding system(RWS) using $CO_2$ laser equipment has focusable distance of laser beam longer than 800 mm from workpiece and can deflect the laser beam by the scanner mirrors very rapidly. In the case of normal welding system based on robot, there is a limit to move the shortest path in short time and this causes interference between robot and workpiece. On the other hand, RWS is the optimized equipment to get big merits with advanced sequence of welding and short cycle time. However, there is still a pending task such as the control of plasma in the welding process of thick sheets therefore, it requires high power laser beam because of the absence of assist gas equipment in itself. In this study, high-tensile steel plates were overlap welded with $CO_2$ RWS for the production of car body and the influence of penetration depth according to the existence of assist gas was analyzed. Excellent tensile strength with enough width of molten zone independent to penetration depth was observed under welding condition with 3.6 kW laser power and 2.8 m/min welding speed without assist gas. Finally, the proto-type automotive parts were produced by applying the deduced optimal welding condition.

• 대한용접접합학회:학술대회논문집
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• 대한용접접합학회 2009년 추계학술발표대회
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• pp.109-109
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• 2009

최근 유럽의 완성차 업체에서 조립라인에 적용을 시작하고 있는 레이저 원격 용접기술은 저항 점용접에서의 문제점들을 동시에 해결하고 작업 시간을 획기적으로 감소시켜 생산성을 향상시킬 수 있는 용접공정으로 떠오르고 있다. 레이저 원격 용접기술은 레이저 빔을 용접부의 원거리에서 조사하여 용접하는 기술로서 레이저의 초점거리와 갈바노미터의 고속 이송를 이용한 최첨단 용접공정이다. 높은 생산성을 유지 하기 위하여 정확한 용접 컨트롤이 필요하지만, 레이저 용접의 경우 용접시 안전 문제로 육안으로 관찰하기가 힘들다. 이러한 문제를 해결하기 위하여 모니터링이 필수적이다. 기존의 레이저 모니터링으로는 음향 센서를 이용하여 음향을 측정하는 방법이나 UV 센서, IR 센서 등의 빛을 이용한 방법이 많이 사용되어왔다. 하지만 이 방법들은 간접적인 방법들로 노이즈에 민감하고 또 설치가 까다로운 단점이 있었다. 본 연구에서는 CCD 카메라를 이용하여 시스템의 복잡함을 줄이고 더 정확하고 빠르게 용접 현상을 관찰하기 위하여 동축 모니터링 시스템을 이용하였으며, 이를 통해 Keyhole을 관찰하고 센서를 이용한 용접 변수(레이저 출력, 용접 속도 등)의 변화에 따른 용접 현상을 규명하였다.

• 한국레이저가공학회지
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• 제8권3호
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• pp.27-30
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• 2005

Nowadays, most automotives companies are making use of laser welding in car body assembly shop. But even though laser welding is better than resistance spot welding in many points, its application has been limited to special technology for manufacturing. The paper introduces in the field of remote welding system (RWS) to improve the process efficiency of laser welding. Positioning time of RWS between welding stitches is dramatically reduced to zero. It is a kind of solutions to generalize laser welding in mass production. This RWS consists of fiber laser, industrial robot and 3-axis scanner.

• 한국안전학회지
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• 제20권3호
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• pp.14-18
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• 2005

The ultrasonic handy scanner to be developed in this research is a nondestructive inspection equipment with various facility. The ultrasonic inspection is the technique area which apply range is increasing greatly with IT. The purpose of this research is development of a ultrasonic handy scan inspection device with the utility in a work spot. The ultrasonic handy scanner to be developed with portability in this research is able to carry out the spot inspection. It can contribute to the quality improvement, cost reduction and safety design.

• 한국공작기계학회논문집
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• 제16권2호
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• pp.92-99
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• 2007

Welding fabrication invariantly involves three district sequential steps: preparation, actual process execution and post-weld inspection. One of the major problems in automating these steps and developing autonomous welding systems, is the lack of proper sensing strategies. Conventionally, machine vision is used in robotic arc welding only for the correction of pre-taught welding paths in single pass. In this paper, novel presented, developed vision processing techniques are detailed, and their application in welding fabrication is covered. The software for joint tracking system is finally proposed.

• 한국생산제조학회지
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• 제23권5호
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• pp.525-531
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• 2014

A cowl cross is a part of the car's instrument panel used to maintain the rigidity of the vehicle body side. The application of laser welding has the benefits of speed and thermal deformation compared to arc welding. An ultra-high strength steel sheet is used to reduce the weight of the vehicle body parts. Generally, formability of such a steel sheet is poor because its elongation is very low. For this reason, a method for cold forming of an ultra-high strength steel sheet is required. This paper describes how to improve the formability and weldability of the ultra-high strength steel sheet. Mechanical tests of this material were also performed to evaluate the welding properties of $CO_2$ (GMAW) and those of laser welding.

• 한국자동차공학회논문집
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• 제21권3호
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• pp.50-57
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• 2013

The high temperature thermal attacks in welding can affect the residual stress of a frame for automotive assembly accompanying frame deformation. Also the residual stress can induce the negative effect on durability performance of the automobile. In order to analyze the frame deformation, the simplified test frame which had the similar shape (form) of the real automotive frame was fabricated. The contactless optical 3D scanner was used for the shape difference measurement of the frame between before and after the welding. The FE-model of the test frame was composed and the deformation and residual stress simulation were performed. The simulated results were compared with the measured results for the reference of the frame design following as the variation of welding sequency. The deformation shape of the frame by simulation was in good agreement with that by the experimental measurement. In addition, the optimized welding sequency with reduced deformation after welding could be achieved through these analyses.

• 한국레이저가공학회지
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• 제11권1호
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• pp.32-35
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• 2008

In the remote welding system using $CO_2$ laser, laser beam can be rapidly transferred to a workpiece by moving mirrors of scanner system. So, it makes reducing the cycle time of welding process. We can also use and apply various patterns of weld beads by linear controlled mirrors. But most of the domestic car makers have usually applied use stitch-shaped weld bead. In that case, we don't have the merit of remote welding system efficiently. Therefore, in this paper, we investigated the characteristic of weld strength according to patterns of weld bead on $CO_2$ laser welding. And we also studied the relationship between shape of weld bead and value of tensile load.

• 대한기계학회논문집A
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• 제41권3호
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• pp.213-218
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• 2017

리모트 용접용 2D 스캐너 F-theta 렌즈의 역설계가 광선 추적기법을 사용하여서 수행이 되었다. 렌즈의 곡면 및 렌즈간 거리를 변수로 설정하고 초점거리를 Marginal Ray Height 로 설정하여, 상용 광선추적기법 프로그램을 사용하여 무한반복 최적화를 수행 하였다. 최종목표 값을 설정 후 Merit Function에 정의된 기준에 따라, 최종 초점거리와 초점의 크기를 최종 목표 값 가중치로 설정하였다. 최적화된 렌즈는 총 4매이며, 벤치마킹된 상용렌즈의 초점거리(185mm) 보다는 다소 근거리인 137mm로 최적화 되었지만, 초점의 크기는 레이저 입사각에 따라 RMS 기준 $1.3{\mu}m$, $6.2{\mu}m$ 그리고 $16.1{\mu}m$로 계산 되었으며, 이는 상용렌즈에 근접하는 성능을 구현한다. 입사각별 왜곡도를 중첩 하여서 비교 분석한 결과, 입사각 $0^{\circ}$와 $12.5^{\circ}$에서는 기존 렌즈와 거의 유사한 형태로 나타나는 것을 볼 수가 있어, 본 연구에서 제안된 역설계기법이 사용자 환경에 따라서 효과적으로 적용되어 최적설계가 이루어질 수 있을 것으로 기대가 된다.

• 한국기계가공학회지
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• 제19권6호
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• pp.96-101
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• 2020

In this paper, we present the results of our research to perform 3D laser scanning functions by adding a focusing lens to a conventional 2D laser scanner. For the optical design, the ray-tracing technique was used along with a total of four lenses as the variable incident focusing lens, the collimating lens, and the F-Theta lens. As design variables, the curvature of the incident focusing lens (Lens #1) was assumed to be us, l mm and sumed mm, and the incident angles were set at 0cidenus, l. In addition, the distance between the focusing lens and the collimating lens was set to vary from 5 mm to 15 mm. When the incident focal length was varied from 5 mm to 15 mm, the exit focal length was calculated to vary from 67.5 mm to 56.8 mm for the lens with R = 100 mm and from 108.5 mm to 99.0 mm for the lens with R = 150 mm. When the incident angle was 0°, the focal aberration was only slightly observable at 10㎛ in both the x- and y-direction. At 7.5° was the focal aberration of approximately 20~50㎛ was measured at 20㎛. To investigate the chromatic aberration of the designed optical device, the distortion of the focus was observed when the 550 nm beam was simulated on lens designed for a 980 nm wavelength.