항공기 Wire Harness 제조공정 시스템의 효율 향상을 위한 회로테스트 분석 및 무선 최적화 방안 연구

이성경 한국항공우주학회 2015 한국항공우주학회 학술발표회 논문집 Vol.2015 No.11

항공기 제작에 있어서 가장 중요한 부분 중에서 하나가 품질보증이다. 항공기에서 결함은 바로 항공기 추락을 의미하기 때문이다. 항공기에 장착된 LRU 들과 각종 장치들 간의 신호연결 및 전원을 공급해 주는 등 인체의 혈관과도 같은 역할을 하는 Wire Harness 는 항공기에서 매우 중요한 역할을 담당하고 있다. 이러한 Wire Harness 는 점점 Fly By Wire 로 항공기의 전자화가 가속화 되면서 항공기에서 많이 늘어나고 있다. 그런데 현재 Wire Harness 를 제작/장착 후 회로를 점검하는 방법에 있어서 비효율적인 공정들이 효율성 및 제품의 품질을 저해하고 있다. 이러한 이유로 기존의 방식을 개선하고 궁극적으로는 한국형 항공기에 적용 가능한 최적화된 방식을 연구하고자 한다. One of the most important parts in aircraft manufacturing is quality assurance. For a defect in an aircraft means the very crash of the aircraft. The wire harness, which works just like blood vessels in the human body because it connects signals between LRUs installed in an aircraft and various devices or supplies electrical power, plays a critical role in an aircraft. Such wire harnesses are greatly increasing in aircrafts as aircraft automation is gradually accelerated by Fly by Wire. As for the current method for checking a circuit after the manufacture/installation of a wire harness, however, its inefficient processes are undermining efficiency and product quality. For this reason, this study intends to improve the existing method, and to investigate optimized methods that are ultimately applicable to Korean type aircrafts.

A combined PVC Swelling and Ball Milling Approach for Highly Efficient Recovery of High-Purity Cu and PVC from Waste Wire Harnesses

( Shogo Kumagai ),( Harendra Kumar ),( Tomohito Kameda ),( Yuko Saito ),( Toshiaki Yoshioka ) 한국폐기물자원순환학회 2022 ISSE 초록집 Vol.2022 No.-

The wire harness assembly, used to conduct electricity to vehicle components and electrical and electronic appliances, is abundantly present in waste electrical and electronic equipment (WEEE) and end-of-life vehicles (ELVs). Wire harnesses usually consist of copper (Cu) strands coated with thin polyvinyl chloride (PVC) cables. Current technologies for recycling this waste are either ineffective or have significant limitations because they are currently only available for thick and uniform cables. Therefore, this work developed combined PVC swelling by organic solvent and ball or rod milling approaches for the recovery of high purity Cu and PVC from thin and ununiform cables in waste wire harnesses. We developed both lab-scale and bench-scale milling reactors to thoroughly investigate the milling efficiency and the separation mechanism, and the subsequent scaling up for the developed process. The PVC swelling behavior and the plasticizer removal from the PVC coatings by the selected organic solvents were thoroughly evaluated by employing Hansen Solubility Parameters (HSPs) and the effectiveness of the swelling ratio on the separation of PVC coatings and Cu wires were investigated by using lab-scale reactor. n-Butyl acetate and acetone were selected as the best solvents for PVC swelling and plasticizer removal. This work achieved complete recovery of PVC coatings, Cu wires, and plasticizers from the waste WH cables by the bench-scale reactors. Thus, this work established both the academic and technical bases of the developed approaches combining PVC swelling and milling processes.

Wire Harness Product Data Management(PDM) 시스템 연구

이성경 한국항공우주학회 2015 한국항공우주학회 학술발표회 논문집 Vol.2015 No.11

PDM 은 기업이 생산하는 제품과 부품에 관한 일체의 정보를 전사적으로 총체적 관리하는 전산시스템을 칭한다. 제품정보를 생성하는 설계를 비롯하여, 영업, 마케팅, 생산, 생산기술, 구매, 자재 및 정보시스템 부문에 이르기 까지 관계되며, 경영자와 관리자로부터 담당자까지 모두 PDM 사용자가 될 수 있다. 이런 역할을 하는 PDM 을 KAI 의 W/H 특성에 맞춰 Wire Harness 제품에 관련된 자료의 관리 또는 고도의 제조 과정 자동화로 항공기 제조회사의 재무 및 기타 관련된 분야에 걸친 업무와 연동되는 시스템들을 한 세트로 해서 전체적인 제품 데이터 관리(PDM) 시스템을 연구하고자 한다. PDM refers to a computerized system for the enterprise-wide management of all information about a product and its parts produced by an enterprise. It is related to sales, marketing, production, production technologies, purchasing, materials, and information system as well as design that creates product information; and all company members ranging from executives to managers and the persons in charge can be the users of PDM. This study intends to investigate the overall product data management (PDM) system, with systems linked to the finance and other relevant business affairs of an aircraft manufacturing company via the management of data or the advanced automation of manufacturing process relating to wire harness products being grouped as one set in keeping with the characteristics of KAI"s wire harnesses.

와이어 하네스의 커넥터 압착공정에 대한 3차원 유한요소해석

구선모(S. M. Gu),윤철호(Z. H. Yin),박진기(J. K. Park),최현순(H. S. Choi),김영석(Y. S. Kim) 한국소성가공학회 2009 한국소성가공학회 학술대회 논문집 Vol.2009 No.10

According to the increase of intelligent vehicles many automotive electric components are installed. The wire harness which connects those also increases. The crimping process for compressing the copper wire bundle into the terminal is a key process to assure the good quality of wire harness. For the case of inadequate forming condition many shape failures such as less-filling, over-filling are happen in the crimping process. Even though the quality of crimping shape is satisfactory the quality check for electrical resistance of wire harness is sometime not satisfied the qualification due to large variation of electrical resistance of wire harness under climate test. This large variation is though to be related with the malfunction automotive electric system and caused by the internal stress of wire, which occurred during the crimping process. In this paper we develop the 3D-FEM simulation scheme and design methodology of optimum terminal shape. Also the effect of terminal shape on the residual stress is discussed.

와이어 하네스 단선 단락 선별을 위한 디지털 고장 검출 시스템 개발

김선영,김아란,박재완,김하선,정재훈,김선영 사단법인 유공압건설기계학회 2023 드라이브·컨트롤 Vol.20 No.4

Wire harness is a component for efficient control when electronic parts are required such as construction machinery and electric vehicles. With emerging issues such as autonomous driving and automation in construction, a wire harness composed of multiple cables has become an essential part because more electronic parts are required. However, when a wire harness failure occurs, systems can be stopped, accidents can occur, and economic damage can be significant. Therefore, in this paper, we developed a digital fault screening system that could easily and quickly diagnose faults in the wire harness. The principle of the developed system was to sequentially send pulse signals to the wire harness and use returned signals to perform fault detection. As a result of diagnosing faults using the developed failure detection system, a detection accuracy of 99.9 % was confirmed through the experiments.

Preliminary Connector Recognition System Based on Image Processing for Wire Harness Assembly Tasks

Francisco Yumbla,Meseret Abeyabas,Tuan Luong,June-Sup Yi,Hyungpil Moon 제어로봇시스템학회 2020 제어로봇시스템학회 국제학술대회 논문집 Vol.2020 No.10

In this paper, we analyze and propose a recognition process of plug-in cable connectors for wiring harness assembly tasks using image processing. For manipulation and routing of wire harness, knowing the accurate pose of the cable connector is very critical in the grasping moment. The recognition process is crucial to minimize the error in the manipulation of the connectors. Nowadays, we notice that collaborative robot manipulators or small size industrial robot manipulators attain high accuracy and repeatability levels (sub-millimeter); thus, demonstrate very precise position control capabilities. Using those capacities and with the correct recognition system, we can apply to the automation of the wire harness assembly process. For that reason, we propose a connector recognition system to obtain the precise position of the connectors on a work table; which is necessary to obtain a successful grasping and manipulation of the connectors in a wire harness. The system and the recognition process are explained in detail, and validated experimentally.

Automotive Wire harness Virtual Validation for Voltage & Current Analysis and Circuit Protection

Hoseung An(안호승),Kyungwon Park(박경원) 한국자동차공학회 2012 한국자동차공학회 학술대회 및 전시회 Vol.2012 No.11

This paper is for virtual verification for automotive wire harness. The wire harness is one of typical power distribution components that are used to carry electrical power from the source to the remotely located loads. The wire system needs to perform in a safe manner when overload and short circuit conditions occur. The scope of simulation in this paper covers voltage & current analysis and circuit protection. GM Korea current procedure is to simulate the electric subsystem by Saber software and to confirm the CAE result by physical test. Also, i2t could be performed based on the real test result for single event. This process is helpful to produce higher reliable and robust design. General guideline is included for setting the boundary condition and component modeling.

산업용 Wire Harness Vision 검사 장비 개발

한승철(Seung-Chul Han) 한국산업융합학회 2008 한국산업융합학회 논문집 Vol.11 No.4

This paper presents vision based inspection system for defects of industrial wire harness. Five type of nonconformities facter such as barrel deform, projected wire, overcoating, rack of wire length, over-strip is considered. Developed inspectio algorithmn has been tested on real specimens from a wire harness factory. Experimental results show that the inspection algorithm an has a good performance.

자동시험체계 TPS 이식에 관한 연구 - 항공기 Wire Harness TPS를 중심으로

윤명섭,박구락,고창배,정영석 한국융합학회 2018 한국융합학회논문지 Vol.9 No.10

본 논문은 항공전자 부분품의 기능시험을 위해 사용하는 전용 자동시험체계(ATS)를 범용 자동시험체계로 TPS를 이식하는 연구이다. 항공전자 부분품의 성능시험을 위해 사용하는 전용 자동시험체계는 적게는 수천만원에서 많게는 수백 억원에 이르는 고단가로, 항공전자 정비 사업을 영위하는 국내 기업에서는 초기 투자비용에 많은 어려움이 있어 사업 확장 의 장애 요인이 되고 있다. 이러한 이유로, 본 논문에서는 전용 자동시험체계를 사용하는 정비대상품인 A항공기에 사용되는 발전기 내의 Wire-Harness를 범용 자동시험체계로 사용하도록 TPS를 이식하는 절차에 대해 연구하였다. 제안한 연구를 통해 전용에서 범용으로 TPS 이식 후 평가 및 검증을 수행한 결과 100% 성능검증을 확인하였으며, 이것은 절차의 표준화를 거쳐 무한한 확장 가능성이 있어 적은 투자로 항공전자 MRO사업의 확장을 원하는 국내 기업들에 큰 도움을 줄 수 있을 것이다. This paper is a study of TPS Migration to a multi-purpose ATS which is used for functional testing of Avionics parts. The dedicated ATS used for the performance test of avionics parts has a lot of difficulties in domestic MRO companies that carry out maintenance of high-level avionics ranging from tens of thousands won to several hundreds of billions won. For this reason, in this paper, I have studied the procedure of TPS migration to use the wire-harness in generators used in A aircraft, which is a maintenance product using a dedicated ATS, as a general-purpose ATS. Through the proposed study, We confirmed the 100% performance verification after the TPS migration from the proprietary to the general purpose. It is possible to expand infinitely through the standardization of the procedure.

자동차용 CAN(Controller Area Network) 네트워크에서 전원분배시스템의 컨트롤러 모듈 구현에 대한 연구

김일구(Ealgoo Kim),이태연(Taeyeon Lee),성진호(Jinho Sung),임지훈(Jihoon Lim),박재홍(Jaehong Park),김형욱(Hyunguk Kim),김용묵,김의봉(Euibong Kim) 한국자동차공학회 2004 한국자동차공학회 춘 추계 학술대회 논문집 Vol.- No.-

Currently automobile CAN network gains it popularity from its effectiveness by reducing wiring harness and thus simplifying the automobile network. The majority spaces of the wiring harness in the previous automobile network is from the power connecting cables that connect every controller modules and electrical loads to the battery. This paper presents a power distribution system that connects all the modules and loads with a single power cable and thus effectively reduces the wiring harness. This paper first analyzes the requirements for the controller module for power distribution system in automobile CAN network and shows results of real implementation of the hardware which is applied to a real automobile system of Hyundai Motor Company.