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2열 코일투입 LH, RH 부품 동시생산 복합성형 공법개발
윤주섭(Jooseop Yun) 한국자동차공학회 2019 한국자동차공학회 학술대회 및 전시회 Vol.2019 No.11
The goal of this study is to develop a forming process for producing LH and RH parts simultaneously in L, R progressive dies by inserting two coils. The development and application of PLC synchronous control technology between coil feeder and press of two-row progressive-die equipment could meet the requirements of each forming process. As a result, productivity innovation of molding method and composite forming technology has made it possible to improve the productivity of LH and RH parts of 590㎫ high-strength materials. To develop a forming process that can be applied to productivity innovation, a two-row coil input progressive-die technology was developed compared to a robot line, and a material transfer guide and actuator of the mold according to the input of two-row materials was applied. In order to develop a heterogeneous composite forming process for simultaneous production of LH and RH parts, the problem of coil feeder facility for two-row coil transfer was solved and the Roll Guide of Uncolier was improved. In addition, the installed screw and guide enable precise straightness control of the coil during leveling, thereby eliminating the quality problems and improving productivity of LH and RH parts. The composite forming process of two-row materials input with high technical difficulty enables centralized production through reduction of facility investment cost and productivity innovation. With facility investment of ₩400 million for 500ton feeder line compared to facility investment of ₩1 billion for robot line, facility reduction cost was reduced by 60%. With the development of the two-row coil input forming process, the production volume per hour was increased from 500 to 1,894. In addition, the improved durability of manufactured parts improved the defect rate from 3% to 0.7%. And it is expected to increase sales of ₩271,655 thousand and reduce costs by ₩68,113 thousand per year.
이종 브래킷 자동용접 너트/볼트 불량검사의 센서융합 공정개선
윤주섭(Jooseop Yun) 한국자동차공학회 2019 한국자동차공학회 학술대회 및 전시회 Vol.2019 No.11
In this paper, we developed a vision system that can collectively detect welding defects such as nut/bolt missing and nut eccentricity on heterogeneous brackets produced in automatic welding machines. Many existing auto-parts manufacturers rely entirely on manual welding inspection processes. The discrimination of OK/NG is a visual inspection by the operator and the situation is a full inspection according to the feeling of the skilled worker. This leads to optical illusions due to worker’s increased fatigue and detection errors due to randomness of the inspector’s judgment. In order to overcome the limitations of visual inspection and to increase productivity by improving the reliability and speed of inspection, it is essential to avoid qualitative judgment and establish quantitative judgment criteria in automatic welding nut/bolt inspection. Therefore, it is necessary to develop an inspection process for detecting missing and defects of nut/bolt welded to brackets using vision system. To develop the vision system for bracket batch inspection, we installed the bracket alignment transfer unit on the outlet of the parts produced by the automatic welding machine, and developed the operation/transfer/vision control technology by PLC communication between the automatic welding machine/alignment transfer unit/vision system. In order to develop an automated SW solution for the inspection process, we designed the UI for bracket registration, recognition and inspection result(OK/NG) to prevent the mixing of parts, and developed nut/bolt missing and nut(hole) eccentric measurement technology on the brackets. In addition, the control and discrimination algorithm of machine vision was evaluated for the performance of welding defect detection system, and the applicability was verified by calculating the time and economic effect on the identification of defects through the process installation of real-time inspection system. The problems were improved and optimized by designing and manufacturing sensors, components and turning chutes for each product. The real-time monitoring of the inspection process through the developed fusion module convenient for acquiring and utilizing the process data, has achieved up to 16 types of brackets, cycle time within 1.5 seconds, False Negative Rate 1.42cpk, and nut eccentricity measurement accuracy of less than 0.2㎜.