Development of a Web-based RCM system for the driverless Rubber-Tired K-AGT system

The Korean Railroad Research Institute (KRRI) developed the rubber-tired AGT system (Model: K-AGT) between 1999 and 2005. The K-AGT is a light rail transit system does not require a driver and generally operates on an elevated railroad for transporting passengers. Accidents caused by driverless vehicles can severely affect social confidence, safety and economy. Therefore, it is very important to minimize the occurrences of such faults, and to accurately perform detailed maintenance tasks and thoroughly investigate the cause of any repeated failures. This research develops the web-based reliability centered maintenance (RCM) system for the K-AGT train system. The framework of the RCM system is based on performing a failure mode and effects analyses (FMEA) procedure on all the sub-systems in the K-AGT system. Out of the devices that have a low reliability, the high failure ranked devices are included high on the list for performing the overall maintenance plans. Through registration of historical failure data and the reliability indexes, the results of the FMEA can be updated. Such a process is repeated continuously and can achieve very accurate predictions for device operational lifetimes and failure rates. Also, the RCM system is designed so that workers can refer to the expert system for the latest procedures to perform the required diagnosis and repair of any failure. The overall RCM system consists of a failure/task management system, a preventive maintenance system, an expert system, a material management system, and an approval system. This research describes the development of the preventive maintenance system and the expert system that have been produced because these are the main functions for the RCM system. This paper was recommended for publication in revised form by Associate Editor Dae-Eun Kim Myung-Won Suh is a Professor of Mechanical Engineering. During 1986–1988, he worked for Ford motor company as researcher. From 1989–1995, he worked in technical center of KIA motors. He took a BS degree in Mechanical Engineering from Seoul National University and an MS degree in Mechanical Engineering from KAIST, South Korea. He obtained his Doctorate at the University of Michigan, USA, in 1989. His research areas include structure and system optimization, advanced safety vehicle and reliability analysis & optimization. Chul-Ho Bae is a PhD candidate at Sungkyunkwan University in Suwon, South Korea. He accomplished fellowship work as researcher at Mississippi State University, USA, in 2003 and 2005. He worked in Institute of Advanced Machi-nery and Technology (IMAT) as a Research Assistant in 2004. He was a part time Lecturer in computer aided Mechanical Engineering of Ansan College of Technology, Suwon Science College, and Osan College during 2004–2005. He took a BS Degree in Mechanical Design and an MS Degree in Mechanical Engineering from the Sungkyunkwan University. His research interests include computer aided engineering, reliability engineering, and optimization.     

A study on reliability centered maintenance planning of a standard electric motor unit subsystem using computational techniques

The design and manufacture of urban transportation applications has been necessarily complicated in order to improve its safety. Urban transportation systems have complex structures that consist of various electric, electronic, and mechanical components, and the maintenance costs generally take up approximately 60% of the total operational costs. Therefore, it is essential to establish a maintenance plan that takes into account both safety and cost. In considering safety and cost limitations, this research introduces an advanced reliability centered maintenance (RCM) planning method using computational techniques, and applies the method to a standard electric motor unit (EMU) subsystem. First, this research devises a maintenance cost function that can reflect the current operating conditions, and maintenance characteristics, of components by generating essential cost factors. Second, a reliability growth analysis (RGA) is performed, using the Army Material Systems Analysis Activity (AMSAA) model, to estimate reliability indexes such as failure rate, and mean time between failures (MTBF), of a standard EMU subsystem, and each individual component Third, two optimization processes are performed to ascertain the optimal maintenance reliability of each component in the standard EMU subsystem. Finally, this research presents the maintenance time of each component based on the optimal maintenance reliability provided by optimization processesand reliability indexes provided by the RGA method. This paper was recommended for publication in revised form by Associate Editor Dae-Eun Kim Myung-Won Suh is a professor of Mechanical Engineering. During 1986–1988, he worked for Ford motor company as researcher. During 1989–1995, he worked in the technical center of KIA motors. He earned a BS degree in Mechanical Engineering from Seoul National University and an MS degree in Mechanical Engineering from KAIST, South Korea. He obtained his Doctorate at the University of Michigan, USA, in 1989. His research areas include structure and system optimization, advanced safety vehicle and reliability analysis & optimization. Chul-Ho Bae is a PhD candidate at Sungkyunkwan University in Suwon, South Korea. He ac-complished fellowship work as researcher at Mississippi State University, USA, in 2003 and 2005. He worked in Institute of Advanced Machinery and Technology (IMAT) as a Research Assistant in 2004. He was a part time Lecturer in computer aided Mechanical Engineering of Ansan College of Technology, Suwon Science College, and Osan College during 2004–2005. He took a BS Degree in Mechanical Design and an MS Degree in Mechanical Engineering from the Sungkyunkwan University. His research interests include computer aided engineering, reliability engineering, and optimization.     

Inter-laboratory correlation exercise on a light-duty diesel passenger vehicle to verify nano-particle emission characteristics by Korea particle measurement program

The Light Duty Inter-Laboratory Correlation Exercise (ILCE) final report, performed with the ‘PMP Golden Vehicle’ at nine laboratories in the EU, Korea and Japan to demonstrate repeatability and reproducibility of the particle number concentration emissions measurement techniques proposed by the Particle Measurement Program (PMP), was released in 2007. The ILCE was conducted by the Korea Particle Measurement Program (KPMP) with a domestic diesel passenger vehicle equipped with a diesel particulate filter (DPF) between three certification laboratories and the research center of an automotive manufacturer to meet future regulations (EURO 5 and EURO 6) of particle number concentration for light-duty vehicles in early 2008. This research focused on measuring the particulate matter emission (particle number and mass) levels of a representative light-duty diesel passenger vehicle during new European driving cycle (NEDC) mode to analyze the repeatability and reproducibility between laboratories in Korea. From the ILCE test results in Korea, the mean total particle number concentration levels ranged from 5.43E+10 #/km to 1.58E+11 #/km and 0.0003 g/km to 0.0036 g/km for particle mass. Repeatability between participating laboratories ranged from 32% to 66% for particle number, 11% to 70% for particle mass; the reproducibility level was 46% for particle number, and 66% for particle mass emission. This paper was recommended for publication in revised form by Associate Editor Kyoung Doug Min Simsoo Park received his B.S. and M.S. degrees from Seoul National University in 1997 and 1979, respectively, and a Ph.D. from the State University of New York at Stony Brook. He served as a Chief Research Engineer at Hyundai Motor Company, a Director for Publication of the KSME, a Technical Advisor of Hyundai-Kia Motor Company, and an Editing Director, Project Director, International Director, Accounting Director, and General Affair Director of KSAE. He is currently Vice President and of Editor-in-Chief of IJAT at KSAE and a professor in school of mechanical engineering at Korea University.     

Three dimensional fretting wear analysis by finite element substructure method

In steam generator of nuclear power plant, flow induced vibration in a U-tube bundle could cause wear and fatigue failure. This vibration causes fretting-wear between the supporting plates and tubes by generating infinitesimal friction. In this study, a substructure method is developed for three dimensional finite element models of fretting wear problems and its feasibility is also verified. The substructure method can reduce large amount of computation time required by conventional finite element analysis.     

Assessment of the sulfide corrosion fatigue strength for a multi-pass welded A106 Gr B steel pipe below the low SSCC limit

In the area of heavy construction, welding processes are vital in the production and maintenance of pipelines and power plants. Welding processes happen to produce residual stresses and change the metal structure as a result of the large nonlinear thermal loading that is created by a moving heat source. The fusion welding process generates formidable welding residual stresses and metallurgical change, which increase the crack driving force and reduce the resistance to the brittle fracture as well as the environmental fracture. This is a serious problem with many alloys as well as the A106 Gr B steel pipe. This pipe that is used in petrochemical and heavy chemical plants either degrades due to corrosive environments, e.g., chlorides and sulfides, and/or become damaged during service due to the various corrosion damage mechanisms. Thus, in this study, after numerically and experimentally analyzing the welding residual stress of a multi-pass welded A106 Gr B steel pipe, the sulfide stress corrosion cracking (SSCC) characteristics were assessed in a 3.5 wt.% NaCl solution that was saturated with H₂S gas at room temperature on the basis of NACE TM 0177-90. The specimens used are of two kinds: un-notched and notched. Then, the sulfide corrosion fatigue (SCF) strength for the un-notched specimen was assessed below the low SSCC limit that was previously obtained from the SSCC tests for the notched specimen. From the results, in terms of the SSCC and SCF, all the specimens failed at the heat-affected zone, where a high welding residual stress is distributed. It was found that the low SSCC limit of un-notched specimens (σ_{SSCCun-notched}) was 46% (230 MPa) of the ultimate tensile strength (σ_U=502 MPa) of a multi-pass welded A106 Gr B steel pipe, and the notched specimens (σ_SSCCnotched) had 40% (200 MPa) of the ultimate tensile strength. Thus, it was determined that σ_{SSCCun-notched} was 13% lower than σ_SSCCnotched. Further, the sulfide corrosion fatigue limit (σ_{SCFun-notched}) was 32% (160 MPa) of the ultimate tensile strength of welded specimens. This σ_{SCF un-notched} was 20% lower than σ_SSCCnotched.     

Development of an automated progressive design system with multiple processes (piercing, bending, and deep drawing) for manufacturing products

This paper describes the research work involved in developing an automated progressive design system with multiple processes such as piercing, bending, and deep drawing for manufacturing products. This approach to make a progressive, flexible working system is based on knowledge-based rules. The knowledge required for this system is formulated from plasticity theories, experimental results, and the empirical knowledge of field experts. The system consists of three main modules: shape treatment, strip layout, and die layout modules. The system is founded on knowledge-based rules and is designed in consideration of several factors, such as the material and thickness of a product, the piercing, bending and deep drawing sequence, and the complexities of blank geometry and punch profiles. The system then generates the strip layout drawing for an automobile product. The die layout module carries out the die design for each process from the results of the strip layout module. The results obtained using the modules enable the designers of manufacturing products with multiple processes to be more efficient in this field.     

Transport of oxygen and carbon dioxide through polycarbonate membrane

Sorption equilibria and permeation rates for oxygen and carbon dioxide in polycarbonate membrane were measured at different temperature between 30 and 60°C and at pressures up to 2.5 MPa. The pressure dependence of mean permeability coefficient to oxygen obeyed the conventional dual-mode mobility model, whereas that to carbon dioxide followed a modified dual-mode mobility model with concentration-dependent diffusivities, as that of polystyrene to the same gas did.     

Intact hip and knee joint moment in coronal plane with unilateral transfemoral amputee

The incidence of osteoarthritis for lower limb amputees, especially unilateral transfemoral amputees, was higher than that of transtibial amputees. Considering level of amputation and bilateral load asymmetry, we could assumed that joint moments in the coronal plane during gait were highly related to the risk of osteoarthritis. Therefore, this study aimed to examine the hip and knee adduction moments in the coronal plane in persons with unilateral transfemoral amputation during walking through gait analysis. The subjects were 12 unilateral transfemoral amputees and 21 healthy persons. Three-dimensional motion analysis was measured bilaterally from 33 persons during walking to calculate temporal-spatial parameters and joint moments. The analysis compared the prosthetic side and the intact side of the amputee group and then analyzed the moment between both the intact sides of the transfemoral amputee group and the healthy persons. The results showed that the intact knee adduction moment of amputees increased by 32% compared to the prosthetic side and more than twice compared to the control group at terminal stance. But the bilateral hip adduction moment was decreased compared to the control group (p<0.05). Therefore it is expected that the higher knee adduction moment on the intact side may cause secondary complication to unilateral transfemoral amputees, but it is difficult to make connection with hip osteoarthritis.     

Development of a press-forming technology of the pressboard for a 154 kV transformer

A pressboard consisting of an angle ring and a cap is installed at the primary and secondary coil windings of a transformer. This pressboard is related to transformer durability. Since transformer capacities are increasing, it is necessary to develop a pressboard of high voltage grade (above 150 kV). In this study, a press-forming technology was developed for the pressboard of a 154 kV transformer. To determine the optimum shape of the pressboard, the press-forming factors were experimentally evaluated through the mechanical tensile strength and AC withstand voltage tests under wet conditions. From the results, the optimum size and shape of the pressboard was found to be R15??R20 mm under a forming pressure of 10 MPa. When the relative humidity (RH) was less than 50%, the moisture absorption rate in oil decreased by 25??40% compared to that in air. However, when RH exceeded 50%, the difference in the moisture absorption rate between the cases of oil and air was just 8??10%. The AC withstand voltage of the pressboard was weak against moisture. The average AC withstand voltage at 40°C and RH of less than 50% decreased by about 15% compared to the dried condition, and the maximum value decreased by 30% at 40°C and RH of more than 50%.     

Effects of electroplated Cu thickness and polyimide plasma treatment conditions on the interfacial fracture mechanics parameters in the Cu/Cr/polyimide system

The interfacial fracture energies of Cu/Cr/polyimide systems are deduced by subtracting work expenditure from the peel strength. Two methods were used to obtain the work expenditure: on based on the X-ray measurement of the plastic strain of peeled metal film and the other based on a theoretical analysis of the foundation model for the attached part of the metal film. These two methods yield reasonably consistent work expenditure in most cases, imparting validity to the experimental and theoretical methods used here. The interfacial fracture energies of the Cr/polyimide interface were shown w.r.t., the film thickness and rf plasma power density activating the polyimide surface. The phase angle of the interface crack between the Cu and polyimide is determined by using elasto-plastic finite element analysis and the path independence of theJ-integral. The presence of the polyimide interlayer increased mode mixity, and the phase angles were virtually independent of the metal film thickness, which is consistent with the nearly constant interfacial fracture energy with Cu film thickness.