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Key components of auto-seeding for high-quality sapphire ingot growth furnace

March 17, 2016 by Leave a Comment

Technology overview: Sapphire is a crystal created by melting aluminum oxide at temperature higher than 2,100˚C followed by being grown as a single crystal. Up until now, https://korean-machinery.com///inquiryindustrial use of sapphire was limited to LED field; however, application fields have been expanded and diversified due to improvement in manufacture technique and cost reduction by entrance of new manufacturers. Among various methods of growing sapphire, Kyropoulos method has an advantage of producing high-quality crystal, better for large caliber; however, process of seeding that induces initial crystallization by contacting seed crystals to surface of melted material must be performed. This process has to be conducted following an instruction manual strictly by a highly skilled engineer who has obtained work technique for a long period of time, which may be considered as a disadvantage. Since it is highly dependent on engineer and manual, the yield has not been stable, thereby posing difficulty in increasing production capacity. The problem triggered the development of key components for auto-seeding.

Core technologies of auto-seeding, which are the measurement of temperature and surface image of melted material, driving module automation and development of linking program, were developed and applied to growth furnace of sapphire. Through application of auto- seeding technology to existing process, sapphire production has been standardized, thereby contributing to stabilization of production yield rate. Therefore, the production is expected to grow more than 200% compared to the previous production when a Kyropoulos grower equipped with the developed technology is installed in mass-production line.

Industrialization: The iPhone by Apple, the smartphone manufacturer, uses sapphire for marketing of premium-quality phone, and major cell phone companies of China have also introduced products with application of sapphire front glass, targeting the large market of China. Furthermore, based on rapidly growing distribution rate of smartphones, China has aggressively engaged in investment for production facility of sapphire single crystal. Kyropoulos equipment applied with auto-seeding technology developed by DKAZTEC Co., Ltd. was acknowledged with its stable yield, large quantity productivity and low production cost, accomplishing sales in scale of KRW 14 billion to a Chinese company. In addition, large sapphire with excellence in optical quality was manufactured, and sapphire window used for defense was produced, which successfully internalized the material highly dependent on foreign countries. Through establishment of the foundation for the domestic field of sapphire and development of the technology, global competitiveness and leadership were secured.

Problem-solving in industrialization: Since the manual seeding previously used implemented the best decisions through multilateral interpretation on the situation based on various information, it posed a problem that was highly dependent on skills and experiences of engineers. In order to automate the process, the development was proceeded separately for a vision system that acts as human eyes, algorithm acting as brain, and driving module part acting as human arms. Errors created from the process of development were interpreted in a simple sense. For example, contamination created from evaporation of melted material and deformation of internal material by high temperature causes a problem of interfering with the vision system; however, the problem was solved with the development of the multichannel system. In addition, for performance of components in driving module (e.g. precision of pulling transfer distance, repeatability, weight accuracy, etc.) and reproducibility of initial form of the grown crystal, reliabilities of materials were obtained through the authorized testing institutes (utilized as statistical figures). As a result, reproducibility could be obtained by characteristics of highly repetitive motion, and the process stabilization was achieved based on the result. In particular, growth furnace of high-quality sapphire was applied with auto-seeding system, thereby preparing a foundation for improvement of the sapphire industry to higher level.

Technology developer: DKAZTEC Co., Ltd. / +82-61-460-5800 / www.dkaztec.co.kr

Kyropoulos growth equipment applied with the developed key components of auto-seeding
/  Analysis image (Captured) of auto-seeding

 

 

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International standards on the electro-foaming fusion wrap

March 17, 2016 by Leave a Comment

Technology overview: The existing electro-fusion sheet for pipes has superior watertightness and durability, compared to a mechanical connection method, as the https://korean-machinery.com///inquirysurface of a pipe and a PE sheet  is melted by electrothermal wire for fusion. However, a gap caused by the overlapped part of sheets or a difference in external diameters of two pipes, arising during production or moving of pipes, can’t be solved by the heat of electrothermal wire, which often leads to leakage. This problem can be solved by the electro-foaming fusion wrap, which can close such gaps through a foaming method for improved watertightness and durability. The electro-foaming  fusion wrap contains electrothermal wire and a temperature sensor inside the foaming fusion sheet. As for products with small and medium diameters (D150~D600), electrothermal  wire is laid at an interval of 8㎜ (single) and 10㎜ (dual) in order to prevent a dent of a pipe wall, caused by rising temperatures of the overlapped part. In addition, electrothermal wire is coated with glass fiber, and base mesh which fixes the wire is included in the foaming sheet so as to solve the short circuit problem of the wire. And the surface area for heat dissipation has been increased by adopting an indirect heating method through glass fiber coating instead of direct heating, which also prevents carbonization of resin caused by high temperature.

Industrialization: The product has especially targeted the European market where most countries use PE pipes. Between 2011 and 2012, a sample of the electro-foaming fusion wrap was sent to KWH Pipe in Finland for testing. As a result, the product was registered with KWH Pipe in 2013 for regular supply, and products of various diameters have been exported to KWH Pipe Sweden. In 2012, KWH Pipe presented the electro-foaming fusion wrap at the Water and Sewer Pipe Exhibition held in Sweden. The successful results in Sweden led to another opportunity such as sample presentation and testing for Plastitalia S.p.A in Italy, Pipelife in Austria, and INOAC in Japan. In particular, there has been an effort to register international standards for the product, so that NP (New Proposal) and CD (Committee Draft) in the area of ISO/ TC 138/SC 1(pipes) were submitted in 2012. The DIS (Draft International  Standard) was circulated to the member bodies for the vote but the draft is to be approved as TS (Technical Specification) first and then as an international standard later because the product is a relatively new item and has not many cases of use in countries other than Korea.

Problem-solving in industrialization: The entry to the domestic market was relatively easy, but penetration to the global market as a new item and standardization was a significant challenge. Therefore, joint research with KWH (Finland), leading the PE sewer pipe market in terms of technologies and scale, began in 2008 prior to the submission of NP (New Proposal) in 2012, and samples were presented to Plastitalia in Italy and Pipelife in Austria so as to make known the product to the global market. In addition, a presentation on the product and standardization was given at the Plastic Pipe Conference in 2011, drawing the attention of the market to EFF WRAP, and then NP was submitted to ISO.

Technology developer:

Industry Academic Cooperation Foundation Mokwon University / +82-42-829-7831 / http://sanhak.mokwon.ac.kr

AZUMI / +82-31-701-1305 / www.azumi.co.kr

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Development of sensor for sensing the brake lining

March 17, 2016 by Leave a Comment

Technology overview: https://korean-machinery.com///inquiryAt present, the Lining Wear Sensor (LWS), notifying the worn-out condition of the lining among the domestic automobile parts, is entirely occupied by the product of H Company, a European automotive electronic component company. However, following the requirement of the digitization and the communication mode, merits of the Inductive, an electronic sensor (non-contact type), have been magnified, thereby changing as a global trend.

H Co’s LWS judges the worn-out degree using plenty of Hall-ICs by the sensing method of Hall-IC type, and then informs the driver of the replacement time of the lining. On the other hand, the Inductive sensor technology of TRUWIN Co., Ltd. using the law of electromagnetic induction is the product which does not need the permanent magnet nor need to consider the characteristic of the magnetization curve of the magnet and the temperature, and it is composed of the sensor part coil sensing the movement of the pedal, the exclusive ASIC design for drive of the whole system, the FET drive circuit of the ECU transmission signal, etc. And we also have enhanced the reliability and the accuracy by grafting the microprocessor as well as upgraded the existing non-contact inductive method in order to be capable of sensing the wide angle . We plan to increase the technology share in the domestic automobile market through development of the sensor like this, and keep on securing price competitiveness in the global market through continuous technical development.

Industrialization: As the inductive sensor design for sensing the wide angle, requiring the program design for the development of the microprocessor and development of the optimal product for the automotive environment, has a considerable level of difficulty in verifying the reliability, it is the cutting edge technology to the extent that at present only three companies can develop the product in the world. TRUWIN has succeeded in localizing almost all of the parts and technologies of the inductive sensor. Having achieved recognition of such excellence, we passed the quality verification system of our customer companies in 2014, thereby applying our product to the domestic vehicles produced in large quantity, and we are mass-producing our product as it has been applied distendedly, step by step. In the overseas market, we are in consultation with M Company regarding various options for entering the Europe market, and we expect to control about 10% of market share in the global commercial vehicle market when we find our way in the world market.

Problem-solving in industrialization: At home and abroad, there is no company owning the technology of the product developed by TRUWIN Co., Ltd (the sensor for sensing the non-contact brake lining using the inductive sensor). The product of H Company has to inevitably use a permanent magnet as it has adopted the method using the Hall element, and thus has the problem of assuring the temperature characteristic of the permanent magnet and solving the weakness for the increase of the cost price. The product of ‘sensor development for sensing the brake lining’(LWS) using the Inductive sensor developed by TRUWIN Co., Ltd. through the ATC project can solve the above- mentioned problems, and it is outstanding and excellent in the aspect of insuring the quality stability and price competitiveness. In addition, we are striving for continuous research and development in order that the LWS developed by TRUWIN Co., Ltd. can be applied to the product specifications by model as the product for the commercialized vehicles. By possessing the fundamental technology in consequence of research and development over the past two years, we expect to secure market competitiveness and advance as a global enterprise and create added value.

Technology developer: TRUWIN Co., Ltd. / +82-42-612-5211 / www.truwin.co.kr

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1200MPa-level high-strength connecting rod-making technology

March 17, 2016 by Leave a Comment

Technology overview: Connecting rods used in automobile engines are the power transmission part converting the linear motion of the piston into the rotating motion at the https://korean-machinery.com///inquirycrank shaft by explosion of fuel, thereby requiring high strength and toughness, and fatigue strength. In addition, recently as the demand for high-strength connecting rods increased with the development of high-powered engines (GDI, T-GDI etc.), we needed the mass production technology of high-strength and high-precision connecting rods, thereby developing the relevant technology. In this study, we have secured the mechanical properties capable of responding to the high-powered engine through the high- strength powder alloy design for powder forging, and have reduced number of processing times and improved the mechanical property relative to the competing production methods by complementing the optimized design of mold (Net-Shape) and the post-treatment process.

In addition, based on the connecting rod design technology using the computer simulation, we have succeeded in producing the connecting rod for high-powered engine. By producing and supplying the test specimen and the test product developed without investment and change of equipment in the short term on the basis on these technologies, we have evaluated the product and applied the mass production system in early stages. Recently with the increasing demand for high-strength and lightweight connecting rods following the downsizing trend of high-powered engines, the recent issue of the automobile industry, it is expected that the demand trend of such connecting rods will be applied to both domestic and foreign markets, thereby doubling the economic effect.

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Industrialization: We succeeded in mass-production of the developed connecting rod without change of the existing production line or additional investment, and beginning with application of the rod to the 2000cc T-GDI engine of Hyundai Motor Company in 2011, we applied the rod to all of the models mounted with a gasoline engine of 2000cc or larger (four models mounted with a 2000cc Theta Engine, three models mounted with a 3000cc Lambda Engine, and one model mounted with a 5000cc Tau Engine) of Hyundai Motor Company in 2013, thereby achieving turnover of about KRW 54 billion from 2011 to 2014 (KRW 2.4 billion in 2011, KRW 14 billion in 2012, KRW 18 billion in 2013, and KRW 20 billion in 2014, respectively). In addition, we also came to achieve the effect that the items of the localized parts pursuant to the reinforcement of Hyundai-KIA Motors’ localized production were maintained by or converted to domestic production. Therefore, it has become more likely that our connecting rod will be applied distendedly to various automobile parts requiring high-tensile and high-fatigue features, and it has become possible for the overseas competitors to produce, substitute and supply the connecting rod in Korea vis-a-vis the localization investment in China. Thus, it is expected that increase of export will be possible as the factories of GM, FIAT, etc. located in China are also reviewing development of the product.

Problem-solving in industrialization: Composition of the alloy powder mainly used for producing the connecting rod with the powder forging process before the research and development was Fe-Cu-C based alloy, and its tensile strength was 800MPa level having difficulty in being applied to the high-powered engine. In order to secure hardness, overseas competitors produce the product by increasing the content of copper(Cu) and sintering at high temperature (1,250℃), there is a limit in securing the property only by adjusting the content of copper and carbon(C), and increasing  the sintering temperature causes the increase of investment for the processing equipment and processing cost. In order to solve this problem, we have concentrated on developing new alloy material for the connecting rod capable of responding to the high-powered engine without introduction of new production method or change of owned equipment. Besides, we could succeed in industrialization by mass-producing the product early as rapid evaluation of the product and complement verification of technology and quality were implemented for the development product attributing to the concentrative research and development through the connection of both the enterprise-oriented industry∙institute research system and the production∙demand enterprise.

Technology developer: Sinteron Co., Ltd. / +82-31-299-8114 / www.sinteron.com

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Digital UV inkjet press

March 17, 2016 by Leave a Comment

Technology overview: Offset, Flexo, etc., the existing typical printing methods, are the analog printing method requiring the process of more than 10 steps in order to acquire the desired results. For example, after plating the color separation film by color, the experienced experts have to adjust the alignment of each color plate. However, with the UV inkjet press developed and industrialized by DILI Corporative Company, you can check the result immediately after having inputted the digital file, https://korean-machinery.com///inquiryand also can enjoy the cost-saving effect, along with the fast output speed, through variable data processing, eco-friendly printing environment, and process simplification which were impossible in the existing analogue printing. In order to realize the digital UV inkjet press like this, DILI has developed the inkjet control technology which forms the image by controlling individually the injection amount of thousands of inkjet nozzles with the level of pico liter (a trillionth liter) on the media transferred with high speed of 50 meters per minute, the high-power UV curing system which cures the injected ink, the output bed optimization technology, the high-accuracy position control system, the automatic head cleaning and capping system, the media tension adjustment algorithm, etc., thereby having optimized them with one another. Though the Korean manufacturing industry reveals to prominence in the world, the printing machine alone showed inferiority compared with Europe and Japan. However, we have received the evaluation that we marked a new milestone through the fundamental technology and product development related to this digital UV inkjet press. We have received the IR 52 Jang Young-sil Award in recognition of the excellence of the relevant product and applied technology.

Industrialization: More than 10 digital UV inkjet press, industrialized through years of development and investment, have been installed at home and abroad, thereby getting the attention of the market at the same time of being launched. The digital UV inkjet press market utilizing the inkjet is in its embryonic stage and on account of the high technical barrier, explosive growth of the market is expected with DILLI and several globalized enterprises having already entered the market as the center. Especially, due to the unique advantage of the digital equipment, replacement demand and interest of the customers owning the existing analogue equipment have greatly picked up. In addition, DILLI’s industrialization of the digital UV inkjet press is a barrier to imports against the foreign-made equipment, and also contributing to increase of exports. In the beginning, DILLI’s equipment was designed to be capable of printing out at the speed of 50 meters per minute with the maximum output width of 216mm and using 5 colors. However, reflecting the demand from both domestic and overseas markets, now the model line is strengthened to be able to print out with the maximum width of 324mm.

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Problem-solving in industrialization: Although we secured the core technology through development of the algorithm for controlling thousands of inkjet nozzles individually,  optimal concave surface design for securing the media oblateness on the printed face, development of the UV curing system, etc., we have faced with the problem of having to align 15 inkjet heads accurately for obtaining the better product of printout. Therefore, DILLI developed the head alignment system capable of fine adjustment easily from the customers’ point of view, and then has completed application for PCT and registration of patent at each relevant country. Through this, we are receiving favorable reaction in the market with the differentiated quality of enabling the installation within a short period compared with competitors as well as improvement of the product of printout.

Technology developer: DILI Corporative Company / +82-31-860-5500 / www.dilli.co.kr

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Large-sized multi-tasking vertical lathe for windmill parts

March 17, 2016 by Leave a Comment

Technology overview: Just recently a large-sized multi-tasking vertical lathe has been required at the parts machining market of the wind power generator, along with the vertical lathe having been conceived as the device exclusively for the parts machining of the large-sized wind power generator. Although, until now, https://korean-machinery.com///inquirythe parts of the wind power generator have been machined using large-sized machining center for vessel, aircraft and construction equipment, more and more specialized large-sized multi-tasking machining systems tend to be developed targeting the wind power generator market which will develop rapidly from now on. However, the Yaw & Pitch bearing machining equipment for the wind power generator is the field under examination in Korea without any full-fledged production, and all of the equipment used domestically are imported from overseas countries. The high-speed, high-precision and hydrostatic rotary table which is the core fundamental technology as the typical high-value equipment among large-sized machining systems in the future and the hard-turning technology of the high-hardness materials on the lathe with the high-stiffness ram are urgently needed to be developed in Korea for advancement of the large-sized vertical lathe. It is expected that with the development of this technology, the fundamental technology will be secured for localization of the multi-tasking vertical lathe for machining the Yaw & Pitch bearing of the wind power generator entirely dependent on import, the foundation for developing various high-value large-sized machining system by overcoming the technical dependencies will be prepared, and the economical effect will be doubled, such as import substitution effect, targeting the overseas wind power generator markets and technical ripple effect on the development of similar high-value machining system.

Industrialization: We have secured the core fundamental technology of the multi-tasking vertical lathe for machining the Yaw & Pitch bearing of the wind power generator previously entirely dependent on import. We autonomously developed the machine tool structure optimization technology, having applied the techniques of core module design and analyzation, and the topology and dimensional optimization method in order to localize the parts machining system for the wind power generator monopolized by the advanced countries. Also we have secured the core technology through the autonomous development of large hydrostatic rotary table and performance verification, and have achieved the preoccupancy effect of the high-value market for the parts machining of the wind power generator by developing the commercialization model. At present, there are active test cuttings by the overseas buyers and customers visit us frequently. We have already concluded three Memorandums of Understanding(MOUs).

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Problem-solving in industrialization: For the purpose of localizing the core technology of the multi-tasking vertical lathe for machining the Yaw & Pitch bearing for the wind power generator, as a result of having performed the structural analysis taking the case of machining in the worst conditions through technical exchange and cooperation with the government-funded research institutes, we have confirmed its structural safety. After having checked the occurrence of distortion at the cross rail of the initial model, we performed the topology optimization and the dimensional optimization in order to reduce the distortion. As a result, we came to compensate and manufacture the cross rail by decreasing the displacement of the tool center point in comparison with the initial model.

Technology developer: Kiheung Machinery Co., Ltd. / +82-42-933-5500 / www.kiheung.com

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80kW traction motor and decelerator technology for C-segment electric vehicles

March 17, 2016 by Leave a Comment

Technology overview: Unlike an internal combustion engine that is mainly operated by an engine, the powertrain of an electric vehicle is a system run by an electric motor with a decelerator using battery.

https://korean-machinery.com///inquiryThe powertrain of an electric vehicle consists of a driving mechanism that directly uses a motor’s torque to run wheels. Since it only uses battery as a power source, it is very important to develop high power output and high performance of traction motor and decelerator, and weight reduction technology. Once these are accomplished, it is possible to extend the vehicle miles traveled. In advanced countries, permanent magnet synchronous motor made of rare earth materials is generally used to achieve high performance and high power density. An acquirement of cost-competitiveness has been greatly attracted in automotive industry as the cost of rare earth materials has been on the rise.

In addition, it is very important to maximize the vehicle miles traveled, reduce the material cost of electric components as well as weight, and improve loadability while maintaining the same amount of battery capacity. In this project, a powertrain mass production technology of weight reducing single- stage decelerator and permanent magnet synchronous motor have been developed to reduce weight and maximize efficiency.

Industrialization: A traction motor, one of the core components of powertrain for electric vehicles and single-stage decelerator have been developed in this project and applied to the mass-production of Soul EV, a C-segment electric vehicle. Moreover, obtaining high performance (vehicle miles traveled), low noise and parking safety are enormously essential for electric vehicles.

In order to maximize productivity, the 80kW traction motor for C-segment electric vehicles developed in this project employs the magnet assembly step-skew technology and the pole pitch angle optimization technology for a reduction of torque ripple which affects the noise and vibration of an electric vehicle.

High performance cooling system to increase the heat dissipation area of cooling channel is crucial for maximizing performance of motor, thus the pin-shaped water cooling channel housing has been employed.

A decelerator is a device that delivers a motor torque to the wheels, and we have developed a decelerating device that can increase motor torque by about 8 times while maintaining the rotational speed.

In this project, a gear layout design of 80kW electric vehicle’s decelerator has been optimized for high performance. Also, transmission efficiency reached the goal by using low viscosity oil and minimizing friction loss. Parking performance and durability specification were acquired through a vehicle test. In addition, by conducting NVH module analysis, support stiffness design optimization and stator tooth design (tooth design decision test), a competitive single-stage decelerator with good NVH performance has been developed.

Problem-solving in industrialization: To increase driving motor’s power density (kW/kg), weight reduction design and reluctance torque design optimization have been applied in this project. Furthermore, for a production cost reduction of permanent magnets, GBD (Grain Boundary Diffusion) technology has been employed to minimize the amount of Dysprosium (Dy) by more than 40%, a rare earth material.

Technology developer: Hyundai Mobis Co., Ltd. / +82-31-288-5103 / www.mobis.co.kr

Decelerator     /     Driving motor     /     Motor decelerator assy

 

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Battery-assembled compact electric car platform and heat pump-typed cooling/heating system

March 17, 2016 by Leave a Comment

Technology overview: The traditional air conditioning devices for electric cars are comprised of a cooling system that uses refrigerant, ie. vapor compression cycle, and a heating system that uses an electric heater, and it operates these two systems at the same time to maintain an appropriate temperature and comfort inside the car. This product has commercialized a heat pump system for electric car, which uses the existing vapor compression cycle, capable of using the cold spot of refrigerant for cooling use under the condition where outdoor temperature is high, and the hot spot https://korean-machinery.com///inquiryof refrigerant can be used for heating use under the condition where outdoor temperature is low. Traditional heaters that use electricity have thermal efficiency lower than 1 (0.9~0.95), consuming electricity energy more than required quantity of heat. While, the heat pump  system  has COP bigger  than 1 at all times (1.5~4), which helps reduce energy consumption by 30~60% compared to the system that uses an electricity heater to get the equivalent heating performance. In addition, it collects waste heat generated from application components of an electric car, such as inverter and drive motor, with the use of the heat pump system helping improve COP and reduce parasitic power. As a result, we could extend distance per charge by about 21% through power saving of the battery of a system requiring heating source up to 7kW for an electric car, and we have secured technology for domestically designing a heat pump system for electric cars.

Industrialization: With regard to developing a high-performance heat pump system using waste heat for the first time in the world, we have enhanced the endurance for components, at the same time being capable of domestically producing all components except for a refrigerant change valve. In addition, as we have realized power saving required for heating the inner space of a vehicle, compared to other competitor’s performance, with driving distance per charge of an electric car being increased. With this, we could satisfy customers’ requirements for increasing driving distance per charge, and have secured better competitiveness than our competitors, resulting in enhanced productivity. Further, with respect to applying a heat pump system to a vehicle, it was required to run dehumidifying and defrosting operations at the same time to remove moisture and frost on the window to assure a driver’s visibility and automatic temperature variable control operation to control the indoor air conditioning. To realize these, we have implemented integrated control logic of optimized operation satisfying the performance required by an air conditioning system for automobiles by properly combining cooling/heating modes, frost recognition and continuous operation modes. As a result, we have secured an independent technology for domestically designing a high- performance heat pump system.

Untitled-17Problem-solving in industrialization: With respect to developing a high-performance air conditioning system to extend the driving distance of an electric car, we have dramatically extended it by about 21% when running a heating system through COP improvement and power-saving by collecting only waste heat generated from application components, such as an inverter and a drive motor, of an electric car with the use a heat pump system. Then, with respect to extending the operation range of a heat pump system when it is -20℃ outside, a heat pump system tends to have deteriorated performance and endurance as the exterior temperature becomes low, due to the characteristics of refrigerant. Thus, it was not possible to run the system at low temperatures. This technology enables the waste heat generated in the application components suffers heat exchange with the refrigerant of low temperature at the entrance of the compressor, increasing the amount of refrigerant flow, and leading to secure an endurance enabling the system to run at up to -20℃. Finally, with respect to developing control technology enabling continuous operation after recognizing frost generation and ice formation on the outdoor fan, in order to overcome the frost generation and ice formation issues, which are chronic ones of a heat pump system, we have developed a method to recognize frost generation and ice formation in an outdoor fan, leading the refrigerant to the inner circulation cycle mode if frost generation is recognized so that the heat pump can continuously work in the heating mode without having a section of defrost operation.

Technology developer:

Hyundai Kia Motors / +82-80-600-6000 / www.hyundai.com

Hanonsystems Co., Ltd. / +82-42-930-6114 / www.hanonsystems.com

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Polymer new material stone unit panel system

March 17, 2016 by Leave a Comment

Technology overview: Structures that are recently being constructed are often high-rise buildings of various forms, in particular reflecting the trend of luxurious image. According to this construction trend, the external walls of the structures are getting using stones, the representative high quality finishing materials showing outstanding endurance. When using stones as finishing materials for mid-to-high rise buildings, the wet construction https://korean-machinery.com///inquirymethod using mortar is often adopted, which requires longer construction period and has issues like whiteout. To deal with these issues and reduce the weight of stone finishing materials used in high rise buildings, dry construction method, including a setting method, is used, which uses adhesive and connecting hardware for weight lightening. However, stones are heavy objects and raise issues at the connecting part of the structure, and as time goes by, significant pollution tends to occur around masonry joint that connects stone plates, which is harmful to the aesthetics of a building. This technology uses polymer new material for an economic and efficient exterior finishing method for structures, capable of resolving issues of the dry construction method. This technology synthesize stone and steel frames using polymer new material, filling in and synthesizing the polymer new material based on the existing method that connects stones and steel frames with iron goods, resulting in preventing the masonry joint of an external wall from being polluted due to rainfall infiltration, and improving heat insulation property. As it is possible to do manufacture by a large panel system unit, this technology reveals structural stability and outstanding construct ability, above all, and even it is easy to do maintenance after construction.

Industrialization: This technology mainly applies to environment-friendly buildings and the external wall construction of buildings which require a high energy management class, and as it helps shrink the thickness more than the stones used in the existing buildings, it is an economic technology contributing to cutting down on construction cost. Further, we have recently developed and applied steel frames that are optimized enough to saving construction cost, and have introduced a system that helps shrink term of works by streamlining installation processes of the fields. Due to these, Samjistone Co. Ltd., which joined in the development of this technology has achieved field application results worth more than KRW 5 billion since the technology development, and it is expected that it will be able to reach more than KRW 10 billion by 2016. In addition, many overseas project sites other than the existing ones are vigorously applying this technology to their works.

Problem-solving in industrialization: For the existing exterior masonry stone works, similar to this technology, it is essential to do the works on a scaffold or a gondola, which is vulnerable to risks. However, this technology involves producing stones by panel unit and using cranes to install them so that we can do construction works safely than before. As most construction works use equipment, it is possible to do the works with one-third of the manpower used in the existing exterior stone works, which helps lower the rate of human life loss accidents. Moreover, as it does not produce dusts or wastes coming from stones cutting, scrap stones or the pallet of imported stones, we can minimize civil complaints raised around the field, and in particular, this technology is better suitable to a construction field that is located in downtown areas.

Technology developer:

Myongji University’s Industry and Academy Cooperation Agency / +82-31-324-1063 / www.mju.ac.kr

 Keimyung University’s industry and academy cooperation agency / +82-53-580-6708 / www.kmu.ac.kr

Samjistone Co., Ltd./ +82-2-981-0027 / www.samjistone.co.kr / Basf Korea / +82-2-3707-7529 / www.basf.co.kr

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Environment-friendly propeller cavitation performance control technology

March 17, 2016 by Leave a Comment

Technology overview: Identifying the cavitation performance of a real vessel propeller through a model propeller test is critical as it forms the basis of vessel propeller design and technology development. We have developed a three-dimensional ship wake flow reproduction technique and a model propeller cavitation performance test technique, which minimize the effect of Reynolds Number, generated due to difference in velocity of flow, and the relative sizes of a model vessel, used in the model test, and a real vessel.

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We have compared and verified the results of the model test with the results of the real vessel propeller real sea trial run, and found it shows excellence in the generation of a real vessel propeller cavitation, and the expected level of variable pressure and propeller noise. Such foundation technologies apply to mostly commercial vessels, including container ship, LNG carrier,  LPG carrier,  VLCC, and PC. We have gathered credible data on various vessel types. We have secured a technology capable of estimating a vessel body’s effective velocity, which uses the numerical analysis of organic speed generated by a propeller, and the results of total velocity measurement of a propeller, in a large cavitation tunnel. We have developed a numerical analysis technique that helps optimize the load distribution of a propeller and minimize cavitation generation, seeking for improving the efficiency of controlling and propelling a propeller cavitation, based on the aforementioned test techniques. We also have developed a technology for verifying the torque balance of a counter rotating propeller (CRP), a technology for improving propulsion efficiency using a Hub Vortex Control Fin, a technology for reducing the cavitation of a propeller blade and controlling the wake flow of a ship body, which makes use of a Vortex Generator, and a technology for reducing and stabilizing cavitations on a Rudder’s tip and shoe.

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Industrialization: The method of testing a large cavitation tunnel, developed in this project will apply to a model test for propulsor and will be used in the cavitation performance verification of a propeller designed in the basic design stage before constructing a vessel, followed by suggesting the direction of design improvement, based on the results. For example, for a 8800TEU container ship, we designed it having the optimal ratio of the expanded area ratio reduced by 15~20% based on the credible results of the model test, resulting in propelling efficiency improved by about 3~4%, and we were successful in commercialization. Moreover, the numerical analysis technology for optimizing propeller design has been transferred to the participating companies and being in use in designing propellers for export vessels. Currently, the research results of this project are utilized not only in the verification of commercial vessels’ propeller cavitation performance, built by domestic shipbuilders and technology development, but also in the national R&D research projert.

Problem-solving in industrialization: Cavitation, generated in a vessel’s propeller, gives various harms, including reduced propelling force and efficiency of a vessel, generation of variable pressure triggering vibrations in the vessel body, eroded surfaces of propellers and rudders, and radiated noise under the water. As such phenomena are not still fully numerically analyzed around the world, we are applying experimental methods at the same time to verify the technology. When we needed to submit precise test results, we had no option but to use foreign test facilities because we were lack in a large cavitation tunnel. Now, we have domestically secured the related test facilities, performance tests and designing methods, as aforementioned, it is now possible to conduct a credible verification in Korea. The technologies will contribute to improving domestic shipbuilding industry’s competitiveness in receiving orders due to the technological superiority, and will give a foundation to independent technology development.

Technology developer: Korea Research Institute of Ships and Ocean Engineering (KRISO) / +82-42-866-3114 / www.kriso.re.kr

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