Transcript 080605 김용재 세미나자료_1

VPD
Design
System Test Team
VPD center, R&D, VCE Korea
VPD
Role and Vision
Design
 System test team은 부품, 소재 및 시스템 등에 대해서 목표수명 동안에 품질과 성능을 유지할 수
있도록 고객의 사용조건(외력, 환경조건)을 토대로 모든 외력과 특성을 분석하여 시험조건을 설정하고
이 시험조건을 구현할 벤치시험을 구성하여 부품 및 시스템 레벨의 내구시험 (유압부품, 구조물, 전장
품), 진동.소음시험, 환경시험 및 소재분석을 수행함으로써 내구성 및 성능을 확보한다.
 System test team sets up a test specification by analyzing all the external loads and characteristics
based on customer's situation (external load, environmental condition etc) so as to maintain quality
and performance of components, materials of system level for target life. And system test team
composes a bench test to implement this test condition and perform durability test (hydraulic
components, structures, electrical parts), vibration/noise test, environment test and material analysis
to secure durability and performance.
 시스템 레벨단계의 구조물, 유압부품 및 전장 품에 대해서 선행적으로 각종 벤치시험 및 환경시험 등을
실시하여 신제품개발 프로세스의 detailed development단계에서 시험 및 평가를 실시하여 기술을
선도한다.
 It is planned to perform various bench tests and environment test in advance for structures, hydraulic
components and electrical parts of system level and to lead test and evaluate technology in the
Detailed Development phase of new product process.
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VPD, System Test
Role and Vision of System Test Team
VPD
Design
 System test team sets up a test specification by analyzing all the external loads
and characteristics based on customer's situation (external load, environmental
condition etc) so as to maintain quality and performance of components, materials
of system level for target life.
 And system test team composes a bench test to implement this test condition and
perform durability test (hydraulic components, structures, electrical parts),
vibration/noise test, environment test and material analysis to secure durability
and performance.
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VPD, System Test
Role and Vision of System Test Team
VPD
Design
 It is planned to perform various bench tests and environment test in advance for
structures, hydraulic components and electrical parts of system level and to lead
test and evaluate technology in the Detailed Development phase of new product
process.
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VPD
System Test Organization
Design
 Define the engineering groups based on the excavator system model
System Test
6
Structure
1+21
5
4
4
Power System
& Control
Noise &
Fluid Thermal
Material
Structure (4)
Noise (3)
Hydraulic (1)
Steel (3)
Vibration (1)
Cooling (1)
Control system (1)
Polymer (1)
Structure
& Vibration (1)
Fluid Thermal (1)
Power system (1)
Elec. S/W (1)
Technicians(3)
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System Test
VPD
Design
• Definition : Parts and components combination, Real operational loading, Component & system coupling effect,
functions and systems integration
• Prepare the system test benches of critical engineering paths in all 4 systems areas
• Simulate the real applications through rigorous correlation analysis
• Execute the systems level verification tests
• Perform metallurgical failure analyses on functional components & parts to find root causes of failures.
6D upper structure
durability test (1)
ATT bench test (2)
[Structure]
RR test for
U/C
[Power]
Power performance
test (2)
Noise & cooling test
(1)
Power durability
test (2)
Swing system
durability test (2)
Travel system
durability test (2)
NVH refinement
test(0.5)
[Control]
Control system test
[Human]
Cab/HVAC
system test (1)
System tuning
test (0.3)
Material analysis
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[Control]
[Human]
[Power]
[Structure]
[Material]
VPD
Structure field test
Design

Structure field test & analysis : 실제 사용조건하에서 Field test을 실시, stress history을 측정하고 Damage분석, 강도평가 및
피로수명 등을 평가

Test item: Attachment, Lower frame, Upper frame, etc

Facility & S/W
Item
Spec
<Strain gage application>
QTY
Data acquisition system
64ch
1set
Potable DAQ
16ch
2 set
Software
N-Soft
4 set
일반토양
굴삭
선회충격
석산,암반
암석 상차
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암석 긁기
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VPD
Machine noise test

Design
Objectives
– 소음법규를 만족하는 저소음 굴삭기를 개발하여 조용하고 안락한 작업이 될 수 있도록 운전자 및 외부 환경 관점에서의 소음
평가를 실시합니다.
– Evaluation of exterior and interior machine noise by noise regulation
 2000/14/EC EU noise Directive
 ISO 6395
 ISO 6396

Specification (Capacity)
– Scope: all excavator products

Applicable Test Case
– Sound power
– Sound pressure
Noise Test Field
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Structure bench test
Design
•
Structure test & analysis : 구조물 및 component의 강도시험, 실제 사용조건에서의 Field test, 필드 하중조건을 구현하는
bench시험을 통하여 강도 및 내구성을 검증하고 또한 운전석의 ROPS, TOPS등의 인증시험을 수행
•
Test item: Attachment bench test, Lower frame bench test, Cab ROPS test, Structure field test, etc
•
Facility & S/W
Item
Spec
QTY
Data acquisition system
(HP3852S)
120ch
1set
- Increase fatigue life evaluation accuracy more than 70%
30ton/300mm
1 set
- Constant amplitude loading  real operational loading
30ton/200mm
2 set
- Multi-axial fatigue test
20ton/ 200mm
1 set
- Launching schedule: 2008
20ton/ 300mm
1 set
10mm/400mm
1 set
50ton/ 200mm
2 set
Fatigue test machine
Attachment Bench Test
Lower Frame Bench Test
New Attachment Bench Test
Specification
Force
250kN
500kN
1,000kN
Cab Test (ROPS)
Stroke
250mm
250mm
250mm
Unit
2
4
5
Fully compressed
time history
7.3m
5m
3m
14.5m
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6.5m
Depth: 6m
3m
VPD
Vibration durability test

Design
Objectives
– 굴삭기의 작업장에서 사용되는 실제 사용 상태 작업 조건을 3차원 6자유도 운동으로 정확하게 실시간 구현하여 진동
내구성 평가를 실시합니다.
– accelerated durability test of major components and upper structure assembly

Specification (Capacity)
– 6 DOF real motion simulator
– Scope: major components and up to 90 ton grade upper structure

Applicable Test Case
– Accelerated durability test
•
Upper frame
•
Cabin & electric
•
Engine component
•
Hydraulics
•
Tanks/cowl frame etc
major components vibration
durability test
Upper structure
vibration durability test
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VPD
Noise & Cooling test

Design
Test Specifications:
– Semi-anechoic room (Cutoff 100Hz, Background noise 35dB, 10.39W X 7H X 13.19L(m))
– HVAC facility inside semi-anechoic room (constant temp. & humidity)
– Test facility for Airflow / Cooling / Noise and Test bench model
– Control system / Data acquisition system with wireless data transfer
– Hydraulic load simulator with a part performance test facility

Applicable Test Cases
Air-flow
 Engine Room's Airflow Visualization
 Engine Room's Airflow Field (Temp./Pressure/Velocity)
 Engine Room's Airflow Resistance
Cooling
Noise
 Heat Exchanger's Air Volume Rate
 Sound Pressure
 Sound Power
 Acoustic Intensity
 Acoustic Playback and Design
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 Heat Exchanger Module’s Performance
 Heat Exchanger Thermal Distribution
 Heat Exchanger 's Optimized Install
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Power performance & durability test

Design
Test Specifications
–
엔진, 펌프, MCV, 실린더와 유압 부품 류의 내구성 검증 (수명, 진동, 마모, 누출)
–
실제 부하 조건을 통한 성능의 검증
–
에너지 효율, 연료 소모량, 오일 오염도 분석
–
압력 손실에 의한 열 부하 계측
– 범위: 90 ton 굴삭기 이상, 400 bar 이상
Applicable Test Case
–
엔진 & 펌프 내구성 시험
Integration

– Items: 엔진 & 펌프
–
MCV & 실린더 내구성 시험
– Items: MCV & actuators
–
동력 시스템 성능 시험
– Items: 시스템 효율 (압력차, 온도차, Q), 연료 소모량
Engine Performance Test
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MCV Performance Test
Component 내구 시험을 System으로 통합하여 유효성을 검증
Cylinder Durability Test
VPD, System Test
Turning Joint Durability Test
Load Simulator
VPD
Electro-Hydraulic control test

Design
Test Specifications
– 전유 제어 시스템 및 제어 Algorithm 개발/시험
– 전유 제어 시스템 Design/Test Guideline 개발

Applicable Test Case
– 유압 및 전유 제어 단품 및 Sub-System Level 성능 및 특성 시험
Electro-Hydraulic Test Bed
Universal Performance Bench
DAQ
DAQ
M
Real-time
Controller
Control
Panel
Control
Panel
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M
M
VPD
Environment test

Design
Test Specifications:
– Test work in chamber (4000W X 4725D X 4150H)
– Air condition cycle bench system (-40~100oC, accuracy ±0.2oC)
– Sun Load system (0~1200 kcal/m3hr, control 1 kcal/m3hr)
– Thermal shock test system
High temp.: within 15 minute, accuracy ± 1.0oC
Low temp.: within 20 minute, accuracy ± 1.0oC
– Electronic break system

Applicable Test Cases
– Key Life Test (1 cycle : Spring, Summer, Autumn, Winter)
– Extra Temperature Durability Test
– Thermal shock Test
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Swing system durability test

Objectives
Verify durability of swing system
Reduce test time & cost

Specification (Capacity)
– Accelerated by motors
– Loaded by pump
– Expected energy regeneration efficiency : 40%

Applicable Test
– Accelerated fatigue & wear test
–
( up to 90 ton class)
 Swing ring & pinion gear
 Swing bearing
 Swing motor
 Swing reduction gear
 Grease sealing
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VPD
Design
Material devel. & Failure analysis
VPD
Design
• Materials laboratory is a group of specialists in the field of applied material science and technology within VCE
EXC. BL. by implementing various failure analyses for finding out the root causes and materials developments
of functional components and parts, material testing, material selection, steel approvals, and other material
related engineering issues.
•소재응용연구그룹은 재료공학과 제반 소재가공기술을 적용하여 각종 기능부품의 소재 및 열처리 품질 신뢰성평가와
열처리 특성 모사해석/시험을 통해 각종 부품의 공정설계를 수행하고, 신제품개발, 강재 승인은 물론 시장으로부터
발생하는 다양한 손상부품의 신속하고 정확한 원인규명을 실시하여 Quick & Complete solution을 제공하는 소재전문가
그룹입니다.
• 소재그룹은 합금설계, 열처리, 표면개질처리, 내식성 및 마찰마모 평가기술 등의 기반기술을 적용하여 당사 제품 군의
내마모 소재기술 및 Component 기능부품의 열처리공정 등을 설계, 응용은 물론 독자적인 연구개발과제 및 의뢰업무를
진행하고, 한편으로 소재 국산화과제를 통해 원가절감과제, 품질개선과제 등을 통하여 품질제고에 일익을 담당하고 있다.
• 주 업무 중의 하나로써 현업부서의 needs에 대응코자 재질과
열처리 관련 애로기술 Trouble shooting은 물론 양산 완성 차의
Component 및 주요 부품의 Field Trouble에 대한 Failure Analysis
원인분석에 소재분석기술을 적용하여 신속하고 정확한 인자규명과
재발방지를 위한 대안제시를 통해 품질 VOLVO에 핵심 역할을
수행하고 있다.
•아울러 각종 금속재료의 물성 평가, 분석을 아울러 겸하고 있으며
또한, 설계 및 구매, 품질 등 제반 생산활동 각 분야에 필요한 소재
애로기술을 consulting 제공하고 지원하여 당사 제품 군의 신뢰성
제고에 일익을 담당하고 있다.
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Analysis & Evaluation Equipment
VPD
Design
Fractography by Scanning EM
Topography
X-ray Spectrometer with EDS
Microstructural Examination
Ferrography test
Specimen Preparation
Impact Tests
Hardness Tests
NSS Corrosion Tests
Various Wear Tests
Const/Temp & Humid. Chamber
Heat treatment Tests & Simulation
Jominy Test
Tensile Tests
Emission Spectrometer
• 아울러 각종 금속재료의 물성 평가, 분석을 아울러 겸하고 있으며 또한, 설계 및 구매, 품질 등 현장 각 분야에 필요한
소재요소기술을 제공하여 당사 제품 군의 신뢰성 제고에 일익을 담당하고 있다. 특성화된 분석설비로 조직분석,평가를 위해 필수적인
Micro & Macro 광학현미경, 파면해석에 필수적인 초고배율의 주사전자현미경과 조직 내부의 상의 분포와 함량비율을 측정할 수 있는
상분석기등은 물론 기계적 물성 평가를 위해 각종 경도기, 충격시험기, 마찰마모시험기, 염수분무시험기, 열처리경화능 시험기와
재질 화학성분 분석용 Spectrometer 등을 갖추고 과제 및 분석업무에 적극적으로 이를 활용하고 있다.
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