Dongwon Yun

Development of roll-to-roll hot embossing system with induction heater for micro fabrication.

In this paper, a hot embossing heating roll with induction heater inside the roll is proposed. The induction heating coil is installed inside a roll that is used as a heating roll of a roll-to-roll (R2R) hot embossing apparatus. Using an inside installed heating coil gives the roll-to-roll hot embossing system a more even temperature distribution on the surface of the heating roll compared to that of previous systems, which used an electric wire for heating. This internal induction heating roll can keep the working environment much cleaner because there is no oil leakage compared to the oiled heating roll. This paper describes the principles and provides an analysis of this proposed system; some evaluation has also been performed for the system. A real R2R hot embossing heating roll system was fabricated and some experiments on micro-pattering have been performed. After that, evaluation has been performed on the results.

Actuation of a robotic fish caudal fin for low reaction torque

In this paper, a novel caudal fin for actuating a robotic fish is presented. The proposed caudal fin waves in a vertical direction with a specific spatial shape, which is determined by a so-called shape factor. For a specific shape factor, a traveling wave with a vertical phase difference is formed on a caudal fin during fin motion. It will be shown by the analysis that the maximum reaction torque at the joint of a caudal fin varies depending on the shape factors. Compared with a conventional plate type caudal fin, the proposed fin with a shape factor of 2π can eliminate the reaction torque perfectly, while keeping the propulsion force unchanged. The benefits of the proposed fin will be demonstrated by experiments.

Effects of preheating and cooling durations on roll-to-roll hot embossing.

In this study, we examined the sensitivity of embossed pattern depth to preheat supply and cooling and investigated how the pattern type and density affect the embossed depth. The main factors that affect embossed pattern qualities of roll-to-roll hot embossing, such as roller temperature, roller speed, and applied force, were determined using the response surface methodology. Eight conditions were then added to determine the time-dependent effects of heat transfer with custom-designed preheating and cooling systems. An extended preheat time for the polymethylmethacrylate substrate contributed to the significant change in the embossed depth, whereas the substrate-cooling did not exhibit a clear increasing or decreasing trend. Larger embossed depths were achieved in the horizontal patterns with lower density than in the vertical patterns, and the lower pattern densities showed greater embossed depths in most embossing conditions. We expect that this result will help to understand the effects of the pre- and posttreatment of roll-to-roll hot embossing by employing time duration factors of heat transfer, depending on the mold pattern type and density.

Investigation of heat treatment of gears using a simultaneous dual frequency inducting heating method

This paper presented the simulation and experiment of gear hardening using the SDF induction technology . Using a thermal-electromagnetic coupled 2D FE model, it performed simulations on heating various gears and selected “optimal” input parameters of SDF induction heating . After constructing a 1 MW-scale SDF inducting heating system, gear hardening performances were evaluated . The trends of the experimental results matched with those of simulations . This study demonstrated the feasibility of 2-D FE modeling for reducing computational costs and accurately predicting gear hardening results “simultaneously” .

A Novel Safety Brake System Based on Magneto-Rheological Fluids

This paper presents a novel Magentorheological (MR) brake with permanent magnets. The proposed MR brake can generate a braking torque at a critical rotation speed without an external power source, sensors, or controllers, making it simple and cost-effective device. The brake system consists of a rotary disk, permanent magnets, springs and MR fluid. Permanent magnets are attached to the rotary disk via springs, and they move outward through grooves with two different gap distances along the radial direction of the stator due to centrifugal force. Thus, the position of the magnets is dependent on the spin speed, and it can determine the magnetic fields applied to MR fluids. Proper design of the stator geometry gives the system unique torque characteristics. To show the performance of an MR brake system, the electromagnetic characteristics of the system are analyzed, and the torques generated by the brake are calculated using the result of the electromagnetic analysis. After the simulation study, a prototype brake system is constructed and its performance is experimentally evaluated. The results demonstrate the feasibility of the proposed MR brake as a speed regulator in rotating systems.Copyright

Thermal-electromagnetic Coupled Analysis for Gear Heat Treatment using Simultaneous Duel Frequency

In this paper, Finite Element Analysis (FEA) for gear heat treatment using simultaneous dual frequency (SDF) induction heating is conducted. To do this, thermal-electromagnetic coupled FE model is built. A two dimensional FE model of gear and heater is introduced to reduce computation time. For more time-efficient analysis, harmonic analysis for electromagnetic model is adopted and transient analysis model, for heat transfer model. Through the coupled analysis, it can be found that the proposed FE model can solve for SDF induction heating of gear and heat treatment parameters can also be determined.

Note: Dynamic analysis of a robotic fish motion with a caudal fin with vertical phase differences

In this paper, a robotic fish with a caudal fin with vertical phase differences is studied, especially focusing on the energy consumption. Energies for thrusting a conventional robotic fish and one with caudal fin with vertical phase differences are obtained and compared each other. It is shown that a robotic fish with a caudal fin with vertical phase differences can save more energy, which implies the efficient thrusting via a vertically waving caudal fin.

Development of Heater Using Eddy Current

In this research, a heater using eddy current for generator is designed and some analysis is performed to validate the system. FEM (finite element method) is used for analysing eddy current phenomena at the various speed of rotor with permanent magnet. A real heater system is fabricated. Some experiment is also performed to validate the analysis result. Through the experiment, the FE analysis is validated and we found that the efficiency of developed heater is over 94%.

Design and analysis of an MR rotary brake for self-regulating braking torques

This paper presents a novel Magneto-rheological (MR) brake system that can self-regulate the output braking torques. The proposed MR brake can generate a braking torque at a critical rotation speed without an external power source, sensors, or controllers, making it a simple and cost-effective device. The brake system consists of a rotary disk, permanent magnets, springs, and MR fluid. The permanent magnets are attached to the rotary disk via the springs, and they move outward through grooves with two different gap distances along the radial direction of the stator due to the centrifugal force. Thus, the position of the magnets is dependent on the spin speed, and it can determine the magnetic fields applied to MR fluids. Proper design of the stator geometry gives the system unique torque characteristics. To show the performance of an MR brake system, the electromagnetic characteristics of the system are analyzed, and the torques generated by the brake are calculated using the result of the electromagnetic analysis. Using a baseline model, a parametric study is conducted to investigate how the design parameters (geometric shapes and material selection) affect the performance of the brake system. After the simulation study, a prototype brake system is constructed and its performance is experimentally evaluated. The experimental results show that the prototype produced the maximum torque of 1.2 N m at the rotational speed of 100 rpm. The results demonstrate the feasibility of the proposed MR brake as a speed regulator in rotating systems.

Dynamic simulation of joint module with MR damper for mobile rescue robot

In this paper, we have developed the dual arms manipulator of a rescue robot. This manipulator will be mounted on the mobile robot platform and, this robot will be used to perform rescue operations in extreme environments. The shock vibration occurs from the road when the robot is driving on the rugged terrain. It also adversely affects the robot as well as the rescuer. We propose the joint module utilizing MR(Magneto-Rheological) fluid in order to depress impact vibration from the environment. Also we have performed dynamic simulations on the dual arms manipulator considering vertically impact acceleration and analyzed the driving torque generated in the joint module.