Production Amount per Day: 560 ⇒ 940 pieces: ⇒ Productivity Improvement of 68%
Electronic Components / Applicator
Adhesive Applicator – CT-Effects Application Example
[ Robot/Electric Actuators ]
[ Controllers ]
RCP2-SA7C (2 axes)
An apparatus for applying an adhesive to the cover of lamp lights and an indicator light in the manufacturing of electronic components.
Z axis: ISB-MXL
Dispensing of the adhesive: RCP2-RA10C
[Problems of the air cylinder used]
They were dispensing the adhesive by using the air cylinder. The dispensing rate was changed because the air pressure was unstable and the adhesive was interrupted or lumped.
The viscosity of the adhesive changes under the conditions such as temperature, so that it took time to adjust the dispensing pressure.
Defective parts were made when the adhesive that attached to the work parts formed adhesive strings that weren’t cut off after dispensing.
[Benefits of the electric actuator]
The 45 seconds cycle time has been reduced to 30 seconds because the amount of adhesive dispensed always stayed stable.
This enabled the supply of adhesive to be stable all day after trial testing each morning.
The failure rate due to adhesive dispensing reduced to almost zero from about 10 pieces a day since they set movement to cut clean the dispensed adhesive. This movement was of the electric actuator in the vertical direction and the slide table.
[CT Effects - Reduction in Cycle Time/Choco Tei]
Equipment with the air cylinder
Equipment with the ROBO Cylinder
Duration of Choco-Tei per event
60 minutes / day
60 minutes / day
Production per day
560 pieces (*1)
940 pieces (*2)
(*1) When the air cylinder was used: (8 hours – 1 hour Choco-Tei) ÷ 45 seconds = 560 pieces per day
(*2) When the ROBO Cylinder was used: (8 hours – 10 minutes) ÷ 30 seconds = 940 pieces per day
Mini Webinar videos at: https://www.youtube.com/playlist?list=PLKoah4afs0KZGh94bwrZy9rrz0pktfIJ9
Learn CT-Effects!, the key to reduce production costs. You may be able to further reduce the costs if you look closely at the CT effects. (This is for the environments of manufacturing, factory, automation, and much more.) So what exactly are CT effects? Check out the video clips!
[Short Video Titles]
CT Effect 2014 001 Intro – Key to Reduce Production Costs at Automation Manufacturer
CT Effect 2014 002 Productivity Improvement and Ceased Time Reduction
CT Effect 2014 003 Application Example of Cycle Time Reduction – Case Study
CT Effect 2014 004 Comparison Air Cylinder and Electric Actuator by Speed on t v Diagram
CT Effect 2014 005 Changeable Speed and Zone Output at Press Fitting Operation
CT Effect 2014 006 & 007 Cut The Costs Get The Huge Saving
(006: Reduce Machines Increase Production by using IAI Actuator ROBO)
(007: Cut The Costs Get The Huge Saving by IAI Electric Actuator)
CT Effect 2014 008 Example of Choco Tei Reduction & Huge Cost Saving LV
CT Effect 2014 009 Long Life Lower Inventory, Energy Cost & CO2Emissions, LV
IAI Electric Actuator: http://intelligentactuator.com
This process carries a pair of parts, and then does spot welding in 3 locations per part. Until now, because it was done manually, more workers were needed to increase production to meet customer demand. In addition, since the project of high-mix low-volume production has been increasing in recent years, the welding process was automated using our ROBO Cylinders this time. It cost $12,000 ($6,000 / unit × 2 units) to build the two units, but it was amortized over 7.5 months.
(Personnel Expenses was calculated at $10 / hour)
After changing to ROBO Cylinder
Due to the manual labor, large differences had come out in production volume and quality depending on the workers. But with the result of the automation, since the parts stop at the same location repeatedly for welding, the quality is stable, and the defects became almost zero.
Compared to the manual labor, cycle time is improved, and production has increased significantly.
Since the worker was now only responsible for the placement and removal of the parts, and they can now handle the two units alone, the labor cost is now half.
In a system for performing the alignment of some resin blocks, the ROBO Cylinder was adopted. The company’s products include designer plates to be used on the floor of a house by bonding resin blocks.
Previously, an air cylinder was used, this was changed to ROBO Cylinder which improved the cycle time and reduced the occurrence of Choco-Tei events.
When air cylinder was used
Because the resin blocks were misaligned by the impact of the air cylinder stop, they were operating it at a reduced speed. However, Choco-Tei was still occurring about 10 times a day because of the misalignment due to unstable speed. To rearrange the resin block and to recover from Choco-Tei, it took about 1 minute.
After changing to ROBO Cylinder
By replacing air cylinder to ROBO Cylinder, and adjusting the pressing force and acceleration/deceleration, they could increase the operating speed while minimizing the impact at the time of stop. In addition, Choco-Tei was reduced to near zero.