Slipper Production Line

Other Industries
Process: Application
slipper-dispensing3
Actuators: RCP2-SS8C and RCP4-RA5C

By automating the adhesive application process,
the product quality has improved greatly!!

【 Issues Until Now

  • The adhesive application process used to be done manually.
  • There was inconsistency in the quality of the finished products, and about 40% of the products were defective.

【Importance of Improvement】

  • To promote the consistency of product quality by automating the application process

【Improvement Details】

  • The application process was automated by introducing
  • two-axes combined Cartesian robots that use Robo Cylinders.

【Improvement Effects】

  • The quality of the work improved, and
    the rate of defective products decreased from approximately 40% →0%.

See more application examples.

IAI America at Pack Expo 2016

screen-shot-2016-10-28-at-11-00-37-am

Visit our booth E-10314 at Pack Expo.  Here is your invite.

Join us as our guest on November 6th – 9th with FREE registration.

Experience a resource-rich expo floor with live demonstrations and working machinery of the latest packing technology, equipment and products.

On display, we’ll have our latest generation of ROBO Cylinder® with battery-less absolute encoders, the RCP6.
RCP6

The affordable pulse motor type IXP SCARA with high-output drivers costs around half a conventional model.
IXP SCARA

The RCS3 Servo Press ROBO Cylinder® offers easy adjustment of push force and position control.
RCS3 Servo Press

Click here to register online for free.








Next Generation ROBO Cylinder® RCP6 Series Catalog

RCP6S PCON-CB/CFB Catalog

Choose from a lineup of 92 models that best suit your needs.

  • Equipped with High Resolution Battery-less Absolute Encoder as Standard
  • Built-in Controller Type Is Also Available for All Models
  • Improved Positioning Repeatability for Standard Specification: ±10μm

Learn more about the RCP6 ROBO Cylinder.

Height adjustment mechanism of inkjet printers

Other Industries
Process: Printing  Raising/Lowering
print-height-adjustment-5fps

Function of the Robo Cylinders being used
Positioning

In equipment that prints barcodes onto work, a rod type ROBO Cylinder® has been adopted for a device that lowers and raises the inkjet printer.

A sensor detects the height of the work, and the height of the inkjet printer is adjusted accordingly.

With this device, it became possible to automatically adjust the printing position even when the height of the work changes.

See more IAI electric actuator application examples

Architectural Aluminum Cutting Equipment Application Example

A touch panel is used to set the size of the cut and to display the length measurement after cutting.

Wire Rod / Architectural Material
Process: Cutting
aluminum-material-cutting
[ Actuator ] RCP2-SS8C-I-56P-10-650-P1
[ Controller ] PCON-C-56PI-DV-2-0

A ROBO Cylinder® has been adopted for sending architectural material to an aluminum cutting device.

A touch panel is used to set the size of the cut and to display the length measurement after cutting.

By using a field network supported PCON, you can read the data and display the present value on the touch panel.

See more IAI electric actuator application examples

Press-fitting plastic caps onto cosmetics bottles – CT-Effects Application Example

Failures were eliminated by replacing air cylinders with ROBO® Cylinders for the press-fit process.

Cosmetics
Failures were eliminated by replacing air cylinders with ROBO® Cylinders for the press-fit process – CT-Effects Application Example
press-fit-cap2
[ Actuator ]
RCP5-RA6C

 

[Issues until now]
  • To meet the required cycle time, the “Approach Movement”→”Press-fit motion” was set at the same high speed with the air cylinder.
  • Press-fitting at high speed caused some caps to become deformed.
[Improvement Details]
  • The Approach Movement speed on the ROBO Cylinder® was set higher than the air cylinder.
  • The Press-fit Motion was set to switch to low speed.
  • The return movement was set to high-speed.
[Improvement Results]
  • Deformation of the cap has been prevented.

Failure Occurrence Rate: 6% → 0%

The Cycle Time was Improved

See more IAI electric actuator application examples

Applying a liquid solution to a copper twisting machine – CT-Effects Application Example

Changing an air cylinder to ROBO Cylinder improved the cycle time for the solution application process.

Papers /Films/Wires/Building Materials
Changing an air cylinder to ROBO Cylinder improved the cycle time for the solution application process – CT-Effects Application Example
dousen-tofu-anime
[ Actuator ]
RCP2-SA6C

 

  • [Issues until now]
    – Air Cylinders were used to move the syringe to apply solution to the copper wires.
    – Uneven amounts of solution were supplied to the felt when low speeds caused instability.
    – In an attempt to fix the unevenness, the discharge amount was increased but became excessive. This caused failures that led to Choco Tei* in the process.

* Choco Tei = Stopping for a brief period, Idling in production line.
See brief video description.

  • [Improvement Details]
    The ROBO Cylinder stabilized the movement of the syringe and fixed the unevenness.
  • [Improvement Results]
    – Saved the amount of solution used
    – Eliminated Choco Tei in the process

    Cycle Time Improved:
    7sec →5sec

    Choco Tei Reduced:
    30min/day →zero

See more IAI electric actuator application examples

Cleaning cardboard printers with a pull-in roller- CT-Effects Application Example

Production has increased by motorizing the cleaning of cardboard printers with a pull-in roller

Others
Cleaning cardboard printers with a pull-in roller – CT-Effects Application Example
roller-cleaning
[ Actuator ]
ISWA-L (Dust proof Splash-Proof Single-Axis Robot Slider Type)

 

  • [Issues until now]
    Since the brushing was done by hand, the following issues occurred in the cleaning process
    1) Incomplete cleaning due to the unevenness in the speed of the stroke of the brush
    2) Incomplete cleaning due to the unevenness in the strength of the stroke of the brush.

    Since the brushing was repeated numerous times until the printer was completely clean, a lot of time was spent on the cleaning process.

  • [Improvement Details]
    The unevenness in the cleaning process was fixed by moving the brush at a constant speed. (The touch of the brush to the machine was also stabilized)
  • [Improvement Results]
    The efficiency of the brushing process improved and the cleaning time became shorter.

    Reduction in cleaning time (per day):
    Reduced from 60min →10min

    Production Time (per day):
    12% increase from 420min →470min

See more IAI electric actuator application examples

Cutting Cords to Variable Specified Lengths – CT-Effects Application Example

Motorizing the feed process increased production, and significantly lowered electricity and labor costs.

Papers/Films/Wires/Building Materials
Cutting Cords to Variable Specified Lengths – CT-Effects Application Example
AE-01-01-senzai-cut
[ Robot/Electric Actuators ]
RCP5-RA6C

 

  • [Issues until now]

    – Air cylinders were used to feed a cord to a specified length.

    – It took time to manually adjust the stopper position each time the product type was changed. (About 5 minutes per changeover = 1 hour/day)

    – It was difficult to cut the correct length, causing workers to repeatedly inspect and adjust the cutting.

  • [Improved with Motorization]

    – Manually adjusting the stopper position was totally eliminated. Adjustments are now done by entering the feed amount on a touch panel. Manual changeovers are a thing of the past.

    – Using a value command function in the ROBO Cylinder made it easy to cut lengths of specified varieties. The manual labor for adjustments was significantly reduced.

    [Improvement Results]

    – Production was increased from 7 hours per day to 8 hours.

    – Reducing the number of steps also reduced labor costs.
     

Reduced man-hours needed for:
– changeover time: 60 minutes/day
– cut inspection and adjustment time: 120 minutes/day
→ Total of 3 hours/day
(Annual Example)
– Labor Time of 3 hours/day (times 250 days/year)
– 3 hours X $10 X 250 days
If labor costs $10/hour
→ Annual Savings of $7,500

*Exchange Rate: 1(USD)=100(Japanese Yen)

Electricity costs reduced with motorization

(Example) Work load: 3kg, Moving distance: 200m
Cycle time: 3 sec. One-day running time: 8 hours


Annual operation days: 250 days
Unit Price: (Air) $0.24/m3 (Electric) $0.15/KWH

〈 Annual Electricity Costs 〉Approximately 95% reduced
Air Cylinder$117.67/year
(Cylinder inner diameter φ25mm)
Electric Cylinder$5.67/year
(□56motor)

See more IAI electric actuator application examples

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