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.

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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

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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

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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

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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)

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New ROBO Cylinder Rotary Type RCP2CR-RT/RCP2W-RT Catalog

RCP2CR-GR/RCP2W-GR

Cleanroom Type and Dust-proof Type Now Available!

Cleanroom Type and Dust-proof/Splash-proof Type are now added to the lineup of the rotary type actuators.

Learn more about the RCP2CR-RT/RCP2W-RT.

New Mini Cylinder RCD Catalog

Mini Cylinder RCD

New Version Now Available

  • Ultra-compact size has been achieved, with a cross-section of only 12 mm and a body length as short as 60 mm.
  • The Mini Cylinder RCD incorporates a newly developed brushless DC motor that generates sufficient torque despite its compact size.

Learn more about the Mini Cylinder RCD.

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