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.
Heat Exchanger Hole Size Confirmation Application Example
Built-in SEL controller
The process of checking the sizes of the holes in a heat exchanger is a successful example of reducing labor costs by shortening the cycle time.
The heat exchanger is an aluminum plate of 1mm thickness that has 900 vacant holes. The pitch of the 4mm diameter holes needs to be accurate. If the hole position deviates from this fixed pitch distance, failure will occur when passing the piping through the holes in the subsequent manufacturing process step.
Previously, the holes were visually inspected by a person one by one which took 45 minutes to test an entire heat exchanger.
As a result of switching to the tabletop robot to perform this inspection process, the operator can perform other duties after pressing the button to start the robot.
The labor costs to produce 20 units reduced from $270 to only $31 thus saving $57,460 a year in labor costs.
The reduction in cycle time in the process of transferring automotive engine parts is a successful example of reducing labor costs and stoppages.
In the past, air cylinders were used but the work parts ended up falling out of the gripper when the cylinders were stopped due to jerky motion.
This resulted in stoppages that occurred about 15 times a day.
When the air cylinders were replaced with ROBO Cylinders, the work parts were then moved smoothly (the jerky motion was eliminated) since acceleration and deceleration were under more control.
The cycle time has been reduced to 4.2 seconds from 4.9 seconds. The time to produce 7,000 parts a day has been reduced to 8.2 hours from 10 hours. As a result, annual labor costs have been reduced by $7,780.
The process step of press fitting a metal pin into a resin ring is a successful example of reducing stoppages and reducing cycle time.
An air cylinder was used in the past but since a pin must be fit by using a constant force slowly, it was difficult to make speed adjustments. Stoppages of seven times per hour occurred due to the pin being damaged during pressing.
By replacing the air cylinder with a ROBO Cylinder, it became possible to press fit at a constant speed such that adjustments were no longer needed. The cycle time has been reduced and damage to the pin in the resin ring has been eliminated.
Once it moves fast to the start of the press fitting operation it is possible to slowly press fit (up to 300kg) by using the ROBO Cylinder. The press fitting is now quick, accurate, and stable which eliminates any stoppages. As a result, the production number per day has increased from 791 parts to 1,008. (Assuming 7 hours of operation per day)
Cable Connector Tensile Tester Application Example
A cable with connectors attached at both ends is tested for tensile strength and is a successful example of how short stoppages (Choco-Tei: CT Effect) were reduced and shorter cycle times were achieved.
One of the connectors is placed into an integrally formed fixture with a fixed base while the connector at the other end of the cable is placed into a fixture which is attached to the moveable slider of the actuator which performs the strength test.
Previously, a worker used a spring and then an air cylinder but pulling the cable slowly was difficult. Stoppages that occurred due to pressure drops when the actuator was in mid-stroke totaled 30 minutes a day.
When the air cylinder was replaced with the RCP4 ROBO cylinder, it is now possible to achieve a constant speed, go to the correct position, and pull the cable with the correct amount of force.
The cycle time is reduced to 5.7 seconds without stoppages. As a result, production increased from 1,680 to 2,520 parts.
Copper Wire Bobbin Winding Machine Application Example
This application significantly reduces the changeover time in a machine that winds a copper wire bobbin.
An actuator is used to wind a bobbin evenly by moving left and right with copper wire that comes out of washing machine. Since a rodless type air cylinder was used in the past, it was used at a reduced speed since the copper wire was damaged and made defective by the jerking of the sudden stops.
Furthermore, in order to change the speed of the air cylinder each time the diameter of the copper wire changes in the changeover, it takes time to adjust the speed controller. Productivity was reduced.
By replacing this rodless air cylinder with a ROBO Cylinder, the movement speed was able to be increased while eliminating any jerking due to stops. In addition, since there are no speed fluctuations due to changes in air pressure, the winding is now good.
An RCP4W dustproof water resistant type of actuator (IP 65) was selected to deal with water droplets that adhere to the copper wire due to the cleaning process.
Previously, dishes were manually fed and retrieved into the machine but it was to be automated using air cylinders to reduce cycle time and labor costs.
Initially, the dishes deviated in position from the suction pad by the impact on the YZ air cylinders which resulted in shutting down the machine and production did not increase.
It was decided to consider using electric actuators instead.
A system combining a two slider rotary nut NS actuator as the Y-axis, and RCP4-SA5C actuators as the Z-axes was considered.
The NS can operate without having the sliders collide since they can move independently on the same axis. It is also able to accelerate and decelerate faster thus allowing the cycle time to be shortened and stop without impact.