Category Archives: Application Examples

Alignment of the Resin Block Application Example

No Specific Industries
Alignment of the Resin Block Application Example
Robot RCA2-TWA4NA, RCS2-TWA5N
Controller ACON, ASEP, MSEP, SCON
  • 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.

Reduction in Cycle Time/Choco Tei — CT Effects

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Heat Exchanger Hole Size Confirmation Application Example

Inspection / Examination / Etc.
Heat Exchanger Hole Size Confirmation Application Example
Robot TT-A3-4040
Controller 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.

Reduction in Cycle Time/Choco Tei — CT Effects

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Engine Parts Transfer Application Example

Automotive
Engine Parts Transfer Application Example
Actuators RCS3-SA8C, RCP2-SA5C, RCP2-GRM
Controllers SCON, PCON
  • 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.

Reduction in Cycle Time/Choco Tei — CT Effects

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Pressing a Pin into a Ring Application Example

No Specific Industries
Pressing a Pin into a Ring Application Example
Actuator RCP2-RA10C
Controller PCON-CFA
  • 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)

Reduction in Cycle Time/Choco Tei — CT Effects

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Cable Connector Tensile Tester Application Example

Inspection / Examination / Etc.
Cable Connector Tensile Tester Application Example
Actuator RCP4
Controller PCON-CA
  • 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.

Reduction in Cycle Time/Choco Tei — CT Effects

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Copper Wire Bobbin Winding Machine Application Example

Paper, Film, Wire Rod, Architectural Material
Copper Wire Bobbin Winding Machine Application Example
Controller PCON-CA
Actuators RCP4W
  • 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.

Reduction in Cycle Time/Choco Tei — CT Effects

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Dish Decorating Application Example

No Specific Industries
Dish Decorating Application Example
Controller PCON x 2
XSEL
Actuators RCP4-SA5C x 2
NS-MXMM
  • Tableware dishes are decorated by a machine.
  • 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.

Reduction in Cycle Time/Choco Tei — CT Effects

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Inspection System for Smartphones Application Example

Inspection / Examination / Etc.
Inspection System for Smartphones Application Example
Controller PCON-C
Actuators RCP2-RTC

Overview of the Equipment

  • Inspects for the presence of imperfections by rotating the smartphone which is attached to a jig.
  • The external inspection in performed by an image processing camera.
  • A rotary type ROBO Cylinder is used for the rotating mechanism.

CT Effect: Significant Reduction in Cycle Time by Introducing the ROBO Cylinder

  • Previously, the smartphone was held in hand while it was visually inspected with a magnifying glass.
  • By introducing an automatic machine, the cycle time was reduced from 60 seconds to 40 seconds. A reduction of 20 seconds or about 33%.

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Test Assembly of Automotive Piston Pin Application Example

Automotive / Examination
Test Assembly of Automotive Piston Pin Application Example
Controller PSEL
Actuators RCP3-TA4R
  • A retaining ring, called the circlip, is used to assemble the pin that connects the connecting rod and the piston of the engine parts.
  • Since the circlip is manually assembled, variations will occur. If the circlip is improperly seated in the groove, it becomes a problem in that it ends up falling off later.
  • The ROBO Cylinder RCP3-TA4R table type was adopted into an automatic inspection machine after the manual assembly which eliminated the circlip failure.
  • The circlip is now inspected for being at the correct position at the assembly stage. It can be double checked using the zone output signal and the position complete output signal to confirm whether the circlip is positioned within the tolerance range.

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Buckwheat Flour Kneading Application Example

Food Processing
Buckwheat Flour Kneading Application Example
Controller PSEP
Actuators RCP2-RA
  • The ROBO Cylinder has been adopted into a machine to automatically knead buckwheat flour.
  • Previously, a rack and pinion mechanism along with a gear reduction general purpose motor was used for the up and down kneading motion of the flour. However, since the buckwheat flour is very viscous, this not only caused a problem with the motor and gear reducer but also broke teeth in the rack which resulted in a lack of pressing force.
  • By changing to ROBO Cylinders, this solved the problem of gear teeth being broken by eliminating the gear rack, and it also made possible an improvement in the pressing force. The flour was kneaded with a stronger force which lead to improved quality and reduced the cycle time.
  • Furthermore, compared to the conventional machine, the structure of the machine became simpler by reducing wiring and programming efforts, thus a significant cost reduction was also realized.

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