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
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.
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.
