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 | |
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| [ Actuator ] | |
| RCP2-SA6C | |
– 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.
– Eliminated Choco Tei in the processCycle Time Improved:
7sec →5sec
Choco Tei Reduced:
30min/day →zero
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 | |
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| [ Actuator ] | |
| ISWA-L (Dust proof Splash-Proof Single-Axis Robot Slider Type) |
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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.
Reduction in cleaning time (per day):
Reduced from 60min →10min
Production Time (per day):
12% increase from 420min →470min
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 | |
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| [ Robot/Electric Actuators ] | |
| RCP5-RA6C | |
– 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） |
Continuity Inspection Tool – CT-Effects Application Example
Labor Cost Reduction ⇒ $9,000/year
One operator
*Labor $18.00/hour 8 hours/day
*Overtime work 2 hours
*250 operational days/year
*Exchange Rate: 1(USD)=100(Japanese Yen)
| Electronic Components | |
| Continuity Inspection Tool – CT-Effects Application Example | |
| [ Robot/Electric Actuators ] |
[ Controllers ] |
| RCP4-SA7C, RCP2-SS8C | PCON-CA |
[Equipment Detail]
It is a continuity inspection tool used for a PC extension board manufacturer.
An air cylinder is used in this application to insert an edge connector on a PC board.
An operator loads and unloads a PC board to the air cylinder manually.
- [Problems in Using an Air Cylinder]
Since you can’t change speed with air cylinders, you will need to move the entire stroke at the same speed to insert the PC board to the inspection tool. The cycle time is 15 seconds, and the number of work pieces that can be inspected in an 8 hour work day was 1,920 pieces *1.Management decided to increase the production volume of the PC boards to 2,400 pieces per 8 hour shift and to accomplish this, 2 hours *2 of over time per day was required.
*1 (8 * 60 * 60) seconds/ 15 seconds/ piece
*2 (2,400 – 1,920) pieces * 15 seconds/ piece
[Benefits of Replacing with ROBO Cylinder]
By switching to ROBO Cylinder, this enables them to move at high speed before insertion and then slow down just before the insertion, which lead to a shorter cycle time of 12 seconds.
It is now able to finish inspection within the operational hours. Also the reduction of labor cost for overtime work was accomplished.
The cost spent to replace the cylinder was retrieved in the 1st year, which resulted in a cost reduction of $9,000 from the 2nd year.
[CT Effects – Reduction in Cycle Time/Choco Tei]
| Subject | Equipment with Air Cylinder | Equipment with the ROBO Cylinder |
| Cycle Time | 15 seconds | 12 seconds |