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Premium member Presentation Transcript PowerPoint Presentation: Robo Expo Introduction of New Generation Cylinder, for Air substitution Sold & Serviced By: ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: Introduction of IAI Sold & Serviced By: ELECTROMATE - 2 - Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: Global Locations Sold & Serviced By: ELECTROMATE - 3 - Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: Introduction of IAI - New Factory Completed Aug 2004 Name : IAI Obane Factory Location : 416-4 Obane Shimizu, Shizuoka City, Shizuoka Pref. Land : 142,040 sq.ft. Building : 35,822 sq.ft. Floor Area : 134,721 sq.ft. Sold & Serviced By: Structure : RC 4 stories ELECTROMATE Toll Free Phone (877) SERVO98 - 4 - Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: Introduction of IAI Sold & Serviced By: ELECTROMATE Toll Free Phone (877) SERVO98 - 5 - Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: Introduction of IAI Sold & Serviced By: ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 - 6 - www.electromate.com sales@electromate.comPowerPoint Presentation: Introduction of IAI IAI was recently voted as the fastest growing private business venture in Japan by a leading Japanese business newspaper. Sold & Serviced By: ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 - 7 - www.electromate.com sales@electromate.comPowerPoint Presentation: Introduction of Robo Cylinder Sold & Serviced By: ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 - 8 - www.electromate.com sales@electromate.comPowerPoint Presentation: Robo Cylinder Family Sold & Serviced By: ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 - 9 - www.electromate.com sales@electromate.comPowerPoint Presentation: Teaching Pendants Sold & Serviced By: ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 - 10 - www.electromate.com sales@electromate.comPowerPoint Presentation: PC Software Sold & Serviced By: ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 - 11 - www.electromate.com sales@electromate.comPowerPoint Presentation: Robo Cylinder Structure Sold & Serviced By: ELECTROMATE Toll Free Phone (877) SERVO98 - 12 - Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: Robo Cylinder Structure Integrated ERC Motor & Controller Controller Motor Encoder - 13 - Sold & Serviced By: ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: Robo Cylinder Functions Sold & Serviced By: ELECTROMATE Toll Free Phone (877) SERVO98 - 14 - Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: Robo Cylinder Functions Sold & Serviced By: ELECTROMATE Toll Free Phone (877) SERVO98 - 15 - Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: Robo Cylinder Functions Robo Cylinder has the following 7 functions 1. Position Moves (Multi-positioning) 2. Pause (Hold) 3. Acceleration Control (Quick start, Smooth start) 4. Push and Hold 5. Pitch (Incremental) Moves 6. Zone Output 7. Speed Control (Constant, Variable) Multi-functions - 16 - Sold & Serviced By: ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: Robo Cylinder Functions 1 1. Position Moves (Multi-positioning) - Function - A maximum of 64 different positions (RCP2) can be set. The positions can be set arbitrarily by PC Software, Teaching Pendant or Serial Protocol, and it is easy to do a model (product) change or position adjustment. - Comparing with Air - Air cylinder is mainly used for point to point movement (2 position). It is complicated and has certain limits when stopping the air cylinder 3 or more positions. Sold & Serviced By: ELECTROMATE Toll Free Phone (877) SERVO98 - 17 - Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: Robo Cylinder Functions 1 1. Positioning Moves Can move and position the objective on the rod or slider with ±0.02mm (ERC ±0.05mm) repeatability. Sold & Serviced By: ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 - 18 - www.electromate.com sales@electromate.comPowerPoint Presentation: Robo Cylinder Functions 1 1. Positioning Moves Motorcycle parts welding fixture The fixture for motorcycle gasoline tank welding with an articulated welding robot. Auto Parts Degreaser A machine which transfers auto parts through each Sold & Serviced By: ￫ Used 19 Robo Cylinders for multi-model production. - process such as degreaser ￫ 19 - shower ￫ dryer. ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: Robo Cylinder Functions 1 1. Positioning Moves Rolled Paper Inspection and Sorting Machine Inspects rolled paper on the conveyor, and rejects defective ones. Robo Cylinder can accommodate and adjust to different and random products in applications. Chemical Observation Machine Observe chemicals on the pallet by a microscope. Sold & Serviced By: ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com - 20 - sales@electromate.comPowerPoint Presentation: Robo Cylinder Functions 2 2. Pause (Hold) - Function - Robo Cylinder can pause (hold) its movement at arbitrary positions. - Comparing with air cylinder - It is very difficult to pause an air cylinder during its motion. Sold & Serviced By: ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 - 21 - www.electromate.com sales@electromate.comPowerPoint Presentation: Robo Cylinder Functions 2 2. Pause (Hold) Pauses the motion when the signal turns OFF The movement pause when the pause input turns off. When the pause input turns on again, the motion will resume to complete the remaining movement. For safety reasons, this signal uses contact B logic (normally on). Sold & Serviced By: ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com - 22 - sales@electromate.comPowerPoint Presentation: Robo Cylinder Functions 2 2. Pause (Hold) Supplying wrapping paper for bread loaf This machine lifts wrapping paper to the picking height for the air gripper. Robo Cylinder moves up while the light sensor is on. Once the sensor is off, Robo Cylinder pause the motion. - 23 - Sold & Serviced By: ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: Robo Cylinder Functions 3 3. Speed Control (Constant, Variable) - Function - Robo Cylinder can change speed on the fly . Robo Cylinder is good for multiple step speed changes (max. 16 steps) while in motion, and constant speed stability movement. - Comparing with air cylinder - It is very difficult to change an air cylinder ’s speed on the fly, but very easy for Robo Cylinder. Unlike air cylinders, Robo Cylinder can move at a constant speed because of its motor and ballscrew driven mechanism. Sold & Serviced By: ELECTROMATE - 24 - Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: Robo Cylinder Functions 3 3. Speed Control (Constant, Variable) Robo Cylinder can change speed on the fly, then position. Sold & Serviced By: ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com - 25 - sales@electromate.comPowerPoint Presentation: Robo Cylinder Functions 3 3. Speed Control (Constant, Variable) DVD Manufacturing Machine The machine moves ionizer to remove static electricity on the DVD during the manufacturing process. It requires quick forward and slow Beverage Filling Machine Lifts the container close to the nozzle, slows down then fills the liquid to avoid splashes. (Splashes could not be prevented when customer Sold & Serviced By: backward motion, and the customer had to use double stacked air cylinders. - used air cylinders) 26 - ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: Robo Cylinder Functions 3 3. Speed Control (Constant, Variable) Wire Winding Machine The machine winds wire to the drum with a constant speed. According to the current drum diameter, the Robo Cylinder slows down speed to oscillate the head for uniformed winding. - 27 - Sold & Serviced By: ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: Robo Cylinder Functions 4 4. Acceleration Control (Quick Start, Smooth Start) - Function - It is easy to change (control) acceleration/deceleration for quick start/stop and smooth start/stop motion . - Comparing with air cylinder - Air cylinders are not able to set its acceleration/deceleration ratio. Sold & Serviced By: ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 - 28 - www.electromate.com sales@electromate.comPowerPoint Presentation: Robo Cylinder Functions 4 4. Acceleration Control (Quick Start, Smooth Start) Acceleration/deceleration ratio can be set arbitrarily. Sold & Serviced By: ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 - 29 - www.electromate.com sales@electromate.comPowerPoint Presentation: Robo Cylinder Functions 4 4. Acceleration Control (Quick Start, Smooth Start) Jelly Transfer Machine The machine transfers jelly from one conveyor to the other. Sold & Serviced By: ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 - 30 - www.electromate.com sales@electromate.comPowerPoint Presentation: Robo Cylinder Functions 5 5. Push & Hold - Function - Robo Cylinder can quickly move the rod just before the objects and slowly push it if it is required. - Comparing with air cylinder - Air cylinders adjusts its push force by changing air pressure. Robo Cylinder can easily adjust its push force by PC software or teaching pendant. Sold & Serviced By: ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 - 31 - www.electromate.com sales@electromate.comPowerPoint Presentation: Robo Cylinder Functions 5 5. Push & Hold - 32 - Robo Cylinder can push and hold an object just like an air cylinder. Sold & Serviced By: ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: Robo Cylinder Functions 5 5. Push & Hold Auto Door Sealing Robo Cylinders fix the door to apply sealing material with articulated robot. This machine can process multi-type products because of Robo Cylinder. - 33 - TAB Bonding Robo Cylinders fix LCD panel for TAB bonding machine. Sold & Serviced By: TAB : Printed circuit on a thin film. ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: Robo Cylinder Functions 5 5. Push & Hold Cushion Insertion Machine Gelatin Cutting Machine The machine pushes gelatin (Konnyaku) through the grid and slices it into thin pieces. Robo Cylinder moves quickly just before the gelatin then pushes it slowly shortening the machine cycle time. Uniform cuts can be obtained by for Medicine Bottle Tablets The machine inserts a cushion into tablet bottle. Robo Cylinder can prevent possible damage to the tablets, cushion and bottle by adju Sold & Serviced By: ts push force. ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 adjusting the push force. - 34 - www.electromate.com sales@electromate.comPowerPoint Presentation: Robo Cylinder Functions 6 6. Pitch (Incremental) moves - Function - Robo Cylinder can move a specified distance (pitch) repeatedly in steps. - Comparing with air cylinder - This function is impossible for air cylinders. Only electric actuators can offer this. Sold & Serviced By: ELECTROMATE - 35 - Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: Robo Cylinder Functions 6 6. Pitch (Incremental) Moves Moving to coordinate location relative to home position, or any specified distance from current location is possible. Sold & Serviced By: ELECTROMATE - 36 - Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: Robo Cylinder Functions 6 6. Pitch (Incremental) moves Auto Parts Feeder Feeding rubber bushing to the articulated robot, by using pitch moves. The articulated robot inserts the rubber bushing into a drain hole of car body. Electronic Parts Inspection System The machine inspects the parts by image sensor (Vision). Robo Cylinder moves th Sold & Serviced By: ts of the parts, using pitch moves. ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 - 37 - www.electromate.com sales@electromate.comPowerPoint Presentation: Robo Cylinder Functions 6 6. Pitch (Incremental) moves Blade feeding machine Test Tube Bar code Reader This machine reads bar codes on the test tubes. for inspection process This machine feeds a steel blade to inspection stage by using pitch moves. It is e Sold & Serviced By: adjust the feeding speed. ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 - 38 - www.electromate.com sales@electromate.comPowerPoint Presentation: Robo Cylinder Functions 7 7. Zone Output - Function - Robo Cylinder can output a signal during movement. - Comparing with air cylinder - Air cylinders require sensor(s) to get an output signal. Sold & Serviced By: ELECTROMATE - 39 - Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: Robo Cylinder Functions 7 7. Zone Output The signal turns on when slider is in the specified range. The output signal can be turned on and off at arbitrary positions (The positions are set by parameter). So, the Robo Cylinder can set danger area etc. without mounting sensors on it. Sold & Serviced By: ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 - 40 - www.electromate.com sales@electromate.comPowerPoint Presentation: Robo Cylinder Functions 7 7. Zone Output Auto Parts Inspection Machine LCD Panel Laminating machine The machine inspects wire harness cable length Laminating LCD panel glasses in a v Sold & Serviced By: chamber. and its strength. It used to be done manually and ELECTROMATE the quality improved after introducing this machine. Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 - 41 - www.electromate.com sales@electromate.comPowerPoint Presentation: Robo Cylinder Functions 7 7. Zone Output Printing Machine for Food Container (Ink Jet Printer) The machine prints production date on food containers using ink jet printer. The zone signal range is set where the actuator moves at a constant speed for printing area. - 42 - Sold & Serviced By: ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: Robo Cylinder Functions Multi-Functions ERC offers 3 types different functions for meeting a ( Air Cylinder Mode) variety of needs. You can select one of the following functions by changing the controller setting. 3 positions type 8 positions type 16 positions type Characteristics Characteristics Characteristics 1. Moves 3 1. Moves 8 1. Moves 16 positions positions positions 2. Actuator moves 2. Available “Home” 2. Available 1 zone just bit ON input for homing output. specified position input. 3. Available 1 zone output. Position number to Start input No need to take two steps like above. Sold & Serviced By: ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 - 43 - www.electromate.com sales@electromate.comPowerPoint Presentation: Robo Cylinder Functions Robo Cylinder has the following 7 functions 1. Position Moves (Multi-positioning) 2. Pause (Hold) 3. Acceleration Control (Quick start, Smooth start) 4. Push and Hold 5. Pitch (Incremental) Moves 6. Zone Output 7. Speed Control (Constant, Variable) Multi-functions - 44 - Sold & Serviced By: ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: Cost Savings with Robo Cylinders Sold & Serviced By: ELECTROMATE - 45 - Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: Cost Savings 1. The Cost of Compressed Air The Cost of Compressed Air (Japan) Compressor ’s electricity consumption Nation wide factories’ electricity consumption = 10% ~ 20% Electric bill of all air compressors in Japan = $15 Billion/year * Data from Tokyo institute of Technology Sold & Serviced By: ELECTROMATE - 46 - Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: Cost Savings 2. Initial Cost Comparison (1) Rod less (Slider type) In House Design Air cylinder Robo cylinder (Electric) Which is the lowest cost ? Sold & Serviced By: ELECTROMATE - 47 - Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: Cost Savings In-House Design (Electric) Description QTY Unit price Amount Stepping Motor and Controller (DC24V) with encoder feed back 1 $608 $608 Linear Guide 2 $250 $500 Ballscrew and Nut Other Mechanical Parts 1 $328 $328 1 $ 200 $200 TOTAL $3,451 Parts Cost $1,636 $1,636 $150 $840 $825 Parts Assembly, Wiring Mechanical design Electric/Software Design 1. Design cost = $50/hr Assembly, Wiring cost = $40/hr 2. Design cost will be applied for first unit only Sold & Serviced By: 3. Not including any indirect cost increase due to larger number of parts handling. ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 - 48 - www.electromate.com sales@electromate.comPowerPoint Presentation: Cost Savings Air cylinder Description QTY Unit price Amount Hy-Rodless Cylinder 1 $1,262.50 $1,262.50 3 position pressure center solenoid valve 1 $112.95 $112.95 3 port solenoid valve for brake 1 $76.35 $76.35 Speed control valve 2 $8.00 $16.00 Silencer 3 $2.80 $8.40 Filter & Regulator 1 $42.65 $42.65 One Touch Connector 10 $2.55 $25.50 TOTAL $1,928 Air tube 6mm 0.4 $21.80 $8.72 Parts Cost $1,553.07 $1,553 $125 $200 $50 Parts Assembly, Wiring Mechanical design Electric/Software Design 1. Design cost = $50/hr Assembly, Wiring cost = $40/hr 2. Design cost will be applied for first unit only Sold & Serviced By: 3. Not including any indirect cost increase due to larger number of parts handling. ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 - 49 - www.electromate.com sales@electromate.comPowerPoint Presentation: Cost Savings Robo Cylinder Description QTY Unit price Amount Robo Cylinder 1 $880 $880 Power & IO Cable (3m) 1 $130 $130 TOTAL $1,295 Parts Cost $1,010 $1,010 $75 $160 $50 Parts Assembly, Wiring Mechanical design Electric/Software Design 1. Design cost = $50/hr Assembly, Wiring cost = $40/hr 2. Design cost will be applied for first unit only Sold & Serviced By: 3. Not including any indirect cost increase due to larger number of parts handling. ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 - 50 - www.electromate.com sales@electromate.comPowerPoint Presentation: Cost Savings Initial Cost Comparison (1) Rod less (Slider type) In House Design (Electric) Air Cylinder Robo Cylinder TOTAL $1,928 TOTAL $1,295 33% Decrease Robo Cylinder is the lowest cost solution ! - 51 - TOTAL $3,451 62% Decrease Sold & Serviced By: ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: Cost Savings 2. Initial Cost Comparison (2) Rod Type Air Cylinder Robo Cylinder How about Rod Type ? Sold & Serviced By: ELECTROMATE - 52 - Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: Cost Savings Air Cylinder Description QTY Unit price Amount Air cylinder (Rod) with 2 sensors 1 $150.60 $150.60 5 ports solenoid valve 1 $54.70 $54.70 Speed control valve 2 $8.00 $16.00 Air Cylinder Silencer 2 $2.80 $5.60 Filter & Regulator 1 $42.65 $42.65 Speed control valve Solenoid valve $294 $125 $160 $50 One Touch Connector 6 $2.55 $15.30 Air tube 6mm 0.4 $21.80 $8.72 $293.57 TOTAL $629 Parts Assembly, Wiring Mechanical design Electric/Software Design 1. Design cost = $50/hr Assembly, Wiring cost = $40/hr 2. Design cost will be applied for first unit only Sold & Serviced By: 3. Not including any indirect cost increase due to larger number of parts handling. ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 - 53 - www.electromate.com sales@electromate.comPowerPoint Presentation: Cost Savings Robo Cylinder Description QTY Unit price Amount Robo Cylinder 1 $560 $560 Power & IO Cable (3m) 1 $130 $130 Parts Cost $690 TOTAL $975 $690 $75 $160 $50 Parts Assembly, Wiring Mechanical design Electric/Software Design 1. Design cost = $50/hr Assembly, Wiring cost = $40/hr 2. Design cost will be applied for first unit only 3. Not including any indirect cost increase due to larger number of parts handling. - 54 - Sold & Serviced By: ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: Cost Savings 2. Initial Cost Comparison (2) Rod Type Air Cylinder Robo Cylinder TOTAL 35% $629 Increase TOTAL $975 Parts Assembly, Wiring Mechanical design Electric/Software Design Air Cylinder ’s initial cost is a bit lo Sold & Serviced By: ELECTROMATE - 55 - Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: Cost Savings 3. Running Cost Robo Cylinder ’s electricity consumption is 1/10 of air cylinder $100 savings per year, per cylinder 1080~1920kwh 120kwh kwh Air cylinder : Bore Ø25 (Pressure 0.5MPa) Robo cylinder: RCP2-SA6 (Slider type) RCP2-RMA (Rod type) Conditions Stroke : 500mm (Slider type) : 300mm (Rod type) Speed : 25~30 cycles/min * Above data is when 37kw compressor is used which was calculated based on 0.75kw compressor measurement result. Sold & Serviced By: * Electricity cost is $0.095/kwh, operating 10 hours / day (2400 hours / year) - 56 - ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: Cost Savings Air System effective energy efficiency is about 14% Air system energy efficiency Air system effective energy efficiency 14% 5% 15% 50% 16% Compressor Loss Air cylinder Loss Piping-Pressure down Loss Air filter and other Loss Data : Tokyo Institute of Technology * Air drier ’s electricity consumption is NOT included in above calculation. Robo Cylinder ’s effective energy efficiency is 80% Sold & Serviced By: 0%! ELECTROMATE - 57 - Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: Cost Savings 4. The Cost of Compressed Air Compressed Air System Leaks Size Cost per Year 1/16 ” $523 1/8 ” $2,095 1/4 ” $8,382 Costs calculated using electricity rate of $0.05 per kilowatt-hour, assuming constant operation and an efficient compressor Data from Assembly Magazine ’s March 2005 Article, “Saving Energy on the Line”. - 58 - Sold & Serviced By: ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: Cost Savings 6. Conclusion Rodless Cylinder (Slider Type) Parts Cost Initial Cost $1,108 $2,923 $1,553 Running Cost (3 years) $369 3 years Total Cost $1,010 $1,928 $2,957 $2,297 $1,295 $34 $34 (Cylinder bore Ø20) $1,329 Sold & Serviced By: ELECTROMATE - 59 - Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: Cost Savings 6. Conclusion Rod type cylinder Parts Cost $690 $294 3 years Total Cost Initial Cost $975 $629 $1,163 $1,008 - 60 - Running Cost (3 years) $534 $33 (Cylinder bore Ø40) Sold & Serviced By: ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: Application Example 1 Example 1 Solar Cell Manufacturing Line (Niigata, Japan) Saved $270,000/Year by replacing Air to Robo Cylinder Solar Cell Assembly Line Walking Beam Multi-Positioning 2 Process 1 START Place Loader,Unloader Quick transfer between stations improved tact time drastically Process 4 Process 3 FINISH Magazine Walking Beam Elevator Smooth and Safe motion by Finish Goods Ejection Safe transportation by controlled accel./decel. Pick and Place Multi-Steps, Precise Positioning controlled accel./decel. with a lot of stopping & going. High Speed and Precise mo Sold & Se rviced By: ELECTROMATE Toll Free Phone (877) SERVO98 SERV099 - 61 - Green Parts are Robo Tolwww.electroma te.com sales@electromate.comPowerPoint Presentation: Application Example 1 Solar Cell Manufacturing Line Air cylinders had been used for this line. The solar cell is very fragile and this line constantly caused about 3% defects due to the air cylinders ’ harsh movements. The defect rate was reduced 90% when Robo Cylinders took the place of air cylinders. As a result, this line saved $250,000/year yield loss. Robo Cylinder and Air Cylinder yield loss comparison table Yield loss per day Yield loss per year (300days/year) Defect Yield Defect Output parts loss Output parts Yield loss Robo Cylinder 65,664 197 $93 19,699,200 59,097 $27,776 Air Cylinder 65,664 1,970 $926 19,699,200 590,976 $277,759 Sold & Serviced By: Original defect rate (air)=3% • Cycle time=4pcs/5sec • Parts cost=$0.47 • Efficiency=95% (Air, Robo ELECTROMA TE - 62 - Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: Application Example 2 Example 2 ABS (Antilock Brake System) Press fit machine (Kanagawa, Japan) Saved $48,000 yield loss per year by switching to Robo Cylinder. Press fit here The Antilock Brake System [ABS] is a safety feature found in most modern cars. It helps drivers maintain control of their vehicles while braking in slippery road conditions and during sudden "panic" braking. - 63 - Antilock Brake System Sold & Serviced By: ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: Application Example 2 ABS (Antilock Brake System) Press fit machine The old machine required adjustments twice a week. The parts defect rate was 3~5%. With the Robo Cylinder, the adjustments was no longer required and the parts defect rate reached 0%. As the result, this customer saved $48,000 yield loss per year. Robo Cylinder and Air Cylinder yield loss comparison table Yield loss per day Yield loss per year (240days/year) Yield Output Defect parts loss Output Defect parts Yield loss Robo Cylinder 300 0 $0 72,000 0 $0 Air Cylinder 300 10 $200 72,000 2,400 $48,000 Original defect rate (air)=3% ~ 5%, Parts cost=$20 Sold & Serviced By: ELECTROMATE - 64 - Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: Application Example 3 Example 3 DVD Manufacturing Line (Tokyo, Japan) Saving $30,000/year by using Robo Cylinder 1. Machine parts cost Cost when air cylinders were used • Two Air cylinders • Two Solenoid valves • Mounting bracket The cost became half by using ERC 2. Assembly time Double stacked air cylinder - - 30 min ERC Robo Cylinder -------15 min ERC also has the following benefits: • Eliminates mounting bracket Anti-Static blower for DVD In the past, double stacked air cylinders Sold & Serviced By: • No adjustment required - 65 - were used for speed control. ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: Application Example 3 DVD Manufacturing Line 3. Productivity When air cylinders were used, the “Ionizer” lasted only a month due to the air cylinder’s abrupt stopping force. The customer had to stop the line for few hours to replace the damaged “Ionizer”. An Ionizer = $600 ~$700. After switching to ERC, the “Ionizer” has not been damaged since because of the controlled acceleration /deceleration. Lost time from stopping the line to replace the “Ionizer” was 2 hours/month meaning 2,500 DVDs could not be produced per month. At a cost of $1 per DVD, the production loss was $2,500/month. Annual loss was $30,000. Sold & Serviced By: ELECTROMATE - 66 - Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: Application Example 4 Example 4 Auto Parts Assembling Machine (Automotive company) Saved $150,000 machine cost by using Robo Cylinder Before Used Air and Hydro Replaced Robo Cylinder Connecting Pin Parts A Press Fit Snap Ring Parts B Press fit the snap ring which fixes the c Sold & Serviced By: cting pin ELECTROMATE - 67 - Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: Application Example 4 Auto Parts Assembling Machine 1. Cycle time dropped to less than half The old air and hydro system could not control speed and thrust of each position and needed to push twice to press the ring securely. Robo Cylinder can control speed and thrust in each position. It can quickly move right before the press position, then slow down for a high thrust press fit. This shortened the cycle time from 10 seconds to 4 seconds . 2. Machine cost saving of $150,000 The old air and hydro system needed many sensors mounted on the actuators to check that the snap ring was pressed in correctly. The “Push” and “Zone Output” functions of the Robo Cylinder, eliminated most of the sensors. Also, one Robo Cylinder took the place of many air and hydro actuators dropping the machine cost from $206,000 to $56,000. - 68 - Sold & Serviced By: ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: New Products Sold & Serviced By: ELECTROMATE - 69 - Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: New Products RCP2-RFA High Thrust Type Generates higher thrust than similar sized air cylinders. Can be used for electric press machines. Max Thrust = 612kg (1,350 lbs) Good for parts press-in applications Max vertical payload = 150kg Max stroke = 300mm Sold & Serviced By: ELECTROMATE - 70 - Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: New Products RCP2W (IP67 Slider Type) Power train is completely closed and sealed by using magnet force, for water proof structure. Actuator can be washed for food applications. § Meets IP67 (Dust & Water resistant) § Max. horizontal payload 30Kg § Max. stroke 600mm § Repeatability + 0.08mm Sold & Serviced By: ELECTROMATE - 71 - Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: New Products RCP2-BA6 & BA7 (Belt Type) Higher Speed (1,500mm/sec) Longer Stroke (1,200mm) Bottom side motor mount is also available. Sold & Serviced By: ELECTROMATE - 72 - Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: New Products IS(P)WA (IS Slider Type / Dust & Water resistance IP65 type) Many new applications can be considered: Part for f Sold & Serviced By: ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: New Products Super Slim size of 25mm high and 25mm wide. Maximum of 64 Positioning Points Incremental Motion Function Maximum Push Force of 100N Pause Function / Zone Signaling - 74 - Sold & Serviced By: ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: New Products XSEL P & Q Controller Compact size and higher performance Up to 6-AXIS, 2400W Capacity Conveyor tracking feature coming soon 3-phase 200VAC Power for Motor Drive Sold & Serviced By: ELECTROMATE - 75 - Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: New Products RCP2 Series Three Finger Grippers Smaller size & lighter weight than existing gripper with three fingers. Unique three finger design is able to grip different shaped parts with high gripping force. Lever Finger Slide Finger - 76 - Sold & Serviced By: ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: New Products New Linear Servo Motor Actuator High acceleration & deceleration: 2.5G High Speed: 2,500mm/sec Maintenance free and environment friendly. Additional models will soon be under development. - 77 - Sold & Serviced By: ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: New Products For any questions regarding Web2CAD and 3D CAD, please contact: Chris Prior (Torrance) Rob Antonio (Itasca) Sold & Serviced By: ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: Sold & Serviced By: ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.com You do not have the permission to view this presentation. In order to view it, please contact the author of the presentation.
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Premium member Presentation Transcript PowerPoint Presentation: Robo Expo Introduction of New Generation Cylinder, for Air substitution Sold & Serviced By: ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: Introduction of IAI Sold & Serviced By: ELECTROMATE - 2 - Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: Global Locations Sold & Serviced By: ELECTROMATE - 3 - Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: Introduction of IAI - New Factory Completed Aug 2004 Name : IAI Obane Factory Location : 416-4 Obane Shimizu, Shizuoka City, Shizuoka Pref. Land : 142,040 sq.ft. Building : 35,822 sq.ft. Floor Area : 134,721 sq.ft. Sold & Serviced By: Structure : RC 4 stories ELECTROMATE Toll Free Phone (877) SERVO98 - 4 - Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: Introduction of IAI Sold & Serviced By: ELECTROMATE Toll Free Phone (877) SERVO98 - 5 - Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: Introduction of IAI Sold & Serviced By: ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 - 6 - www.electromate.com sales@electromate.comPowerPoint Presentation: Introduction of IAI IAI was recently voted as the fastest growing private business venture in Japan by a leading Japanese business newspaper. Sold & Serviced By: ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 - 7 - www.electromate.com sales@electromate.comPowerPoint Presentation: Introduction of Robo Cylinder Sold & Serviced By: ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 - 8 - www.electromate.com sales@electromate.comPowerPoint Presentation: Robo Cylinder Family Sold & Serviced By: ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 - 9 - www.electromate.com sales@electromate.comPowerPoint Presentation: Teaching Pendants Sold & Serviced By: ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 - 10 - www.electromate.com sales@electromate.comPowerPoint Presentation: PC Software Sold & Serviced By: ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 - 11 - www.electromate.com sales@electromate.comPowerPoint Presentation: Robo Cylinder Structure Sold & Serviced By: ELECTROMATE Toll Free Phone (877) SERVO98 - 12 - Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: Robo Cylinder Structure Integrated ERC Motor & Controller Controller Motor Encoder - 13 - Sold & Serviced By: ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: Robo Cylinder Functions Sold & Serviced By: ELECTROMATE Toll Free Phone (877) SERVO98 - 14 - Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: Robo Cylinder Functions Sold & Serviced By: ELECTROMATE Toll Free Phone (877) SERVO98 - 15 - Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: Robo Cylinder Functions Robo Cylinder has the following 7 functions 1. Position Moves (Multi-positioning) 2. Pause (Hold) 3. Acceleration Control (Quick start, Smooth start) 4. Push and Hold 5. Pitch (Incremental) Moves 6. Zone Output 7. Speed Control (Constant, Variable) Multi-functions - 16 - Sold & Serviced By: ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: Robo Cylinder Functions 1 1. Position Moves (Multi-positioning) - Function - A maximum of 64 different positions (RCP2) can be set. The positions can be set arbitrarily by PC Software, Teaching Pendant or Serial Protocol, and it is easy to do a model (product) change or position adjustment. - Comparing with Air - Air cylinder is mainly used for point to point movement (2 position). It is complicated and has certain limits when stopping the air cylinder 3 or more positions. Sold & Serviced By: ELECTROMATE Toll Free Phone (877) SERVO98 - 17 - Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: Robo Cylinder Functions 1 1. Positioning Moves Can move and position the objective on the rod or slider with ±0.02mm (ERC ±0.05mm) repeatability. Sold & Serviced By: ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 - 18 - www.electromate.com sales@electromate.comPowerPoint Presentation: Robo Cylinder Functions 1 1. Positioning Moves Motorcycle parts welding fixture The fixture for motorcycle gasoline tank welding with an articulated welding robot. Auto Parts Degreaser A machine which transfers auto parts through each Sold & Serviced By: ￫ Used 19 Robo Cylinders for multi-model production. - process such as degreaser ￫ 19 - shower ￫ dryer. ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: Robo Cylinder Functions 1 1. Positioning Moves Rolled Paper Inspection and Sorting Machine Inspects rolled paper on the conveyor, and rejects defective ones. Robo Cylinder can accommodate and adjust to different and random products in applications. Chemical Observation Machine Observe chemicals on the pallet by a microscope. Sold & Serviced By: ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com - 20 - sales@electromate.comPowerPoint Presentation: Robo Cylinder Functions 2 2. Pause (Hold) - Function - Robo Cylinder can pause (hold) its movement at arbitrary positions. - Comparing with air cylinder - It is very difficult to pause an air cylinder during its motion. Sold & Serviced By: ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 - 21 - www.electromate.com sales@electromate.comPowerPoint Presentation: Robo Cylinder Functions 2 2. Pause (Hold) Pauses the motion when the signal turns OFF The movement pause when the pause input turns off. When the pause input turns on again, the motion will resume to complete the remaining movement. For safety reasons, this signal uses contact B logic (normally on). Sold & Serviced By: ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com - 22 - sales@electromate.comPowerPoint Presentation: Robo Cylinder Functions 2 2. Pause (Hold) Supplying wrapping paper for bread loaf This machine lifts wrapping paper to the picking height for the air gripper. Robo Cylinder moves up while the light sensor is on. Once the sensor is off, Robo Cylinder pause the motion. - 23 - Sold & Serviced By: ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: Robo Cylinder Functions 3 3. Speed Control (Constant, Variable) - Function - Robo Cylinder can change speed on the fly . Robo Cylinder is good for multiple step speed changes (max. 16 steps) while in motion, and constant speed stability movement. - Comparing with air cylinder - It is very difficult to change an air cylinder ’s speed on the fly, but very easy for Robo Cylinder. Unlike air cylinders, Robo Cylinder can move at a constant speed because of its motor and ballscrew driven mechanism. Sold & Serviced By: ELECTROMATE - 24 - Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: Robo Cylinder Functions 3 3. Speed Control (Constant, Variable) Robo Cylinder can change speed on the fly, then position. Sold & Serviced By: ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com - 25 - sales@electromate.comPowerPoint Presentation: Robo Cylinder Functions 3 3. Speed Control (Constant, Variable) DVD Manufacturing Machine The machine moves ionizer to remove static electricity on the DVD during the manufacturing process. It requires quick forward and slow Beverage Filling Machine Lifts the container close to the nozzle, slows down then fills the liquid to avoid splashes. (Splashes could not be prevented when customer Sold & Serviced By: backward motion, and the customer had to use double stacked air cylinders. - used air cylinders) 26 - ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: Robo Cylinder Functions 3 3. Speed Control (Constant, Variable) Wire Winding Machine The machine winds wire to the drum with a constant speed. According to the current drum diameter, the Robo Cylinder slows down speed to oscillate the head for uniformed winding. - 27 - Sold & Serviced By: ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: Robo Cylinder Functions 4 4. Acceleration Control (Quick Start, Smooth Start) - Function - It is easy to change (control) acceleration/deceleration for quick start/stop and smooth start/stop motion . - Comparing with air cylinder - Air cylinders are not able to set its acceleration/deceleration ratio. Sold & Serviced By: ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 - 28 - www.electromate.com sales@electromate.comPowerPoint Presentation: Robo Cylinder Functions 4 4. Acceleration Control (Quick Start, Smooth Start) Acceleration/deceleration ratio can be set arbitrarily. Sold & Serviced By: ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 - 29 - www.electromate.com sales@electromate.comPowerPoint Presentation: Robo Cylinder Functions 4 4. Acceleration Control (Quick Start, Smooth Start) Jelly Transfer Machine The machine transfers jelly from one conveyor to the other. Sold & Serviced By: ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 - 30 - www.electromate.com sales@electromate.comPowerPoint Presentation: Robo Cylinder Functions 5 5. Push & Hold - Function - Robo Cylinder can quickly move the rod just before the objects and slowly push it if it is required. - Comparing with air cylinder - Air cylinders adjusts its push force by changing air pressure. Robo Cylinder can easily adjust its push force by PC software or teaching pendant. Sold & Serviced By: ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 - 31 - www.electromate.com sales@electromate.comPowerPoint Presentation: Robo Cylinder Functions 5 5. Push & Hold - 32 - Robo Cylinder can push and hold an object just like an air cylinder. Sold & Serviced By: ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: Robo Cylinder Functions 5 5. Push & Hold Auto Door Sealing Robo Cylinders fix the door to apply sealing material with articulated robot. This machine can process multi-type products because of Robo Cylinder. - 33 - TAB Bonding Robo Cylinders fix LCD panel for TAB bonding machine. Sold & Serviced By: TAB : Printed circuit on a thin film. ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: Robo Cylinder Functions 5 5. Push & Hold Cushion Insertion Machine Gelatin Cutting Machine The machine pushes gelatin (Konnyaku) through the grid and slices it into thin pieces. Robo Cylinder moves quickly just before the gelatin then pushes it slowly shortening the machine cycle time. Uniform cuts can be obtained by for Medicine Bottle Tablets The machine inserts a cushion into tablet bottle. Robo Cylinder can prevent possible damage to the tablets, cushion and bottle by adju Sold & Serviced By: ts push force. ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 adjusting the push force. - 34 - www.electromate.com sales@electromate.comPowerPoint Presentation: Robo Cylinder Functions 6 6. Pitch (Incremental) moves - Function - Robo Cylinder can move a specified distance (pitch) repeatedly in steps. - Comparing with air cylinder - This function is impossible for air cylinders. Only electric actuators can offer this. Sold & Serviced By: ELECTROMATE - 35 - Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: Robo Cylinder Functions 6 6. Pitch (Incremental) Moves Moving to coordinate location relative to home position, or any specified distance from current location is possible. Sold & Serviced By: ELECTROMATE - 36 - Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: Robo Cylinder Functions 6 6. Pitch (Incremental) moves Auto Parts Feeder Feeding rubber bushing to the articulated robot, by using pitch moves. The articulated robot inserts the rubber bushing into a drain hole of car body. Electronic Parts Inspection System The machine inspects the parts by image sensor (Vision). Robo Cylinder moves th Sold & Serviced By: ts of the parts, using pitch moves. ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 - 37 - www.electromate.com sales@electromate.comPowerPoint Presentation: Robo Cylinder Functions 6 6. Pitch (Incremental) moves Blade feeding machine Test Tube Bar code Reader This machine reads bar codes on the test tubes. for inspection process This machine feeds a steel blade to inspection stage by using pitch moves. It is e Sold & Serviced By: adjust the feeding speed. ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 - 38 - www.electromate.com sales@electromate.comPowerPoint Presentation: Robo Cylinder Functions 7 7. Zone Output - Function - Robo Cylinder can output a signal during movement. - Comparing with air cylinder - Air cylinders require sensor(s) to get an output signal. Sold & Serviced By: ELECTROMATE - 39 - Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: Robo Cylinder Functions 7 7. Zone Output The signal turns on when slider is in the specified range. The output signal can be turned on and off at arbitrary positions (The positions are set by parameter). So, the Robo Cylinder can set danger area etc. without mounting sensors on it. Sold & Serviced By: ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 - 40 - www.electromate.com sales@electromate.comPowerPoint Presentation: Robo Cylinder Functions 7 7. Zone Output Auto Parts Inspection Machine LCD Panel Laminating machine The machine inspects wire harness cable length Laminating LCD panel glasses in a v Sold & Serviced By: chamber. and its strength. It used to be done manually and ELECTROMATE the quality improved after introducing this machine. Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 - 41 - www.electromate.com sales@electromate.comPowerPoint Presentation: Robo Cylinder Functions 7 7. Zone Output Printing Machine for Food Container (Ink Jet Printer) The machine prints production date on food containers using ink jet printer. The zone signal range is set where the actuator moves at a constant speed for printing area. - 42 - Sold & Serviced By: ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: Robo Cylinder Functions Multi-Functions ERC offers 3 types different functions for meeting a ( Air Cylinder Mode) variety of needs. You can select one of the following functions by changing the controller setting. 3 positions type 8 positions type 16 positions type Characteristics Characteristics Characteristics 1. Moves 3 1. Moves 8 1. Moves 16 positions positions positions 2. Actuator moves 2. Available “Home” 2. Available 1 zone just bit ON input for homing output. specified position input. 3. Available 1 zone output. Position number to Start input No need to take two steps like above. Sold & Serviced By: ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 - 43 - www.electromate.com sales@electromate.comPowerPoint Presentation: Robo Cylinder Functions Robo Cylinder has the following 7 functions 1. Position Moves (Multi-positioning) 2. Pause (Hold) 3. Acceleration Control (Quick start, Smooth start) 4. Push and Hold 5. Pitch (Incremental) Moves 6. Zone Output 7. Speed Control (Constant, Variable) Multi-functions - 44 - Sold & Serviced By: ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: Cost Savings with Robo Cylinders Sold & Serviced By: ELECTROMATE - 45 - Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: Cost Savings 1. The Cost of Compressed Air The Cost of Compressed Air (Japan) Compressor ’s electricity consumption Nation wide factories’ electricity consumption = 10% ~ 20% Electric bill of all air compressors in Japan = $15 Billion/year * Data from Tokyo institute of Technology Sold & Serviced By: ELECTROMATE - 46 - Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: Cost Savings 2. Initial Cost Comparison (1) Rod less (Slider type) In House Design Air cylinder Robo cylinder (Electric) Which is the lowest cost ? Sold & Serviced By: ELECTROMATE - 47 - Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: Cost Savings In-House Design (Electric) Description QTY Unit price Amount Stepping Motor and Controller (DC24V) with encoder feed back 1 $608 $608 Linear Guide 2 $250 $500 Ballscrew and Nut Other Mechanical Parts 1 $328 $328 1 $ 200 $200 TOTAL $3,451 Parts Cost $1,636 $1,636 $150 $840 $825 Parts Assembly, Wiring Mechanical design Electric/Software Design 1. Design cost = $50/hr Assembly, Wiring cost = $40/hr 2. Design cost will be applied for first unit only Sold & Serviced By: 3. Not including any indirect cost increase due to larger number of parts handling. ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 - 48 - www.electromate.com sales@electromate.comPowerPoint Presentation: Cost Savings Air cylinder Description QTY Unit price Amount Hy-Rodless Cylinder 1 $1,262.50 $1,262.50 3 position pressure center solenoid valve 1 $112.95 $112.95 3 port solenoid valve for brake 1 $76.35 $76.35 Speed control valve 2 $8.00 $16.00 Silencer 3 $2.80 $8.40 Filter & Regulator 1 $42.65 $42.65 One Touch Connector 10 $2.55 $25.50 TOTAL $1,928 Air tube 6mm 0.4 $21.80 $8.72 Parts Cost $1,553.07 $1,553 $125 $200 $50 Parts Assembly, Wiring Mechanical design Electric/Software Design 1. Design cost = $50/hr Assembly, Wiring cost = $40/hr 2. Design cost will be applied for first unit only Sold & Serviced By: 3. Not including any indirect cost increase due to larger number of parts handling. ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 - 49 - www.electromate.com sales@electromate.comPowerPoint Presentation: Cost Savings Robo Cylinder Description QTY Unit price Amount Robo Cylinder 1 $880 $880 Power & IO Cable (3m) 1 $130 $130 TOTAL $1,295 Parts Cost $1,010 $1,010 $75 $160 $50 Parts Assembly, Wiring Mechanical design Electric/Software Design 1. Design cost = $50/hr Assembly, Wiring cost = $40/hr 2. Design cost will be applied for first unit only Sold & Serviced By: 3. Not including any indirect cost increase due to larger number of parts handling. ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 - 50 - www.electromate.com sales@electromate.comPowerPoint Presentation: Cost Savings Initial Cost Comparison (1) Rod less (Slider type) In House Design (Electric) Air Cylinder Robo Cylinder TOTAL $1,928 TOTAL $1,295 33% Decrease Robo Cylinder is the lowest cost solution ! - 51 - TOTAL $3,451 62% Decrease Sold & Serviced By: ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: Cost Savings 2. Initial Cost Comparison (2) Rod Type Air Cylinder Robo Cylinder How about Rod Type ? Sold & Serviced By: ELECTROMATE - 52 - Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: Cost Savings Air Cylinder Description QTY Unit price Amount Air cylinder (Rod) with 2 sensors 1 $150.60 $150.60 5 ports solenoid valve 1 $54.70 $54.70 Speed control valve 2 $8.00 $16.00 Air Cylinder Silencer 2 $2.80 $5.60 Filter & Regulator 1 $42.65 $42.65 Speed control valve Solenoid valve $294 $125 $160 $50 One Touch Connector 6 $2.55 $15.30 Air tube 6mm 0.4 $21.80 $8.72 $293.57 TOTAL $629 Parts Assembly, Wiring Mechanical design Electric/Software Design 1. Design cost = $50/hr Assembly, Wiring cost = $40/hr 2. Design cost will be applied for first unit only Sold & Serviced By: 3. Not including any indirect cost increase due to larger number of parts handling. ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 - 53 - www.electromate.com sales@electromate.comPowerPoint Presentation: Cost Savings Robo Cylinder Description QTY Unit price Amount Robo Cylinder 1 $560 $560 Power & IO Cable (3m) 1 $130 $130 Parts Cost $690 TOTAL $975 $690 $75 $160 $50 Parts Assembly, Wiring Mechanical design Electric/Software Design 1. Design cost = $50/hr Assembly, Wiring cost = $40/hr 2. Design cost will be applied for first unit only 3. Not including any indirect cost increase due to larger number of parts handling. - 54 - Sold & Serviced By: ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: Cost Savings 2. Initial Cost Comparison (2) Rod Type Air Cylinder Robo Cylinder TOTAL 35% $629 Increase TOTAL $975 Parts Assembly, Wiring Mechanical design Electric/Software Design Air Cylinder ’s initial cost is a bit lo Sold & Serviced By: ELECTROMATE - 55 - Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: Cost Savings 3. Running Cost Robo Cylinder ’s electricity consumption is 1/10 of air cylinder $100 savings per year, per cylinder 1080~1920kwh 120kwh kwh Air cylinder : Bore Ø25 (Pressure 0.5MPa) Robo cylinder: RCP2-SA6 (Slider type) RCP2-RMA (Rod type) Conditions Stroke : 500mm (Slider type) : 300mm (Rod type) Speed : 25~30 cycles/min * Above data is when 37kw compressor is used which was calculated based on 0.75kw compressor measurement result. Sold & Serviced By: * Electricity cost is $0.095/kwh, operating 10 hours / day (2400 hours / year) - 56 - ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: Cost Savings Air System effective energy efficiency is about 14% Air system energy efficiency Air system effective energy efficiency 14% 5% 15% 50% 16% Compressor Loss Air cylinder Loss Piping-Pressure down Loss Air filter and other Loss Data : Tokyo Institute of Technology * Air drier ’s electricity consumption is NOT included in above calculation. Robo Cylinder ’s effective energy efficiency is 80% Sold & Serviced By: 0%! ELECTROMATE - 57 - Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: Cost Savings 4. The Cost of Compressed Air Compressed Air System Leaks Size Cost per Year 1/16 ” $523 1/8 ” $2,095 1/4 ” $8,382 Costs calculated using electricity rate of $0.05 per kilowatt-hour, assuming constant operation and an efficient compressor Data from Assembly Magazine ’s March 2005 Article, “Saving Energy on the Line”. - 58 - Sold & Serviced By: ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: Cost Savings 6. Conclusion Rodless Cylinder (Slider Type) Parts Cost Initial Cost $1,108 $2,923 $1,553 Running Cost (3 years) $369 3 years Total Cost $1,010 $1,928 $2,957 $2,297 $1,295 $34 $34 (Cylinder bore Ø20) $1,329 Sold & Serviced By: ELECTROMATE - 59 - Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: Cost Savings 6. Conclusion Rod type cylinder Parts Cost $690 $294 3 years Total Cost Initial Cost $975 $629 $1,163 $1,008 - 60 - Running Cost (3 years) $534 $33 (Cylinder bore Ø40) Sold & Serviced By: ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: Application Example 1 Example 1 Solar Cell Manufacturing Line (Niigata, Japan) Saved $270,000/Year by replacing Air to Robo Cylinder Solar Cell Assembly Line Walking Beam Multi-Positioning 2 Process 1 START Place Loader,Unloader Quick transfer between stations improved tact time drastically Process 4 Process 3 FINISH Magazine Walking Beam Elevator Smooth and Safe motion by Finish Goods Ejection Safe transportation by controlled accel./decel. Pick and Place Multi-Steps, Precise Positioning controlled accel./decel. with a lot of stopping & going. High Speed and Precise mo Sold & Se rviced By: ELECTROMATE Toll Free Phone (877) SERVO98 SERV099 - 61 - Green Parts are Robo Tolwww.electroma te.com sales@electromate.comPowerPoint Presentation: Application Example 1 Solar Cell Manufacturing Line Air cylinders had been used for this line. The solar cell is very fragile and this line constantly caused about 3% defects due to the air cylinders ’ harsh movements. The defect rate was reduced 90% when Robo Cylinders took the place of air cylinders. As a result, this line saved $250,000/year yield loss. Robo Cylinder and Air Cylinder yield loss comparison table Yield loss per day Yield loss per year (300days/year) Defect Yield Defect Output parts loss Output parts Yield loss Robo Cylinder 65,664 197 $93 19,699,200 59,097 $27,776 Air Cylinder 65,664 1,970 $926 19,699,200 590,976 $277,759 Sold & Serviced By: Original defect rate (air)=3% • Cycle time=4pcs/5sec • Parts cost=$0.47 • Efficiency=95% (Air, Robo ELECTROMA TE - 62 - Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: Application Example 2 Example 2 ABS (Antilock Brake System) Press fit machine (Kanagawa, Japan) Saved $48,000 yield loss per year by switching to Robo Cylinder. Press fit here The Antilock Brake System [ABS] is a safety feature found in most modern cars. It helps drivers maintain control of their vehicles while braking in slippery road conditions and during sudden "panic" braking. - 63 - Antilock Brake System Sold & Serviced By: ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: Application Example 2 ABS (Antilock Brake System) Press fit machine The old machine required adjustments twice a week. The parts defect rate was 3~5%. With the Robo Cylinder, the adjustments was no longer required and the parts defect rate reached 0%. As the result, this customer saved $48,000 yield loss per year. Robo Cylinder and Air Cylinder yield loss comparison table Yield loss per day Yield loss per year (240days/year) Yield Output Defect parts loss Output Defect parts Yield loss Robo Cylinder 300 0 $0 72,000 0 $0 Air Cylinder 300 10 $200 72,000 2,400 $48,000 Original defect rate (air)=3% ~ 5%, Parts cost=$20 Sold & Serviced By: ELECTROMATE - 64 - Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: Application Example 3 Example 3 DVD Manufacturing Line (Tokyo, Japan) Saving $30,000/year by using Robo Cylinder 1. Machine parts cost Cost when air cylinders were used • Two Air cylinders • Two Solenoid valves • Mounting bracket The cost became half by using ERC 2. Assembly time Double stacked air cylinder - - 30 min ERC Robo Cylinder -------15 min ERC also has the following benefits: • Eliminates mounting bracket Anti-Static blower for DVD In the past, double stacked air cylinders Sold & Serviced By: • No adjustment required - 65 - were used for speed control. ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: Application Example 3 DVD Manufacturing Line 3. Productivity When air cylinders were used, the “Ionizer” lasted only a month due to the air cylinder’s abrupt stopping force. The customer had to stop the line for few hours to replace the damaged “Ionizer”. An Ionizer = $600 ~$700. After switching to ERC, the “Ionizer” has not been damaged since because of the controlled acceleration /deceleration. Lost time from stopping the line to replace the “Ionizer” was 2 hours/month meaning 2,500 DVDs could not be produced per month. At a cost of $1 per DVD, the production loss was $2,500/month. Annual loss was $30,000. Sold & Serviced By: ELECTROMATE - 66 - Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: Application Example 4 Example 4 Auto Parts Assembling Machine (Automotive company) Saved $150,000 machine cost by using Robo Cylinder Before Used Air and Hydro Replaced Robo Cylinder Connecting Pin Parts A Press Fit Snap Ring Parts B Press fit the snap ring which fixes the c Sold & Serviced By: cting pin ELECTROMATE - 67 - Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: Application Example 4 Auto Parts Assembling Machine 1. Cycle time dropped to less than half The old air and hydro system could not control speed and thrust of each position and needed to push twice to press the ring securely. Robo Cylinder can control speed and thrust in each position. It can quickly move right before the press position, then slow down for a high thrust press fit. This shortened the cycle time from 10 seconds to 4 seconds . 2. Machine cost saving of $150,000 The old air and hydro system needed many sensors mounted on the actuators to check that the snap ring was pressed in correctly. The “Push” and “Zone Output” functions of the Robo Cylinder, eliminated most of the sensors. Also, one Robo Cylinder took the place of many air and hydro actuators dropping the machine cost from $206,000 to $56,000. - 68 - Sold & Serviced By: ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: New Products Sold & Serviced By: ELECTROMATE - 69 - Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: New Products RCP2-RFA High Thrust Type Generates higher thrust than similar sized air cylinders. Can be used for electric press machines. Max Thrust = 612kg (1,350 lbs) Good for parts press-in applications Max vertical payload = 150kg Max stroke = 300mm Sold & Serviced By: ELECTROMATE - 70 - Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: New Products RCP2W (IP67 Slider Type) Power train is completely closed and sealed by using magnet force, for water proof structure. Actuator can be washed for food applications. § Meets IP67 (Dust & Water resistant) § Max. horizontal payload 30Kg § Max. stroke 600mm § Repeatability + 0.08mm Sold & Serviced By: ELECTROMATE - 71 - Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: New Products RCP2-BA6 & BA7 (Belt Type) Higher Speed (1,500mm/sec) Longer Stroke (1,200mm) Bottom side motor mount is also available. Sold & Serviced By: ELECTROMATE - 72 - Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: New Products IS(P)WA (IS Slider Type / Dust & Water resistance IP65 type) Many new applications can be considered: Part for f Sold & Serviced By: ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: New Products Super Slim size of 25mm high and 25mm wide. Maximum of 64 Positioning Points Incremental Motion Function Maximum Push Force of 100N Pause Function / Zone Signaling - 74 - Sold & Serviced By: ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: New Products XSEL P & Q Controller Compact size and higher performance Up to 6-AXIS, 2400W Capacity Conveyor tracking feature coming soon 3-phase 200VAC Power for Motor Drive Sold & Serviced By: ELECTROMATE - 75 - Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: New Products RCP2 Series Three Finger Grippers Smaller size & lighter weight than existing gripper with three fingers. Unique three finger design is able to grip different shaped parts with high gripping force. Lever Finger Slide Finger - 76 - Sold & Serviced By: ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: New Products New Linear Servo Motor Actuator High acceleration & deceleration: 2.5G High Speed: 2,500mm/sec Maintenance free and environment friendly. Additional models will soon be under development. - 77 - Sold & Serviced By: ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: New Products For any questions regarding Web2CAD and 3D CAD, please contact: Chris Prior (Torrance) Rob Antonio (Itasca) Sold & Serviced By: ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.comPowerPoint Presentation: Sold & Serviced By: ELECTROMATE Toll Free Phone (877) SERVO98 Toll Free Fax (877) SERV099 www.electromate.com sales@electromate.com