iai robo expo presentation 2005

Robo ExpoIntroduction of New Generation Cylinder, for Air substitution

2005.5.5 V4

ELECTROMATEToll Free Phone (877) SERVO98

Toll Free Fax (877) SERV099www.electromate.com

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Introduction of IAI

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Global Locations

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Introduction of IAI - New Factory

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NameLocationLandBuildingFloor AreaStructure

: IAI Obane Factory: 416-4 Obane Shimizu, Shizuoka City, Shizuoka Pref.: 142,040 sq.ft.: 35,822 sq.ft.: 134,721 sq.ft.: RC 4 stories

Completed Aug 2004



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Introduction of IAI

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Introduction of IAI

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Introduction of IAI

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IAI was recently voted as the fastest growing private businessventure in Japan by a leading Japanese business newspaper.



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Introduction of Robo Cylinder

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Robo Cylinder Family

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Teaching Pendants

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PC Software

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Robo Cylinder Structure

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Robo Cylinder Structure

Integrated ERC Motor & Controller

Motor

Encoder

Controller



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Robo Cylinder Functions

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1. Position Moves (Multi-positioning)2. Pause (Hold)3. Acceleration Control (Quick start,

Smooth start)4. Push and Hold5. Pitch (Incremental) Moves6. Zone Output7. Speed Control (Constant, Variable)

Multi-functions

Robo Cylinder has the following 7 functions



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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.



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1. Positioning MovesCan move and position the objective on the rod or slider with +0.02mm (ERC +0.05mm) repeatability._ _



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Motorcycle parts welding fixture Auto Parts Degreaser

1. Positioning Moves

The fixture for motorcycle gasoline tank welding with an articulated welding robot. Used 19 Robo Cylinders for multi-model production.

A machine which transfers auto parts through each process such as degreaser ￫

shower ￫

steam ￫

dryer.ELECTROMATE

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Rolled Paper Inspection and Sorting Machine Chemical Observation Machine

1. Positioning Moves

Inspects rolled paper on the conveyor, and rejects defective ones. Robo Cylinder can accommodate and adjust to different and random products in applications.

Observe chemicals on the pallet by a microscope.



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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.



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2. Pause (Hold) 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).

Pauses the motion when the signal turns OFF



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Supplying wrapping paper for bread loaf 2. Pause (Hold)

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. ELECTROMATE


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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.



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3. Speed Control (Constant, Variable) Robo Cylinder can change speed on the fly, then position.



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3. Speed Control (Constant, Variable)DVD Manufacturing Machine Beverage Filling Machine

The machine moves ionizer to remove static electricity on the DVD during the manufacturing process. It requires quick forward and slow backward motion, and the customer had to use double stacked air cylinders.

Lifts the container close to the nozzle, slows down then fills the liquid to avoid splashes. (Splashes could not be prevented when customer used air cylinders) ELECTROMATE


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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. ELECTROMATE


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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.


Air cylinders are not able to set its acceleration/deceleration ratio.



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Acceleration/deceleration ratio can be set arbitrarily.




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Jelly Transfer Machine


The machine transfers jelly from one conveyor to the other.



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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.



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5. Push & HoldRobo Cylinder can push and holdan object just like an air cylinder.



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Auto Door Sealing TAB Bonding

5. Push & Hold

Robo Cylinders fix the door to apply sealing material with articulated robot. This machine can process multi-type products because of Robo Cylinder.

Robo Cylinders fix LCD panel for TAB bonding machine.

TAB : Printed circuit on a thin film. ELECTROMATEToll Free Phone (877) SERVO98


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Gelatin Cutting MachineCushion Insertion Machine for Medicine Bottle Tablets

5. Push & Hold

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 adjusting the push force.

The machine inserts a cushion into tablet bottle. Robo Cylinder can prevent possible damage to the tablets, cushion and bottle by adjusting its push force. ELECTROMATE


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6. Pitch (Incremental) moves

- Function -

Robo Cylinder can move a specified distance(pitch) repeatedly in steps.


This function is impossible for air cylinders.Only electric actuators can offer this.



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6. Pitch (Incremental) MovesMoving to coordinate location relative to home position, or any specified distance from current location is possible.



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Auto Parts Feeder Electronic Parts Inspection System


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.

The machine inspects the parts by image sensor (Vision). Robo Cylinder moves the pallets of the parts, using pitch moves. ELECTROMATE


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Test Tube Bar code Reader


This machine reads bar codes on the test tubes.

Blade feeding machine for inspection process

This machine feeds a steel blade to inspection stage by using pitch moves. It is easy to adjust the feeding speed. ELECTROMATE


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7. Zone Output

- Function -

Robo Cylinder can output a signal during movement.


Air cylinders require sensor(s) to get an output signal.



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7. Zone Output 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.The signal turns on when

slider is in the specified range.



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7. Zone Output

Auto Parts Inspection Machine LCD Panel Laminating machine

The machine inspects wire harness cable length and its strength. It used to be done manually and the quality improved after introducing this machine.

Laminating LCD panel glasses in a vacuum chamber.ELECTROMATE


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7. Zone OutputPrinting 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.



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Multi-Functions

ERC offers 3 types different functions for meeting a variety of needs. You can select one of the following functions by changing the controller setting.

3 positions type

Characteristics

Actuator moves just bit ON specified position input.

2.

Moves 3 positions

1.

8 positions type

Characteristics

Available “Home” input for homing

2.

Moves 8 positions

1.

16 positions type

Characteristics

Available 1 zone output.

2.

Moves 16 positions

1.

Available 1 zone output.

3.

Position number

Start inputto

No need to take two steps like above.

( Air Cylinder Mode)



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1. Position Moves (Multi-positioning)2. Pause (Hold)3. Acceleration Control (Quick start,

Smooth start)4. Push and Hold5. Pitch (Incremental) Moves6. Zone Output7. Speed Control (Constant, Variable)

Multi-functions

Robo Cylinder has the following 7 functions



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Cost Savings with Robo Cylinders

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Cost Savings

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Electric bill of all air compressors in Japan = $15 Billion/year

Compressor’s electricity consumptionNation wide factories’ electricity consumption

= 10% ~ 20%

The Cost of Compressed Air (Japan)

1. The Cost of Compressed Air

* Data from Tokyo institute of Technology



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Cost Savings

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2. Initial Cost Comparison

In House Design (Electric)

Robo cylinderAir cylinder

Which is the lowest cost ?Which is the lowest cost ?

(1) Rod less (Slider type)



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Cost Savings

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TOTAL $3,451

In-House Design (Electric)

1. Design cost = $50/hr Assembly, Wiring cost = $40/hr2. Design cost will be applied for first unit only

3. Not including any indirect cost increase due to larger number of parts handling.

Parts Assembly, Wiring Mechanical design Electric/Software Design

$150 $840 $825$1,636

Description QTY Unit price AmountStepping Motor and Controller (DC24V) with encoder feed back 1 $608 $608Linear Guide 2 $250 $500Ballscrew and Nut 1 $328 $328Other Mechanical Parts 1 200$ $200

$1,636Parts Cost



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Cost Savings

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Air cylinder

TOTAL $1,928




$1,553 $125 $200 $50

Description QTY Unit price AmountHy-Rodless Cylinder 1 $1,262.50 $1,262.503 position pressure center solenoid valve 1 $112.95 $112.953 port solenoid valve for brake 1 $76.35 $76.35Speed control valve 2 $8.00 $16.00Silencer 3 $2.80 $8.40Filter & Regulator 1 $42.65 $42.65One Touch Connector 10 $2.55 $25.50Air tube 6mm 0.4 $21.80 $8.72

$1,553.07Parts Cost



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Cost Savings

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Robo Cylinder




TOTAL $1,295

$1,010 $75 $160 $50

Description QTY Unit price Amount

Robo Cylinder 1 $880 $880Power & IO Cable (3m) 1 $130 $130

$1,010Parts Cost



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Cost Savings

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RoboCylinder

AirCylinder

In House Design

(Electric)

33% Decrease

33% Decrease

62% Decrease

62% Decrease

TOTAL$3,451

TOTAL$1,295

TOTAL$1,928

Robo Cylinder is thelowest cost solution !Robo Cylinder is thelowest cost solution !

Initial Cost Comparison(1) Rod less (Slider type)



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Cost Savings

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Robo CylinderAir Cylinder

How about Rod Type ?How about Rod Type ?

2. Initial Cost Comparison(2) Rod Type



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Cost Savings

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TOTAL $629

Air Cylinder

Air Cylinder

Speed control valve

Solenoid valve




$294 $125 $160 $50

Description QTY Unit price AmountAir cylinder (Rod) with 2 sensors 1 $150.60 $150.605 ports solenoid valve 1 $54.70 $54.70Speed control valve 2 $8.00 $16.00Silencer 2 $2.80 $5.60Filter & Regulator 1 $42.65 $42.65One Touch Connector 6 $2.55 $15.30Air tube 6mm 0.4 $21.80 $8.72

$293.57



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Cost Savings

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TOTAL $975

Robo Cylinder

$690 $75 $160 $50

Description QTY Unit price AmountRobo Cylinder 1 $560 $560Power & IO Cable (3m) 1 $130 $130

$690Parts Cost



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Cost Savings

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Air Cylinder’s initial cost is a bit lowerAir Cylinder’s initial cost is a bit lower

Robo Cylinder

AirCylinder

35% Increase

35% Increase

TOTAL$975

TOTAL$629


2. Initial Cost Comparison(2) Rod Type



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Cost Savings

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3. Running Cost

120kwh

$100 savings per year, per cylinder

* Above data is when 37kw compressor is used which was calculated based on 0.75kw compressor measurement result.* Electricity cost is $0.095/kwh, operating 10 hours / day (2400 hours / year)

Robo Cylinder’s electricity consumption is 1/10 of air cylinder

Air cylinder

Robo cylinder

Conditions

Speed

:

:

Stroke

:

Bore Ø25 (Pressure 0.5MPa)

RCP2-SA6 (Slider type)

RCP2-RMA (Rod type)

25~30 cycles/min

: 500mm (Slider type)

: 300mm (Rod type)

kwh

1080~1920kwh



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Cost Savings

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Robo Cylinder’s effective energy efficiency is 80% ~ 90%!

Air system energy efficiency

Air System effective energy efficiency is about 14%

* Air drier’s electricity consumption is NOT included in above calculation.

50%

16%

15%

5%

Air system effective energy efficiency

Compressor LossAir cylinder Loss

Piping-Pressure down Loss

Air filter and other Loss

14%

Data : Tokyo Institute of Technology



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Cost Savings

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4. The Cost of Compressed Air

Compressed Air System Leaks

Size Cost per Year

1/16” $523

1/8” $2,095

1/4” $8,382Costs 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”.ELECTROMATE


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Cost Savings

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6. Conclusion Rodless Cylinder (Slider Type)

Parts Cost Initial Cost Running Cost (3 years)

3 years Total Cost

(Cylinder bore Ø20)

$1,108$1,553

$1,010

$2,923

$1,928$1,295 $34

$369

$34

$2,957$2,297

$1,329



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Cost Savings

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6. Conclusion Rod type cylinderParts Cost Initial Cost Running Cost (3 years)

3 years Total Cost

(Cylinder bore Ø40)

$294$690

$629 $975 $534

$33

$1,163$1,008



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Application Example 1

STARTSTARTPlace Magazine

Conveyor

ElevatorMulti-Steps, Precise Positioning

Process 1

Process

2

Process 3

Process 4

FINISHFINISH

Walking BeamMulti-Positioning

Walking BeamSmooth and Safe motion by controlled accel./decel. with a lot of stopping & going.

Loader,UnloaderQuick transfer between stations improved tact time drastically

Finish Goods Ejection Safe transportation by controlled accel./decel.

Pick and PlaceHigh Speed and Precise motion

Green Parts are Robo Cylinder

Saved $270,000/Year by replacing Air to Robo Cylinder

Solar Cell Manufacturing Line (Niigata, Japan)

Solar Cell Assembly Line

Example 1



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Original defect rate (air)=3% • Cycle time=4pcs/5sec • Parts cost=$0.47 • Efficiency=95% (Air, Robo Cylinder)

Yield loss per day Yield loss per year (300days/year)

OutputDefect parts

Yield loss Output

Defect 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

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

Solar Cell Manufacturing Line



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ABS(Antilock Brake System)Press fit machine (Kanagawa, Japan)Example 2

Saved $48,000 yield loss per year by switching to Robo Cylinder.

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.

Antilock Brake System

Press fit here



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Original defect rate (air)=3% ~ 5%, Parts cost=$20

Yield loss per day Yield loss per year (240days/year)

Output Defect partsYield 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

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

ABS (Antilock Brake System) Press fit machine



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DVD Manufacturing Line (Tokyo, Japan)Example 3

Saving $30,000/year by using Robo Cylinder

1. Machine parts cost

2. Assembly time

Cost when air cylinders were used• Two Air cylinders• Two Solenoid valves• Mounting bracketThe cost became half by using ERC

Double stacked air cylinder - - 30 minERC Robo Cylinder - - - - - - -15 min

ERC also has the following benefits:• Eliminates mounting bracket• No adjustment required

Anti-Static blower for DVDIn the past, double stacked air cylinders were used for speed control.



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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.ELECTROMATE


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Auto Parts Assembling Machine (Automotive company)Example 4

Saved $150,000 machine cost by using Robo Cylinder

Parts A Parts B

Connecting Pin

Snap Ring

Press fit the snap ring which fixes the connecting pin

Press FitBefore

Used Air and Hydro

Replaced Robo Cylinder



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Auto Parts Assembling Machine

1. Cycle time dropped to less than half

2. Machine cost saving of $150,000

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.

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.



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New Products

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New Products

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RCP2-RFA High Thrust TypeGenerates 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



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New Products

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RCP2W (IP67 Slider Type)Power train is completely closed and sealed byusing 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



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New Products

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RCP2-BA6 & BA7 (Belt Type)Higher Speed (1,500mm/sec)

Longer Stroke (1,200mm)Bottom side motor mount is also available.



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New Products

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IS(P)WA(IS Slider Type / Dust & Water resistance IP65 type)

Many new applications can be considered:Parts washing & Actuator wash downfor food applications and so on.



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New Products

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Super Slim size of 25mm high and 25mm wide.Maximum of 64 Positioning Points

Incremental Motion FunctionMaximum Push Force of 100N

Pause Function / Zone SignalingELECTROMATE


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New Products

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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



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New Products

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RCP2 Series Three Finger Grippers

Lever Finger Slide Finger

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.



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New Products

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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.



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New Products

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3D CAD DrawingsFor any questions regarding Web2CAD and 3D CAD, please contact:

Chris Prior (Torrance)

Rob Antonio (Itasca)



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