IAI robo expo presentation 2005

Robo Expo
Introduction of New Generation Cylinder, for Air substitution

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Toll Free Phone (877) SERVO98
Toll Free Fax (877) SERV099
www.electromate.com
2005.5.5 V4
sales@electromate.com

Introduction of IAI

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- 2 - www.electromate.com

Global Locations

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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.
Structure : RC 4 stories Sold & Serviced By:

ELECTROMATE

Introduction of IAI

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Introduction of IAI

IAI was recently voted as the fastest growing private business
venture 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

Controller

Motor

Encoder Sold & Serviced By:

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Robo Cylinder Functions

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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 Sold & Serviced By:

ELECTROMATE

Robo Cylinder Functions 1


- 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 Moves Can move and position the objective on the rod or
slider with _ _
+0.02mm (ERC +0.05mm) repeatability.

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1. Positioning Moves
Motorcycle parts welding fixture Auto Parts Degreaser

The fixture for motorcycle gasoline tank welding with A machine which transfers auto parts through each
an articulated welding robot. process such as degreaser ￫ shower ￫ steam ￫ dryer.
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Used 19 Robo Cylinders for multi-model production. ELECTROMATE


1. Positioning Moves
Rolled Paper Inspection
Chemical Observation Machine
and Sorting Machine

Inspects rolled paper on the conveyor, and rejects Observe chemicals on the pallet by a microscope.
defective ones. Robo Cylinder can accommodate Sold & Serviced By:

and adjust to different and random products in
ELECTROMATE
applications. Toll Free Phone (877) SERVO98


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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The movement pause when the pause input turns off. When
2. Pause (Hold) 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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ELECTROMATE


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

This machine lifts wrapping paper to the picking height for the
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air gripper. Robo Cylinder moves up while the light sensor is on.
ELECTROMATE
Once the sensor is off, Robo Cylinder pause the motion. Toll Free Phone (877) SERVO98



- 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.

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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DVD Manufacturing Machine Beverage Filling Machine

The machine moves ionizer to remove static Lifts the container close to the nozzle, slows down
electricity on the DVD during the manufacturing then fills the liquid to avoid splashes.
process. It requires quick forward and slow (Splashes could not be prevented when customer
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backward motion, and the customer had to use used air cylinders) ELECTROMATE
double stacked air cylinders. Toll Free Phone (877) SERVO98


Wire Winding Machine

The machine winds wire to the drum with a constant
speed. According to the current drum diameter, the Sold & Serviced By:

Robo Cylinder slows down speed to oscillate the head
ELECTROMATE
for uniformed winding. Toll Free Phone (877) SERVO98


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 & Hold Robo Cylinder can push and hold
an object just like an air cylinder.

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5. Push & Hold
Auto Door Sealing TAB Bonding

Robo Cylinders fix the door to apply sealing Robo Cylinders fix LCD panel for TAB bonding
material with articulated robot. This machine machine.
can process multi-type products because of Sold & Serviced By:

Robo Cylinder. TAB : Printed circuit on a thin film. ELECTROMATE


5. Push & Hold
Cushion Insertion Machine
Gelatin Cutting Machine for Medicine Bottle Tablets

The machine pushes gelatin (Konnyaku) through The machine inserts a cushion into tablet bottle.
the grid and slices it into thin pieces. Robo Robo Cylinder can prevent possible damage to
Cylinder moves quickly just before the gelatin the tablets, cushion and bottle by adjusting its Sold & Serviced By:

then pushes it slowly shortening the machine push force. ELECTROMATE
cycle time. Uniform cuts can be obtained by Toll Free Phone (877) SERVO98
adjusting the push force. - 34 - www.electromate.com


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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ELECTROMATE


Moving to coordinate location relative to home position,
or any specified distance from current location is possible.

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ELECTROMATE


Auto Parts Feeder Electronic Parts Inspection System

Feeding rubber bushing to the articulated robot, The machine inspects the parts by image sensor
by using pitch moves. The articulated robot (Vision). Robo Cylinder moves the pallets of the
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inserts the rubber bushing into a drain hole of parts, using pitch moves. ELECTROMATE
car body. Toll Free Phone (877) SERVO98


Blade feeding machine
Test Tube Bar code Reader for inspection process

This machine reads bar codes on the test tubes. This machine feeds a steel blade to inspection
stage by using pitch moves. It is easy to adjust
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the feeding speed. ELECTROMATE


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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The output signal can be turned on and off at
7. Zone Output arbitrary positions (The positions are set by
parameter). So, the Robo Cylinder can set danger
The signal turns on when area etc. without mounting sensors on it.
slider is in the specified range.

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ELECTROMATE


7. Zone Output
Auto Parts Inspection Machine LCD Panel Laminating machine

The machine inspects wire harness cable length Laminating LCD panel glasses in a vacuum chamber.
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and its strength. It used to be done manually and
ELECTROMATE
the quality improved after introducing this machine. Toll Free Phone (877) SERVO98


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 Sold & Serviced By:

range is set where the actuator moves at a ELECTROMATE
constant speed for printing area. Toll Free Phone (877) SERVO98


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.
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ELECTROMATE


Robo Cylinder has the following 7 functions
2. Pause (Hold)
3. Acceleration Control (Quick start,
Smooth start)
4. Push and Hold
6. Zone Output

Multi-functions Sold & Serviced By:

ELECTROMATE

Cost Savings with Robo Cylinders

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Cost Savings

1. The Cost of Compressed Air

The Cost of Compressed Air (Japan)

Compressor’s electricity consumption
= 10% ~ 20%
Nation wide factories’ electricity consumption

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

* Data from Tokyo institute of Technology
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Cost Savings

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

In House Design Air cylinder Robo cylinder
(Electric)

Which is the lowest cost ?
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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 1 $328 $328
Other Mechanical Parts 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
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3. Not including any indirect cost increase due to larger number of parts handling. ELECTROMATE

Cost Savings

Air cylinder Description
Hy-Rodless Cylinder
QTY Unit price
1 $1,262.50
Amount
$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 TOTAL $1,928
Connector 10 $2.55 $25.50
Air tube 6mm 0.4 $21.80 $8.72
Parts Cost $1,553.07

$1,553 $125 $200 $50

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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

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Cost Savings

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

In House TOTAL
Design
(Electric) $3,451

Air TOTAL
Cylinder $1,928

Robo TOTAL
Cylinder $1,295 33% 62%
Decrease Decrease

Robo Cylinder is the
lowest cost solution !
- -
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www.electromate.com
51 sales@electromate.com

Cost Savings

(2) Rod Type

Air Cylinder Robo Cylinder

How about Rod Type ? Sold & Serviced By:

ELECTROMATE

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
One Touch
Speed control valve Connector 6 $2.55 $15.30
Air tube 6mm 0.4 $21.80 $8.72
Solenoid valve $293.57

TOTAL $629
$294 $125 $160 $50


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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


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

(2) Rod Type

Air 35% TOTAL
Cylinder $629
Increase

Robo TOTAL
Cylinder
$975


Air Cylinder’s initial cost is a bit lower Sold & Serviced By:

ELECTROMATE

Cost Savings

3. Running Cost
Robo Cylinder’s electricity consumption is 1/10 of air cylinder

$100 savings per year, per cylinder

Air cylinder : Bore Ø25 (Pressure 0.5MPa)
Robo cylinder : RCP2-SA6 (Slider type)
1080~1920kwh
RCP2-RMA (Rod type)
Conditions Stroke : 500mm (Slider type)
120kwh
: 300mm (Rod type)
Speed : 25~30 cycles/min
kwh

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

Cost Savings

Air System effective energy efficiency is about 14%

Air system energy
efficiency

Air system effective Compressor Loss
energy efficiency 14%
Air cylinder Loss
5% Piping-Pressure down
Loss
15% 50% Air filter and other
Loss

16%

Data : Tokyo Institute of Technology

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

Robo Cylinder’s effective energy efficiency is 80% ~ 90%! Sold & Serviced By:

ELECTROMATE

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”. Sold & Serviced By:

ELECTROMATE

Cost Savings

6. Conclusion Rodless Cylinder (Slider Type)
Parts Cost Initial Cost Running Cost (3 years)

$2,923 $369
$1,108
$1,553 $1,928
$1,010 $1,295 $34 $34

3 years Total
Cost

$2,957
$2,297 (Cylinder bore Ø20)
$1,329
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ELECTROMATE

Cost Savings

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

$690 $534
$975
$629
$294
$33

3 years Total
Cost

$1,163 (Cylinder bore Ø40)

$1,008
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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 Loader,Unloader
Quick transfer between stations
improved tact time drastically
Walking Beam Process
Multi-Positioning
Process 4
2

Process 1 Process 3
FINISH
START
Place
Conveyor

Magazine Finish Goods Ejection
Safe transportation by
controlled accel./decel.
Walking Beam
Elevator Smooth and Safe motion by Pick and Place
Multi-Steps, controlled accel./decel. with a High Speed and Precise motion
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Precise Positioning lot of stopping & going. ELECTROMATE
- 61 - Green Parts are Robo Cylinder www.electromate.com


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


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" Antilock Brake System
braking. Sold & Serviced By:

ELECTROMATE


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
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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: Anti-Static blower for DVD
• Eliminates mounting bracket In the past, double stacked air cylinders
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• No adjustment required were used for speed control.
ELECTROMATE


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.
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ELECTROMATE


Example 4 Auto Parts Assembling Machine (Automotive company)

Saved $150,000 machine cost by using Robo Cylinder

Before Press Fit

Used Air and Hydro Snap
Connecting Ring
Pin

Replaced Robo Cylinder Parts A Parts B
Press fit the snap ring which fixes the connecting pin
Sold & Serviced By:

ELECTROMATE


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. Sold & Serviced By:

ELECTROMATE

New Products

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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

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

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ELECTROMATE

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

New Products

IS(P)WA
(IS Slider Type / Dust & Water resistance IP65 type)
Many new applications can be considered:
Parts washing & Actuator wash down
for food applications and so on.

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ELECTROMATE

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
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ELECTROMATE

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

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

Sold & Serviced By:

ELECTROMATE

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. Sold & Serviced By:

ELECTROMATE

New Products

3D CAD Drawings
For any questions regarding Web2CAD
and 3D CAD, please contact:
Chris Prior (Torrance)
Rob Antonio (Itasca)

Sold & Serviced By:

ELECTROMATE

Sold & Serviced By:

ELECTROMATE
www.electromate.com

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