Presentation on theme: "Offering human oriented production process"— Presentation transcript:
1 Offering human oriented production process KOYAMA BARINDERSINTOKOGIO, LTD
2 Who is KOYAMA? Company Name: KOYAMA Co., Ltd. Business Place: Headquarter & Kawanakajima Plant Nagano City, Nagano Pref., JAPANEstablishment: October, 1945Capital: 98 million JPYNumber of employee: 455 (as of December 2012)Major customers: FUJI Heavy Industries, KOMATSU MITSUBISHI Heavy Industries, YANMAR,HITACHI Construction, etc.Establishment : January, 2011(KBT – KOYAMA BARINDER THAILAND)
3 Who is KOYAMA?KOYAMA has been a developing foundry producing iron casting with established foundry technology under stable management since foundation in 1945.KOYAMA’s 4 major business categoriesIron CastingMachiningLabor-saving Machine (BARINDER)Light Alloy (Aluminum)
4 Who is KOYAMA?BARINDER was developed in 1972 for the purpose of labor-saving in the foundry.BARINDER has been loved and used by many foundry customers as a system specialized for qualified finishing of castings, in over 28 different countries in the world.
5 Problem of conventional manual work Problem of conventional manual work for removing burrs and fins of castingHuman error (Uneven quality by workers)Taking time for preparationNumerous hazards
6 What is BARINDER? HARD ! DIRTY ! DANGEROUS ! BARINDER is a solution to the conventional manual finishing and de-burring work, realizing automation!!HARD !DIRTY !DANGEROUS !
7 Problem of conventional manual work Hand grinders■Grinder for small and medium size work■Grinder for large size work■Double-end grinderHolding a heavy-weight grinder or work with the same posture is a heavy work, that obstructs high dimensional accuracy finishing.
8 Problem of conventional manual work HazardsSafety issues・Vibration (White finger disease)・Noise・Dust flying・Injury by accident・Heavy work, back pain, etc.VibrationNoise, DustBack pain
9 Solution by BARINDERIntroducing BARINDER will solve the aforementioned problems and contribute to the following advantages!!Improved productivityImproved grinding accuracySpace saving, Energy savingImproved working environment
10 Advantages by introducing BARINDER Sophisticated and easy operationEasy programmingLong-life toolsReduced running cost and dust generation by diamond toolEasy fixture change and shortened preparation timeQuick correspondence to frequent work changeCan handle complicated profileSmall installation spaceExcellent durability and maintainabilityPlural-unit operation by a single operatorImproved productivity and quality by high-efficient and high-speed process
11 Advantages by introducing BARINDER Sustained quality and dimensional accuracy of finish■ Manual finishing workNon-uniform finish■Automatic finishing by BARINDERUniform finish
12 Composition of BARINDER Main UnitOperation panelFront shutterHoodChip and dust collection box
13 Composition of BARINDER Work clamp barSmall wheelWorkMain wheelWork set fixture
15 Composition of BARINDER Unique horizontal & vertical work moving mechanismNACR Control System has achieved fast moving of work, by horizontal rotation table, horizontal joint arm and vertical lift mechanism.
16 【NACR Control System】NACR control is a system that converts the motion of the mechanism by polar coordinate to the rectangular coordinate.NACR is KOYAMA’s original control software achieving easy operation similar to NC control, utilizing robot arm mechanism.X-axisA-axisY-axisZ-axis
17 【Automatic Load control system】 Grinding speed (work feed speed) is controlled to vary so that the load to the work is sustained same.Advantages:1. Improved efficiency of tool drive motor (Reduced electricity consumption)2. Shortened grinding time3. Improved life of tool and machine (Reduced heat generation from tool)4. Reduced tool motor size (due to equalized grinding load)5. Improved grinding accuracy
18 Composition of BARINDER Pallet changer type Main unitHoodOperation panelChange rotation doorSafety door
19 Composition of BARINDER Pallet changer type Work clamp barSmall wheelMain wheelWorkPalletWork set fixture
20 【Work feed mechanism】 Pallet changer type 2-position Pallet changer or work load/unload system is available as an option, for more efficient work feed.Pallet change is generally used for two same fixture, however, it can also be used for two different fixtures to process different works alternately or randomly.
21 【Work feed mechanism】 Pallet changer type Advantage of work feed system1. Work set or change is possible while the work is processed in the machine. (This system is particularly effective for medium and large size work.)2. Automated line can be built by adding work transfer system after processing.
22 【Tool: Wheel】 Grinding tool: Diamond Wheel Main wheel Small-wheel Complex shape can be processed by utilizing two different tools.
23 【Tool: Wheel】 Features Diamond grains are bonded to various shape of iron wheel. Tool diameter does not change in large volume.Tool itself has high durability, achieving high-accurate and high-speed finishing.Φ 355xT12x Φ 80Φ 405xT10x Φ 80Φ 405xT4x Φ 80
24 【Tool: Wheel】 Small wheel High-speed (Max. 15,000 rpm) small tool is effectively used to clean narrow and small area where main wheel cannot reach.Various size of tool is available according to the shape of work.
25 Programming 1. Hand Teaching (available in F300 & F400 Series Direct teaching using the work is the base of the programming.There are 3 different methods in Direct teaching. Each method has unique features. Combination of each method is also available.1. Hand Teaching (available in F300 & F400 SeriesClamp unitOperator hold the work, which is held by the clamp unit and sits on the fixture mounted on A-axis table. Then the operator let the teaching point touch the grinding tool. Coordinate value is input on the touch panel.Main wheelFixture
26 Programming2. Manual pulse generator teaching Manual pulse generator attached to the operation panel has selector switch of axis and job-dial. Work table (fixture) moves by the number of pulse by jog-dial on each axis. Operator moves the work by this dial operation and let the teaching point touch the tool so that coordinate value can be input by 1-push operation. This method is effective for more accurate position teaching.
27 Programming 3. JOG Teaching Operator moves the work by operating by the switches on the touch panel. Coordinate value where work touches the tool will be written to the program. (Equipped as standard in all models)In this mode, only minimum drive force for teaching is required. Teaching can be performed under safe circumstance. (Safe operation control system) ; (Available in F300 and F400 series)
28 Programming Part of the grinding program can be modified by block. ・ Modification or correction of grinding program is easy by only input of moving direction (front/back, left/right, up/down, rotation) and value of movement.・ Correction of data in the specified block can be done by pointing the range. (NACR control system)
29 Networking of BARINDER 98 (99 for changer type) grinding programs can be stored in BARINDER.If number of programs exceed above, BARINDER can communicate with outer devices such as NACR device, CNC equipment or PC, using NACR Network System via. Hub by Ethernet.Function (1) Upload and download of NACR and CNC programs (2) Input/output of CNC parameters (3) Directory display in PC (4) Printout of grinding program
30 Basic BARINDER Models 300 Series MODEL X6-FDS12R-331 X6-FDS12R-331GR Max. work sizeΦ300 x H200 mmMax. work weight8kgToolMain x 1Main x 1, Sub x 1
32 Basic BARINDER Models 400 series Model X6-FDH22R-443GR X7-FDH22R-455GR-CMax. work sizeΦ400 x H200mmΦ500 x H200mmMax. work weight20kg30kgToolMain x 1, Sub x 1ChangerNoneEquipped
33 Basic BARINDER Models 500 Series Model X6-FDH22R- 577GR X7-FDH22R- 56FGR-CX7-FDH22R- 59FGR-CMax. work sizeΦ700 x H250mmΦ600 x H400mmL750 x W430 x H450mmMax. work weight50kg100kgToolMain x 1, Sub x 1ChangerNoneEquipped
35 Major Applicable Work Sample Caliper body18 sec/pcDifferential case40 sec/pcManifold43 sec/pcWater pump37 sec/pcCrankshaft60 sec/pcCylinder block120 sec/pcBracketPipe joint holderGear box24 sec/pcDifferential carrier70 sec/pc80 sec/pcCylinder head
36 Worldwide users and countries 2,600 units of BARINDER sold to worldwide users (as of the end of year 2012)■Europe UKSWEDEN FINLANDDENMARKHOLLANDBELGIUMGERMANYFRANCEITALYHUNGARYSPAINPORTUGALTURKEY■AsiaJAPANCHINAKOREATAIWANTHAILANDMALAYSIASINGAPOREINDONESIAINDIA■ North-South AmericaCANADAU.S.A.MEXICOBRAZIL
38 Awards7th “Development Award of Machine for automobile for small and medium size business” in 1976Technical Award of Japan High Grade Cast Iron Association in 1992Technical Award of Japan High Grade Cast Iron Association in 2001GENERAL MOTORS “Worldwide Supplier of the year” in 2002
39 Thanks & appreciate your attention! SINTOKOGIO, LTD