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Offering human oriented production process

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Presentation on theme: "Offering human oriented production process"— Presentation transcript:

1 Offering human oriented production process

2 Who is KOYAMA? Company Name: KOYAMA Co., Ltd.
Business Place: Headquarter & Kawanakajima Plant Nagano City, Nagano Pref., JAPAN Establishment: October, 1945 Capital: 98 million JPY Number 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 categories Iron Casting Machining Labor-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 casting Human error (Uneven quality by workers) Taking time for preparation Numerous hazards

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 grinder Holding 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
Hazards Safety issues ・Vibration (White finger disease) ・Noise ・Dust flying ・Injury by accident ・Heavy work, back pain, etc. Vibration Noise, Dust Back pain

9 Solution by BARINDER Introducing BARINDER will solve the aforementioned problems and contribute to the following advantages!! Improved productivity Improved grinding accuracy Space saving, Energy saving Improved working environment

10 Advantages by introducing BARINDER
Sophisticated and easy operation Easy programming Long-life tools Reduced running cost and dust generation by diamond tool Easy fixture change and shortened preparation time Quick correspondence to frequent work change Can handle complicated profile Small installation space Excellent durability and maintainability Plural-unit operation by a single operator Improved productivity and quality by high-efficient and high-speed process

11 Advantages by introducing BARINDER
Sustained quality and dimensional accuracy of finish ■ Manual finishing work Non-uniform finish ■Automatic finishing by BARINDER Uniform finish

12 Composition of BARINDER
Main Unit Operation panel Front shutter Hood Chip and dust collection box

13 Composition of BARINDER
Work clamp bar Small wheel Work Main wheel Work set fixture

14 Break bracket VTR

15 Composition of BARINDER
Unique horizontal & vertical work moving mechanism NACR 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-axis A-axis Y-axis Z-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 time 3. 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 unit Hood Operation panel Change rotation door Safety door

19 Composition of BARINDER Pallet changer type
Work clamp bar Small wheel Main wheel Work Pallet Work 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 system 1. 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 80 Φ 405xT10x Φ 80 Φ 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 Series Clamp unit Operator 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 wheel Fixture

26 Programming 2. 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 size Φ300 x H200 mm Max. work weight 8kg Tool Main x 1 Main x 1, Sub x 1

31 Basic BARINDER Models 300 Series

32 Basic BARINDER Models 400 series Model X6-FDH22R-443GR
X7-FDH22R-455GR-C Max. work size Φ400 x H200mm Φ500 x H200mm Max. work weight 20kg 30kg Tool Main x 1, Sub x 1 Changer None Equipped

33 Basic BARINDER Models 500 Series Model X6-FDH22R- 577GR
X7-FDH22R-       56FGR-C X7-FDH22R-        59FGR-C Max. work size Φ700 x   H250mm Φ600 x   H400mm L750 x W430 x H450mm Max. work weight 50kg 100kg Tool Main x 1, Sub x 1 Changer None Equipped

34 Basic BARINDER Models 500 Series

35 Major Applicable Work Sample
Caliper body 18 sec/pc Differential case 40 sec/pc Manifold 43 sec/pc Water pump 37 sec/pc Crankshaft 60 sec/pc Cylinder block 120 sec/pc Bracket Pipe joint holder Gear box 24 sec/pc Differential carrier 70 sec/pc 80 sec/pc Cylinder head

36 Worldwide users and countries

37 Major Worldwide Users

38 Awards 7th “Development Award of Machine for automobile for small and medium size business” in 1976 Technical Award of Japan High Grade Cast Iron Association in 1992 Technical Award of Japan High Grade Cast Iron Association in 2001 GENERAL MOTORS “Worldwide Supplier of the year” in 2002

39 Thanks & appreciate your attention!

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