KOYAMA BARINDERKOYAMA BARINDER

Offering human oriented production process

SINTOKOGIO, LTD

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)

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 CastingIron Casting

Labor-saving MachineLabor-saving Machine(BARINDER)(BARINDER)

Light Alloy Light Alloy (Aluminum)(Aluminum)

MachiningMachining

Who is KOYAMA?

BARINDERBARINDER 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.

Problem of conventional manual work

• Problem of conventional manual work for removing burrs and fins of casting– Human error (Uneven quality by Human error (Uneven quality by

workers) workers) – Taking time for preparationTaking time for preparation– Numerous hazardsNumerous hazards

What is BARINDER?

• BARINDER is a solution to the conventional manual finishing and de-burring work, realizing automation!!

• HARD !HARD !

•DIRTY !DIRTY !

•DANGEROUS DANGEROUS !!

Problem of conventional manual work

• Hand grinders

■■Grinder for small and Grinder for small and medium size workmedium size work

■■Grinder for large size Grinder for large size workwork

■■Double-end grinderDouble-end grinder

Holding a heavy-weight grinder or Holding a heavy-weight grinder or work with the same posture is a work with the same posture is a heavy work, that obstructs high heavy work, that obstructs high dimensional accuracy finishing.dimensional accuracy finishing.

Problem of conventional manual work

• Safety issues・・ Vibration (White finger disease)Vibration (White finger disease)・・ NoiseNoise・・ Dust flyingDust flying・・ Injury by accidentInjury by accident・・ Heavy work, back pain, etc.Heavy work, back pain, etc.

Back pain

Vibration

Noise, Dust

Hazards

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

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

Advantages by introducing BARINDER

• Sustained quality and dimensional accuracy of finish■ ■ Manual finishing Manual finishing workwork

■■Automatic finishing by Automatic finishing by BARINDERBARINDER

Non-uniform finishNon-uniform finish

Uniform finishUniform finish

Composition of BARINDER

• Main UnitOperation

panelFront

shutter

Hood

Chip and dust collection box

Composition of BARINDER

Work clamp bar

Small wheel

Work

Main wheel

Work set fixture

Break bracket VTR

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.

【 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.

Y-axis

X-axis

Z-axis

A-axis

【 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

Composition of BARINDERPallet changer type• Main unit

Operation panelChange

rotation door

Hood

Safety door

Composition of BARINDERPallet changer type

Work

Work set fixture

Pallet

Work clamp bar Small wheel

Main wheel

【 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.

【 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.

【 Tool: Wheel 】• Grinding tool:

Diamond Wheel

– Main wheel– Small-wheel

Complex shape can be processed by utilizing two different tools.

【 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

【 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.

Programming

• 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.

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.

1. Hand Teaching (available in F300 & F400 Series

Fixture

Main wheel

Clamp unit

Programming

2. Manual pulse generator teachingManual 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.

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)

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)

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

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

Basic BARINDER Models

•300 Series

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

Basic BARINDER Models

•500 Series

ModelX6-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 100kg

Tool Main x 1, Sub x 1

Changer None Equipped Equipped

Basic BARINDER Models

•500 Series

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 block120

sec/pc

Bracket

43 sec/pc

Pipe joint holder

60 sec/pc

Gear box

24 sec/pc

Differential carrier70 sec/pc

Differential carrier80 sec/pc

Cylinder head120

sec/pc

Worldwide users and countries

• 2,600 units of BARINDER sold to worldwide users (as of the end of year 2012)

■Europe　　 UK SWEDEN FINLAND DENMARK HOLLAND BELGIUM GERMANY FRANCE ITALY HUNGARY SPAIN PORTUGAL TURKEY

■Asia JAPAN CHINA KOREA TAIWAN THAILAND MALAYSIA SINGAPORE INDONESIA INDIA

■ 　 North-South AmericaCANADAU.S.A.MEXICOBRAZIL

Major Worldwide Users

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

Thanks & appreciate your attention!

SINTOKOGIO, LTD