Intelligent Actuator robo expo nov 2009

ROBO ExpoIntroduction to the Next Generation of CylinderIncluding the Mini & Micro ROBO Cylinders

ELECTROMATEToll Free Phone (877) SERVO98

Toll Free Fax (877) SERV099www.electromate.com

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IAI Overview



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IAI Worldwide

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Name

Location

Land

Building Addition

Floor Area Addition

Structure Addition

: IAI Obane Factory

: 416-4 Obane Shimizu, Shizuoka City, Shizuoka Pref.

: 142,040 sq.ft.

: 12,195 sq.ft.

: 115,270 sq.ft.

: 10 stories

New Addition

IAI Head Office – Japan

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2008 Fuji Economic Group Survey

Single Axis Robot (Units Sold)

% M

ark

et

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2008 Fuji Economic Group Survey

Single Axis Robot (Units Sold)

% M

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Introduction to IAI Products

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Robo Cylinder Series

• Compatible with various mounting mechanisms (clevis, trunnion, etc.)

• Multi-point positioning to a maximum of 512 points

• Running cost just 1/3 to 1/10 that of an air cylinder

• Comes with the AQ seal, which minimizes the frequency of greasing

• Four series to choose from: ERC2, RCP2, RCA, RCS2

• New Position Controllers (PCON, ACON, SCON) and Programmable Controllers (PSEL, ASEL, SSEL, XSEL) are available.

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Product Lines

ERC

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Product Lines

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Product Lines

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Product Lines

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Controllers

PSEL SCON SSELASEL

PCON ACON

Product Lines



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Single Axis Position Robo Cylinder Controllers

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2-Axis Robo Cylinder Controllers

• 2 Axes of motion of Robo Cylinders is now possible with a single 2 axis controller

• Applicable to RCP2, RCA, RCS, RCS2 actuators

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2-Axis Applications

Actuators:

X: RCP2-RGD4C

Z: RCP2-RGD4C

Controller:

Actuators:

X: RCA-SA5C

Y: RCA-SA5C

Controller:

Cutting Assembly

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Actuators:

Y: RCP2-SA5C

Z: RCP2-SA6C

Controller:

Pick & Place

Actuators:

X: RCS2-SA5C

Y: RCS2-SA5C

Controller:

Push & Hold

2-Axis Applications

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Single Axis Robots

IS(P)A ISDA

IF FS RS

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Product Lines

SCARA Robots

IX-NSN – High SpeedIX-NNN – Standard

IX-NNW –Dustproof/Splash-proof IX-NNC – Clean Room

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SCARA Robots (continued)

IX-TNN – Wall MountIX-UNN – Wall Mount

Inverse

IX-HNN – Ceiling Mount IX-INN – Ceiling Mount Inverse (Tabletop Mount)

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SCARA Applications

Assembly Measurement & Sort

IX-NNN2515IX-NNN5020

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High Speed

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IX SCARA High Speed Type

• Higher speed motors

• Faster processing

• More intelligent control of payload

• Max payload up to 20kg

• Vertical axis stroke up to 200mm

• Arm length up to 800mm

• Quicker cycle times

• Multiple model types



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Clean Room Type

RCP2CR

IS(P)DCR IX-NNC

RCS2CR

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RCACR



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Product Lines

Dust & Splash Proof(IP65 rated)

IS(P)WA IX-NNWRCP2W-RA4C/RA6C

RCP2W-RA10CRCS2W-RA4CRCAW-RA3C/RA4C

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Moment Load

Torque Load

RCS2-RA13R Ultra-High Thrust Actuator

• Max press force of up to 2 tons (19,600 N)

• Repeatability of +/- 0.01mm

• Move loads of up to 500 kg horizontally and 300 kg vertically

• Brake option available for vertical applications

• The actuator integrates a ball spline to accept radial and rotational loads

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Product Lines



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RCS2-RA13R

1-axis control

Control up to 3 units

XSEL-P/Q

Applicable Controllers

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Product Lines



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• Able to withstand strong/repeated splashes or washing processes

• Watertight, Complete protection from dust

• Two types for different applications

Standard Type

Dust & Splash Proof(IP67 rated)

RCP2W-SA16C

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Actuators:

X, X’: ISWA

Y: RCP2W

Controllers:

Multi-axis Applications

Water Jet Cutting

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Multi-axis Applications

Actuators:

X: RCA-SA4R

Y: RCA-SA5R

Z: RCP2-RTC

Controllers:

CuttingFinishing

Actuators:

ISA-MXM, RS

ISA-MXM, RS

Controller:

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• Eases the inputting of data by directly importing point data from a 2D DXF CAD file to the point table for complex motion paths

• Reduces the errors from manually typing in point value data

• Fine speed control and path precision can be realized

DXF Converter Software with SEL Software

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DXF Converter Software with SEL Software

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Cartesian Coordinate Systems

ICS(P)A2/3-Gantry

ICS(P)A4ICS(P)A2

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Tabletop Robots (TT-200/TT-400)

•Available as cantilever or gantry, and 2 or 3 axes

•Sizes available: 200 x 200 and 400 x 400

•Easy to operate design includes push button start/stop, program select switch, and program number/error code display

•Built in controller will operate with newer X-SEL software

•Pre-configured, compact design allows it to be portable

•Good for work cell production flow; multiple units can feed one robot for part loading

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TT-A3-I-2020-10B

Product Lines

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•Enables a simple method of connecting a PLC to a series of ACON and PCON controllers

•Up to 16 controllers can be connected together

•Controllers can be multiplexed through the use of REXT-SIO units

•REXT-CTL units can also be used to connect SCON and PCON-CF controllers

•Supports DeviceNet, Profibus, CC-Link, or Modbus

•Controllers are DIN rail mounted

•Power and safety connections are connected via a bus and are thus wired once instead of multiple times

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Product Lines



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Latest Products



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Mini ROBO Cylinder

• A great air cylinder replacement

• 18 new models to choose from

• Strokes from 20mm to 288mm

• Lead screw or Ball screw driven

• Load capacity up to 6kg

• Max speeds up to 1600mm/s (with linear servo)

Mini ROBO Cylinder

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Mini ROBO Cylinder



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Mini ROBO Cylinder



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Mini ROBO Cylinder



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Mini ROBO Cylinder



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Mini ROBO Cylinder



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Micro Cylinder RCL

• Compact size (16mm diameter)

• Smooth quiet operation with linear motor

• Built in encoder supports multiple positioning points (up to 512 points).

• Acceleration up to 2G and loads up to 2 kg

• Brake option available for use in vertical applications

Latest Products

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Micro Slider RCL-SA

• Space saving compact linear servo slider

• Smooth quiet operation with linear motor

• Built in encoder supports multiple positioning points (up to 512 points)

• Acceleration up to 2G and loads up to 2 kg

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Latest Products



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PSEP / ASEP Controllers

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Latest Products

Single Slider Single Slider

SpecificationSpecification

Double Slider Double Slider

SpecificationSpecification

•Long strokes up to 3,000 mm

•High Speeds up to 2,400 mm/s

•Up to 80 kg payload

•Up to 1G acceleration / deceleration

•Multiple Slider Specification

•Rotary Nut

•Space-saving Design

NS – Rotary Nut Actuator

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Small Type (60W)

Medium Type (200W)Large Type (400W)

New

New

Latest Products

NS – Rotary Nut Actuator

4848



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Latest Products

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●Two additional sizes to the family: Smaller & Larger Sizes ●Smaller Size is the smallest outside size among the competition● Hollow Output Shaft for installed wiring and equipment to pass through ●Multi-Rotation Type (L) is a standard option

Vertical Type

Medium Size (Existing) Small Size

Flat Type

Large Size

RTB(L)

RTC(L)

RTBB(L)

RTCB(L)

RTBS(L)

RTCS(L)

Robo Rotary (RCP2-RT) : New Smaller & Larger Size

Latest Products

5050



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Latest Products

RCP2-RTL with Multiple Rotation Capabilities

� +/- 9999.99 degrees when commanded to a position

� 18~28 revolutions when commanded to a position

�Unlimited rotations CW or CCW when indexing*

Vertical Type

Medium Size (Existing) Small Size

Flat Type

Large Size

RTBL

RTCL

RTBBL

RTCBL

RTBSL

RTCSL

*The distance of a single rotation during indexing is limited to +/- 360 degrees or less

5151



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Latest Products

Table Type

Slider Type

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Latest Products - Reverse Motor Mount

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IK2 (2IK2 (2--axis linear) Xaxis linear) X--YY

IK3 (3IK3 (3--axis linear) Xaxis linear) X--YY--ZZ

IK Series Complete Kits

• Uses ROBO Cylinder actuators for a compact multi-axis system

• Easy to assemble

• Includes all necessary components for assembly (bolts/brackets/cable track)

• Max speeds up to 1000mm/s and loads up to 24 kg

• Many combinations are available to suit your unique needs

Latest Products

Cartesian Coordinate Systems 2-3 axes of motion

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Cartesian Coordinate Systems

2-6 axes of motion

NS + ISA

(Rotary Nut, Ball Screw)

LSA + ISA

(Linear Motor, Ball Screw)

Latest Products

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Latest Products

ZR Unit

• Available in 2 sizes (Small/Medium)

• Z-axis stroke up to 200mm at 1256mm/s

• R-axis rotation speed 2200 deg/s

• Max payload of 6 kg

•Available as a stand-alone system or can be incorporated into Cartesian system

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Lever Finger

Slider Finger

• Three fingers facilitate centering of load

• High gripping force from a compact body

• Two types for different applications

• Maintains the gripping force even after the power is off

Latest Products – ROBO Cylinder (3 Finger Gripper)

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•Perfect for tight spacing •Easy centering of loads

Latest Products – ROBO Cylinder (2 Finger Gripper)

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Latest Products - ROBO Cylinder (2 Finger Gripper)

RCP2CR, RCP3W

• Available in Cleanroom/Dustproof/Standard Types

• Strokes up to 8mm for slider types and 180 deg for lever types

• Max speed of 78mm/s

• Positioning repeatability of +/-0.01mm/degrees

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Latest Products - ROBO Cylinder (Long Stroke 2 Finger Gripper)

Long Stroke Gripper

• Max stroke of 100mm (50mm per side)

• Available in both standard and high-speed types

• Grip force of up to 40N (20N per finger)

• Repeatability of +/- 0.01mm

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Short Length Type

RCP2/RCA-SRA

• Actuator length shortened by up to 129mm while stroke stays the same for a 45% reduction in length.

• Max payload up to 35kg

• Max speed up to 250mm/s

• Stroke from 20mm to 200mm

•Max push force 170N

Latest Products - ROBO Cylinder (Short Rod Type)

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Latest Products - CON/SEL-TG Teaching Pendant

CON/SEL-TGTeaching Pendant

• Compatible with Safety

Category Class 4 with addition of external safety circuit

• ANSI robot standard compatible 3-position enabling switch

• IP54 protective structure for use in adverse environmental conditions

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Air Cylinder vs. Electric Actuator Efficiency Comparison Demo

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PC Software: More Functions

Old

New

Threshold(for high thrust actuators only)

New ! New ! New ! New ! New !New !

Power Saving Mode (PCON / SCON only)

RCM-101-MW / USB�Position Data

Parameter Editing

�Positioning functions allows easy, continuous movement

(Not used yet)

(ACON / SCON only)

New !

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ROBO Cylinder Benefits



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─ ─

Robo Cylinder Features

Environmental Health

(Saving Energy)

Easily Change Program

Settings for ImprovedEfficiency

Reduced Running Costs

Eliminating Startup Adjustments

Reduce Labor Costs

More Stable Operation

Lowers the Defect Rate

Highly Functional System Reduces the Overall

Production Costs

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PLCAir Cylinder Control

Retreat to end completion signal

Advance to end completion signalAdvancement signal

Retreat signal

Retreat to end signal Advance to end sensor

Output Input

24v DC Power

Air for advancement

Air Cylinder

Air

Compressor Regulator Valve Air for retreat

Lubricator

Flow Control

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No. � � � � � � � � �

0 0 600 0.011 30 400 0.22 70 600 0.2

PLC

Retreat to end completion signal

Advance to end completion signalOutput Input

RoboCylinder Control

Advancement signal

Retreat signal

Robo Cylinder

Attached cable

24v DC Power

(to position 0) (position 0 complete signal)

(to position 1) (position 1 complete signal)

Position, speed and acceleration settings

0.2600702

0.2400301

0.0160000

DecelerationAccelerationStop positionNo.

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1. Position Moves (Multi-Point Positioning)2. Pitch (Incremental) Moves3. Pause (Hold)4. Speed Control (Constant, Variable)5. Acceleration Control

(Independent Accel / Decel)6. Push and Hold7. Zone Output

Robo Cylinder has the following 7 functions

Robo Cylinder Functions

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1. Position Moves (Multi-positioning)

- Function -

A maximum of 512 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.

- Compared 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.

Robo Cylinder Functions 1

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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.


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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. Pitch (Incremental) moves

- Function -

Robo Cylinder can move a specified distance

(pitch) repeatedly in steps.

- Compared with air cylinder -

This function is impossible for air cylinders.

Only electric actuators can offer this.


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


For teaching pendant only

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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.


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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.


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3. Pause (Hold)

- Function -

Robo Cylinder can pause (hold) its movement at arbitrary positions.


It is very difficult to pause an air cylinder during its motion.


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3. 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

3. 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.


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4. Speed Control (Constant, Variable)

- Function -

Robo Cylinder can change speed on the fly.

Robo Cylinder is good for two step speed change (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 ball screw driven mechanism.


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


0.300.30200.00200.001

0.300.30100.00100.000

Deceleration

(G)

Acceleration

(G)

Speed

(mm/sec)

Position

(mm)

No

0.10

10.00

Positioning

Band (mm)

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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)


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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.


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5. Acceleration Control (Independent Accel / Decel)

- Function -

It is easy to change (control) acceleration/deceleration independently.


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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6. Push & Hold

- Function -

Robo Cylinder can quickly move the rod just before the objectiveand slowly push it if it is required.

- Compared with air cylinder –

Air cylinders adjusts its push force by changing air pressure.

Robo Cylinder can easily adjust its push force by PC software orteaching pendant.


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6. Push & HoldRobo Cylinder can push and hold it’s rod to a objective like an air cylinder.


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Auto Door Sealing TAB Bonding

6. 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.


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Gelatin Cutting MachineCushion Insertion Machine for Medicine Bottle Tablets

6. 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.


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7. Zone Output

- Function -

Robo Cylinder can output a signal during movement.

- Comparing with air cylinder -

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.


0.300.3050.00100.000

Deceleration

(G)

Acceleration

(G)

Speed

(mm/sec)

Position

(mm)

No

80.0070.00

Zone +Zone -

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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.


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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 range is set where the actuator moves at a constant speed for printing area.


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1. Position Moves (Multi-Point Positioning)2. Pitch (Incremental) Moves3. Pause (Hold)4. Speed Control (Constant, Variable)5. Acceleration Control

(Independent Accel / Decel)6. Push and Hold7. Zone Output

Robo Cylinder has the following 7 functions

Robo Cylinder Functions

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Cost Savings with Robo Cylinders

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Electric bill of all air compressors in Japan = 1.5 Trillion Yen/year

Compressor’s electricity consumption

Nation wide factories’ electricity consumption= 10% ~ 30%

The Cost of Compressed Air (Japan)

1. Beginning

* Data from Tokyo Institute of Technology

Cost Savings

$15 Billion/year, based on $1 = 100 Yen (Jan 2009)

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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)

Cost Savings

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TOTAL $2,923

In-House Design (Electric)

1. Design cost = $50/hr Assembly, Wiring cost = $40/hr

2. 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$1,108

Cost Savings

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Air cylinder

TOTAL $1,928





$1,553 $125 $200 $50

Cost Savings

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Robo Cylinder





TOTAL $1,295

$1,010 $75 $160 $50

Cost Savings

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RoboCylinder

AirCylinder

In House Design

(Electric)

33%Decrease

33%Decrease

56%Decrease

56%Decrease

TOTAL$2,923

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)

Cost Savings

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Robo CylinderAir Cylinder

How about Rod Type ?How about Rod Type ?


(2) Rod Type

Cost Savings

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TOTAL $629

Air Cylinder

Air Cylinder

Speed control valve

Solenoid valve





$294 $125 $160 $50

Cost Savings

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TOTAL $975

Robo Cylinder

$690 $75 $160 $50

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) Rod Type

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

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 Loss

Air cylinder Loss

Piping-Pressure down Loss

Air filter and other Loss

14%

Data : Tokyo Institute of Technology

Cost Savings

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3

Cost Savings

CostComparison

The rodless type of ROBO Cylinders are affordable even without factoring in the lower running costs.

A rod type air cylinder is initially cheaper but after comparing 3 years of running costs the ROBO Cylinder comes out ahead in price.

ROBOCylinder

Advantage

Lower Defect Rates

Reduce Design and Assembly Time

Conserve Energy for the Environment

Easy To Make Adjustments

Lower Maintenance Time

Reduce Air Leakage Costs

Reduce Cycle Times

Start-up Adjustments Unnecessary

ISO14000 Compliant

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New Controllers with Power Saving Features (ERC2 • PCON • PSEL)

The holding current in standstill state for a pulse motor is larger in comparison than an AC Servo motor.

3

Cost Savings

Two kinds of energy conservation modes are available:

1. Full Servo Control Mode. The pulse motor is servo-controlled to reduce the holding current. The holding current can be reduced by 1/2.

2. Automatic Servo-off Mode. After positioning is completed, the servo will turn off automatically upon elapse of a specified time.

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4. How much is the Compressed Air?

If air pipe has a hole and air pressure is 0.5MPaThe wasted energy (electricity) cost per year due to the leakage is

….

Compressed Air is NOT Free !

Hole Diameter

1mm

10mm

Leakage/year (m )

8,920

890,000

Leakage Cost/year

$245

$25,550

* Data from air products manufacture

3

Cost Savings

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5. 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

Cost Savings

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6. Conclusion Rod type cylinder

Parts Cost Initial Cost Running Cost (3 years)

3 years Total Cost

(Cylinder bore Ø40)

$294

$690$629

$975$534

$33

$1,163

$1,008

Cost Savings

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STARTSTARTPlace Magazine

Conveyo

r

ElevatorMulti-Steps, Precise Positioning

Process 1

Pro

cess

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 with Robo Cylinder

Solar Cell Manufacturing Line (Niigata, Japan)

Solar Cell Assembly Line

Example 1

Application Example 1

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

$277,759590,97619,699,200$9261,97065,664Air Cylinder

$27,77659,09719,699,200$9319765,664Robo Cylinder

Yield lossDefect partsOutput

Yield loss

Defect partsOutput

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

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

$48,0002,40072,000$20010300Air Cylinder

$0072,000$00300Robo Cylinder

Yield lossDefect partsOutputYield loss Defect partsOutput

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

The old machine required adjustment 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 bracketNo adjustment required

Anti-Static blower for DVDIt used to have double stacked air cylinders 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.


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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. Tact 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 tact 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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