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What Is a Dispenser?

A jet dispenser is a device that dispenses a fixed amount of solution from a container. It is also simply referred to as a dispenser.

They are often used in industrial applications, such as applying adhesives to gasket materials or soldering small amounts of solder to electronic circuit boards. However, dispensers for hand washing detergents and alcohol sanitizers are commonly used for household purposes.

Dispensers are also named according to their method. The most common type is the air pulse dispenser, in which the solution is dispensed from a syringe.

Uses of Dispensers

The following are some of the main applications where dispensers are used.

• Automobiles
  Automotive parts are made up of many components, which are again made of many small parts. When assembling parts such as instrument panels and bearings, dispensers are used to join the parts together.
  Some dispenser molds have a dispensing tip diameter of only a few millimeters so that even the smallest parts can be handled.
• Electronic parts
  As with automotive parts, many electronic parts are very fine, so dispensers with thin tips are used.
  A typical example is soldering on electronic circuit boards. Conventionally, a method called screen printing has been used. Compared to the past, equipment has become smaller, and more precise parts are required. Since it is difficult for screen-printing to support miniaturization due to the shape requirements, soldering by dispensers is used.

Principle of Dispensers

The principle differs depending on the method, but here we introduce the air pulse method, which is a typical dispenser.

The air pulse system consists of an air source, piping, regulator, controller, and syringe.

First, compressed air is released from the air source. The compressed air travels through the piping to the regulator.

The regulator reduces the pressure of the compressed air and sends the air to the controller at a constant and stable pressure. The regulator is connected to the controller because sending compressed air directly to the controller side would result in damage to the components.

The controller regulates the pressure supply to the syringe. The condition of the supply is set by the operator.

When pressure is applied to the syringe, the solution in the syringe is dispensed.

Although the supply pressure is adjusted by the regulator or controller to be constant, in practice, there is a problem. As the solution in the syringe decreases, the dispensed volume also decreases. To reduce the dispensing volume variation, it is necessary to reset the conditions according to the remaining solution volume.

What Is Transfer Machinery?

Transfer machinery is a general term for equipment used to move goods and materials.

Specifically, there are various types of conveyor, elevator, pipeline, rail, and self-propelled types, depending on the shape and size of the object to be conveyed and the purpose of the conveyance.

Transfer machinery may refer to a single unit, such as a conveyor, a conveyor system integrated into a production system, or a conveyor system integrated into a logistics system, such as a warehouse, factory, or distribution system.

Transfer machinery is generally handled in the factory automation (FA) industry. In many cases, we offer not only single units but also optimal conveying systems for the objects to be conveyed, their contents, installation conditions, and so on.

Uses of Transfer Machinery

Transfer machinery is used to move goods and materials in distribution warehouses for the transportation industry, inventory control warehouses for the mail-order industry, warehouses that handle pickup, packaging, and shipping, production plants, and processing facilities. Movement includes horizontal, elevated, inverted, rotary, and fluidized movement, and conveyor units are used for each of these applications.

If the purpose cannot be achieved by the conveyor unit alone, they are combined and used in a system that performs the desired conveyance.

Principle of Transfer Machinery

1. Conveyor Transport

Conveyor units are available in belt, chain, and roller types. In the belt or chain type, the belt or chain is stretched around a certain section of the conveyor. In the roller type, rollers are placed at regular intervals over a certain section.

The belt, chain, or rollers are then rotated by a motor. By placing the object to be conveyed on the belt, chain, or rollers, the object is moved parallel to the belt, chain, or rollers.

2. Rail Transport

In the case of rail conveyance, rails are installed in the conveyance section. A container equipped with a drive unit is installed on the rail, and the container is driven while the object to be transported is placed inside the container.

3. Inverted Conveyance

In conveyance, it is sometimes necessary to invert the object to be conveyed in order to align the direction of the object. For example, bottles that are lying on their sides may need to be placed upright and their contents placed inside.

In such cases, a mechanism is needed to convey the object while inverting it.

4. Rotary Conveyance

In conveyance, there are cases where it is necessary to rotate the object to be conveyed in order to align the direction of the object. For example, labels on boxes flowing in an indeterminate direction may need to be aligned.

In such cases, a system that rotates the object to be conveyed is required.

5. Lifting and Lowering Conveyance

In some cases, conveyance may require moving an object up and down. For example, the object may need to be moved up and down from the height of a shelf to the height of a conveyor.

In such cases, a mechanism to raise or lower the object to be transferred by machinery is required, and equipment, such as a lifter or elevator, is used. 

6. Pipeline Conveying

In some cases, powder or granular materials are conveyed. For example, food flour or pellets of plastic material are moved in an unpacked state.

In such cases, a pipeline is installed in the conveyance section and gravity or air pressure is used to move the material through the pipeline. 

7. Self-Propelled Conveyance

Transfer machinery includes self-propelled automatic guided vehicles (AGVs), which can be programmed to travel along any route and do not require any transfer equipment along the route.

Therefore, AGVs are used in outdoor locations where it is difficult to set up Transfer Machinery.

Other Information on Transfer Machinery

Difference From Logistics

Although you may see articles that refer to transfer machinery as “logistics,” in reality, transfer machinery and logistics are two different things. Logistics is the centralized management of the entire flow of goods, including procurement, distribution, processing, and shipping.

In contrast, transportation may be a part of that process, but it does not cover the entire scope of the process.

What Is a Seamless Pipe?

A seamless pipe is a pipe with no joints in the longitudinal direction of the pipe.

Steel pipes are generally manufactured by rounding steel plates into a cylindrical shape and welding them together. However, the presence of joints in pipes can lead to serious accidents in terms of strength and reliability, such as crude oil leaking from pipes depending on the intended use.

Seamless pipes are manufactured using the Mannesmann method or other methods that do not produce joints that could cause a reduction in strength. Since there is no risk of defects occurring at joints, seamless pipes are used when high strength and reliability are required.

Uses of Seamless Pipes

Seamless pipes are widely used to transport fluids such as gas, oil, and water. There are also many types of seamless steel pipes, as there are also pipes for construction applications.

• Seamless Pipes for Construction
• Seamless Steel Pipes for Fluid Conveying
• Seamless steel pipes for high-pressure boilers
• Cold-drawn precision seamless steel pipe

Since the materials and standards of seamless pipes vary depending on the application, it is necessary to select the seamless pipe that best suits each purpose. Examples of specific applications include oil and natural gas facilities, boiler tubes for thermal power plants, and high-pressure piping for industrial machinery.

Principle of Seamless Pipes

The Mannesmann process is the typical manufacturing method for producing seamless pipe. It is the most productive way to produce seamless pipe. Simply put, the Mannesmann method forms pipes from round bars, not steel plates. Since the pipe is formed from a round bar, no joints are created.

In the mannequin method, the material for the round bar-shaped pipe, called billet, is first heated to a high temperature (about 1,300°C) until it becomes bright red. When the billet is ready to be rolled, a tool called a plug (for seamless pipe bore forming) is pressed against the center of the billet to form it into a pipe.

If the plug is just pressed against the billet as it is, the billet will be pushed out to the outside and will not be formed into a pipe shape. Therefore, the billet is formed by holding the outer circumference with rolls such as cone and barrel molds. The material pushed out by the plug is pushed forward, so the outside shape can be formed while the inside diameter is formed.

In general, severe rolling of hot billets inevitably results in deterioration of surface properties. Similarly, thick-walled products, which are subjected to a lighter rolling process, are relatively easier to produce. However, there are now companies that specialize in thin-wall processing despite seamless piping. They range from ultra-thin small-diameter seamless pipes with a thickness of 0.08 mm to large-diameter seamless pipes with a diameter of 426.0 mm, the largest diameter ever manufactured in Japan.

Other Information on Seamless Pipes

1. The Difference Between Seamless Pipe and Welded Pipe

The difference between seamless pipe and welded pipe is the use of welding in the pipe manufacturing process. The reason why seamless pipe is needed in the first place is that “grooved corrosion” occurs at welded joints.

This groove corrosion is a V-shaped corrosion that occurs on the weld (inside) of the pipe. Because welding is generally accompanied by high temperatures, changes in the metallurgical structure of the joint are inevitable. The difference in microstructure between the weld and the base metal causes a potential difference, which in turn causes corrosion. Once corrosion occurs, the formation of grooves accelerates corrosion, which eventually reaches the surface of the pipe or leads to fluid leakage due to lack of strength. This is the mechanism of grooved corrosion.

The primary reason for selecting seamless pipes is to prevent groove corrosion, but there is also a type of welded pipe called groove corrosion-resistant steel pipe. Groove corrosion-resistant steel pipes are made by adjusting the molecular composition of the base material (reducing sulfur content) and adding special elements to the weld zone. They are more expensive than ordinary pipes, but not as expensive as seamless pipes, and are widely used for liquids that pose no risk of leakage, such as water.

2. Price Difference Between Seamless Pipe and Welded Pipe

This section describes the price difference between seamless pipe and welded pipe (ERW pipe is used here as an example). Here, as an example, we consider SUS304 as the material. The price of a seamless pipe is about 1.5~2 times higher than that of an ERW pipe. The price difference is small when the pipe diameter is small, but the larger the diameter, the larger the price difference.

When considering a whole plant, the price of piping alone is 1.5~2 times higher than that of a single pipe, so the price difference is not that great when replacing a part of the piping, but when constructing a new plant, the overall cost changes significantly. Therefore, it is important to select appropriate piping according to the fluid to be handled to reduce costs.

What Is a Digital (Video) Microscope?

A digital microscope (or video microscope) is an instrument used to magnify an object for observation. However, the term digital microscope generally refers to a microscope equipped with a digital camera and is distinguished from an optical video microscope. Compared to optical video microscopes, digital microscopes have a deeper depth of focus and the ability to measure angles and lengths, which are their main features.

An optical microscope has two lenses, an objective lens, and an eyepiece, while digital microscopes have only an objective lens, and the part corresponding to the eyepiece lens is a digital camera. This can be said to be the most significant difference between an optical microscope and a digital microscope. The digital microscope usually projects the observed object on a monitor.

Several models are available from various manufacturers, with magnifications ranging from several times to several thousand times.

Uses of Digital Microscopes

Video microscopes are used not only for magnifying and observing objects but also for evaluations and analyses based on the obtained image data.

They have been introduced in varied fields such as the automotive and aviation industries, the electronic device industries, the medical and cosmetic industries, and the chemical and material industries, and are used in a wide range of applications from research and development to quality assurance.

For example, in failure analysis of electronic components, digital microscopes can be used to inspect the appearance of IC chips, analyze failures of defective products, inspect foreign objects, and analyze their size and shape.

Principle of Digital Microscopes

In a digital microscope, an object is magnified by an optical lens (objective lens), and the part that corresponds to the human eye in optical microscopes is a digital camera. The image magnified by the optical lens is detected by the image sensor and the image is displayed on a monitor.

The magnifying power of optical microscopes is expressed as the product of the magnifying power of the objective lens and the eyepiece. In the case of digital microscopes, however, the size of the monitor and the size of the image sensor of the camera affect the magnifying power, which is different from the concept of magnifying power of optical video microscopes. Digital microscope’s magnification is also expressed as the product of the magnification of the objective lens and the magnification of the monitor. The magnifying power of the monitor is calculated by dividing the monitor size by the image sensor size.

In addition to magnification, resolution, or the ability to distinguish details, it is necessary to observe an object in greater detail. If the resolution is not sufficient, the observed image will be blurred and details cannot be observed clearly. In the case of digital microscopes, the resolution of the objective lens, the resolution of the optical lens of the digital camera, the resolution of the image sensor, and the resolution of the monitor all affect the resolution.

It is necessary to select a model that provides optimal magnification and resolution according to the object to be observed and the purpose. To meet user requirements for these advanced resolution processing capabilities, 4K monitor-type images have recently been introduced.

Other Information About Digital Microscopes

1. Use of Digital Microscopes in Dentistry

One of the applications of digital microscopes is in dentistry. By taking advantage of the focusing function of digital microscopes, it is possible to observe minute-affected areas that are difficult to detect with the naked eye.

In particular, when performing root canal therapy, which is the complete removal of caries, digital microscopes are used to make it possible for the dentist to remove as much of the affected area as possible. 

The use of digital microscopes improves the quality of treatment and reduces the risk of recurrence due to overlooked areas. However, it should be noted that dental treatment using video microscopes is, in principle, not covered by insurance and must be paid out-of-pocket.

2. Cosmetic Use of Digital Microscopes

Digital microscopes are also used for cosmetic-related treatments and diagnoses, such as cosmetic surgery and scalp checkups. By looking at the skin under microscopic magnification, details such as dryness of the skin and the development of the hairline can be observed.

Clients undergoing cosmetic surgery can also gain a sense of satisfaction from the medical examination by being able to check the condition of their skin and scalp on the screen. It also motivates the client to improve their condition. 

3. Examples of Functions of the Latest Digital Microscopes

Digital microscopes are nowadays often used for detailed analysis of the inside of electronic components and semiconductor ICs down to a few microns, replacing scanning electron microscopes (SEM), which require observation in a vacuum. For this purpose, for practical use, it is necessary to increase magnification and resolution by orders of magnitude from a few millimeters to a few microns during observation.

This operation requires changing the objective lens as in optical video microscopes, but some digital microscopes in recent years have built-in automatic rotation for lens change and automatic focusing function for lens change, making this process almost fully automatic.

In terms of image processing, there are now highly functional types that can combine images with high magnification into a single large image by arranging them vertically and horizontally like tatami mats, and that can process an object into a three-dimensional (3D) image by utilizing the image focus adjustment function.

There are examples where digital microscopes are used to check the wiring of semiconductor ICs and to analyze internal defects in electronic components by combining these functions.

4. Digital Microscope Prices

The price of digital (or video) microscopes varies depending on their applications and performance. Digital microscopes with a narrow range of magnification and field of view start at around 10,000 yen, while those used for beauty molding or simple inspection of the scalp are priced at around 50,000 yen, and those used for medical purposes are in the 100,000 yen or more range.

Furthermore, digital microscopes such as those used for product inspection in the manufacturing industry, such as semiconductor manufacturing, require high magnification and micron-level magnification, high-resolution image display, so the price range is generally in the several million yen range.

Low latency screen display and high frame rate are also important for use in surgery and treatment, but digital microscopes with low latency and high frame rate tend to be priced higher. In addition, there are products on the market that allow the magnification of the display to be enlarged by changing the lens. In this case, the image processing capability is also advanced, and the price increases further due to the need for a dedicated monitor and sophisticated control software.

What Is a Seam Welder?

A seam welder is a machine that performs welding by pressure welding. It is used in fusion welding, pressure welding, and brazing, applying pressure to heated metals to join them. Seam welders enable high-precision welding with less dependence on the welder’s technical skills.

Uses of Seam Welders

Seam welders are essential for manufacturing products requiring airtight seals, such as canned juice, food, and fuel tanks. They are also used in producing cases for sensors and electronic devices that must be sealed from the outside air. This includes quartz devices and MEMS, which integrate semiconductors, sensors, actuators, and electronic circuits. In the automotive industry, seam welding is utilized to enhance the rigidity of fuel tanks and structural components, offering continuous joints that increase body strength compared to spot welding.

Principle of Seam Welders

Seam welders join materials by sandwiching them between two roller electrodes that transmit an electric current, melting and fusing the parts with applied pressure. The process achieves continuous sealing by rotating the rollers, with the machine settings, such as welding speed and current magnitude, predetermined for automatic operation. Suitable for welding thin plates, seam welding is a type of resistance welding that relies on electrical resistance to generate heat.

Other Information on Seam Welders

1. Advantages of Seam Welding

• Accessible to operators without advanced skills, thanks to preset conditions on the seam welder.
• The pre-joining accuracy of the flange portion is less critical, as it is adjusted between rollers during welding.
• Offers a safer working environment with no sparks or flashes common in other welding processes.

2. Disadvantages of Seam Welding

Seam welding requires significant initial investment due to the size and cost of seam welders, and the process consumes considerable electricity due to the heat generated by electrical resistance.

What Is a Sequencer?

A sequencer, also called a programmable logic controller (PLC), is a device that controls the operation of a machine according to a programmed condition or sequence.

Its name comes from the sense of something that moves a machine in sequence. In recent years, sequencers can also control analog signals such as pressure and communicate information between devices.

Uses of Sequencers

Sequencers are mainly used industrially. They can be found in a wide variety of applications, ranging from heavy industrial infrastructure such as power plants and waste disposal plants to processing plants that make microchips. Sequencers are mainly used to automate machinery and equipment. They allow machines to automatically perform repetitive operations, thus saving labor.

Home appliances such as washing machines also use sequence control, but microcomputers are used for the control devices. This is because it is more economical to use microcomputers for mass-produced machines. Sequencers are often used for certain industrial equipment, and in everyday life, you may see them in the driver’s seat of a train.

Principle of Sequencers

A sequencer consists of a power supply unit, board, input unit, output unit, memory, and arithmetic unit (CPU). The internal drive power supply of the sequencer is a weak DC voltage; a commercial power supply of about 100 VAC to 240 VAC is converted to a weak DC voltage in the power supply section.

The power supplied from the power supply unit is distributed to each part by the board. The board also transmits input/output signals from the arithmetic section to the input/output section. Input signals from sensors and pushbutton contacts are transmitted to the input section of the sequencer. Depending on the type of input section, contact digital signals or voltage analog signals can be input.

In the sequencer, decisions are made based on a program written in advance by the arithmetic section. The arithmetic section constantly scans the program at ultra-high speed. When an output decision is made by the program, an output signal is sent from the output section of the sequencer.

The output signals are used to operate motors, lamps, and other devices. Like inputs, output signals can be analog or digital outputs. Programs and input/output devices on/off information are temporarily stored in the sequencer’s memory. The ladder diagram method, in which the sequence circuit is logicized, is frequently used for the program.

Programming tools exist for each device of each company, and these tools are used to edit the program. Inside the sequencer, analog signals are also treated as digital signals. Digital signals refer to data represented only by 0s and 1s, while analog signals represent not only 1s and 0s but also continuous data. Examples of analog data include measuring instruments such as thermometers and pressure gauges.

Advantages of Using Sequencers

The greatest advantage of using a sequencer is the labor-saving wiring for control. In the case of digital input/output only, it can be reproduced by a relay circuit without using a sequencer. However, if relay circuits are used for complex control, the wiring becomes more complicated, and production and maintenance take an enormous amount of time. In complex control, sequencers are often used for labor and cost reasons.

In recent years, automatic data collection and complex signal processing can also be realized with sequencers. Some devices can communicate with the Internet via an Ethernet port or wirelessly with a PC. Sequencers have also become more reliable, with redundant power supplies and arithmetic units becoming possible. Today, sequencers are indispensable in industrial settings.

What Is Electronic Load?

An Electronic Load is a device that is connected to the device under test and functions as a load resistor.

Conventionally, a resistor was connected to the device under test and used as the load, but the resistor had to be replaced every time the resistance value was changed. The advantage of an Electronic Load is that the load size can be set arbitrarily.

By using an external controller, the load setting can be switched at high speed. In addition, there are functions such as constant-current mode, in which a constant current is applied from the device under test, and constant-voltage mode, in which the output voltage of the device under test is maintained at a constant level, making it suitable for a variety of measurements and tests.

Applications of Electronic Loads

Electronic Loads are used for performance evaluation tests and product inspections of electronic circuits, power supplies, batteries, and other devices. Specifically, the following are some of the uses of electronic loads:

• Driving capability of Electronic Loads in electronic circuits.
• Load characteristic testing of power supplies.
• Charge/discharge testing of batteries.

In addition, since the load can be controlled by an external controller, it can be used to automate testing, such as by changing the load conditions to suit the purpose.

Functions of Electronic Load

Electronic Load has a built-in amplifier composed of a bipolar transistor or FET that controls the current (load current) drawn into it. The characteristic functions are described below.

1. Power Consumption/Conversion Method

The method of power consumption and conversion depends on the type of Electronic Load.

Thermal Conversion Type Electronic Load
The power consumed in Electronic Load is converted into heat by the semiconductor elements that make up the amplifier. This is apparently the same effect as when current flows through a resistor, but since the semiconductor elements generate heat, a heat dissipation mechanism is required.

Power Regenerative Electronic Load
Electric power input into an Electronic Load is converted into alternating current by an inverter. Since the converted current is returned to the power distribution network, power consumption is small and heat dissipation is relatively simple. However, since the regenerated power energy is returned to the power grid, it is limited to environments where grid-connected operation is possible.

2. Electronic Load Operating Modes

In general, Electronic Loads are equipped with the following four modes, and the most appropriate mode is selected according to the purpose of the test:

Constant Current Mode
In this mode, the Electronic Load operates with a set constant current, regardless of its input voltage. The Electronic Load is adapted so that the load current remains constant even when the output voltage of the device under test fluctuates.

Constant Resister Mode
In this mode, the set resistance value is held constant like a fixed resistance. It is characterized by maintaining the set resistance value except during the transient period immediately after power-on. This mode is useful for conducting capacity tests on batteries, star-tup tests for electronic equipment, and other scenarios where load current needs to vary linearly with input voltage.

Constant Voltage Mode
This mode maintains the output voltage of the device under test at a constant value. When the output voltage of the device under test fluctuates, the Electronic Load changes the load current to maintain a constant output voltage. As a result, the output voltage of the device under test remains constant, although the load current fluctuates.

It is often used for testing fuel cells and battery chargers, among other. In battery charger testing, complex battery voltage behavior can be reproduced and tested with Electronic Loads.

Constant Power mode

In this mode, the Electronic Load works to consume the set power. First, the voltage of the device under test is measured, the current value is calculated based on that voltage and the set power value, and the current is drawn accordingly.

How to Select an Electronic Load

Electronic Loads are indispensable in the development and production of power sources such as power supplies and batteries when testing the performance of each device. The following are some considerations when selecting an Electronic Load device: 

1. Power Capacity and Withstand Voltage

If the device under test is a power supply, it should, in principle, have a power capacity that covers its maximum output power. The withstand voltage specification must also be greater than or equal to the voltage that may actually be applied to the device. 

2. Minimum Voltage That an Electronic Load Device Can Handle

Electronic Loads are generally difficult to use in the lower voltage range, and the minimum voltage that an Electronic Load can handle is called the minimum operating voltage. As mentioned above, Electronic Loads control the current that flows through an amplifier composed of a bipolar transistor or FET. Therefore, if the voltage is below the voltage at which that amplifier operates, the Electronic Load will not operate properly.

As a result, the current cannot be drawn at a lower voltage than a certain voltage. That is, if the voltage at both ends of the Electronic Load is lower than the minimum operating voltage, it will not operate.

3.Ambient Temperature and Time

For Electronic Loads, attention should be paid to the specifications of the ambient temperature that guarantees the maximum load. In particular, it must be taken into account that thermally-converted Electronic Loads are limited to use at high temperatures because the ambient temperature rises due to their own heat generation.

In addition, there may be a limit to the time that the maximum load can be maintained, so it is necessary to check the descriptions in catalogs and spec sheets in advance.

What Is a Permalloy?

A Permalloy is a type of nickel-iron alloy, especially one with a nickel content of 35-80%.

The name Permalloy is common, but the official name defined by the Japanese Industrial Standard JIS C 2531 is an iron-nickel soft magnetic material. A Permalloy has a low coercivity and high permeability and has the characteristics of a high magnetic shielding effect and a high magnetic focusing effect.

Another property is that it can exhibit high magnetization when a fine magnetic field is applied, and it also increases the impedance in AC circuits.

Uses of Permalloys

Permalloys are used to prevent magnetic leakage from magnetic heads installed in magnetic recording devices such as TVs, PCs, videotapes, and hard disks. The aforementioned properties make permalloys suitable as a magnetic shielding material.

In addition, biomagnetic measurement, a next-generation diagnostic method that has been attracting attention in recent years, requires the measurement of extremely weak magnetic fields and must be shielded from the effects of environmental magnetic fields. Therefore, a magnetically shielded room with permalloy magnetic shielding has been installed to prevent the influence of environmental magnetic fields.

Principle of Permalloys

Permalloys are a type of nickel-iron alloy with a nickel content of 35-80%, but raw permalloys do not have a very high magnetic permeability. Permalloys undergo a process called “magnetic annealing” and “strain relief burning.”

1. Magnetic Annealing

Magnetic annealing is a heat treatment to remove oxide films, etc., which prevents the movement of magnetic domains where the magnetic moment of the atoms in permalloys are aligned. This removal of impurities allows the external magnetic domains to move.

The removal of these impurities promotes the movement of magnetic walls and rotation of magnetic domains when an external magnetic field is applied, thereby improving soft magnetic properties. The magnetic permeability of permalloys after magnetic annealing is about 100 times higher than that of permalloys before magnetic annealing.

2. Strain-Relief Burning

Straining and burning is a process performed at lower temperatures than magnetic annealing to remove residual stress by recrystallization. The purpose is to make it easier to process. It is also possible to achieve even higher magnetic permeability by adding molybdenum, copper, or chromium.

Other Information on Permalloys

1. Main Types of Permalloys and Magnetic Properties

There are several types of permalloys, which are used for different purposes. Two of the most commonly used are Permalloy B (PB) and Permalloy C (PC), where PB is a binary alloy of iron and nickel and PC is a multi-alloy of iron, nickel, molybdenum (Mo) and copper (Cu).

In magnetic materials, the higher the saturation magnetization Bs, which indicates the absolute value of magnetic force, the more suitable the material is for magnetic shielding in strong magnetic fields. On the other hand, the larger the magnetic permeability μ (the larger the maximum permeability near saturation magnetization Bs), the more suitable it is for magnetic shielding in weak magnetic fields because it can respond to changes in weak magnetic fields.

In this case, the maximum permeability of PB and PC are 50,000 and 180,000, respectively, and the saturation magnetization Bs is 1.55T for PB and 1.72T for PC. In other words, PB with large saturation magnetization is suitable for shielding in strong magnetic fields, while PC with large permeability is suitable for shielding in weak magnetic fields.

2. Practical examples of Permalloy Cores

In addition to its function as a magnetic shield as described above, permalloys also have a function as a core that detects weak magnetic fields increases the magnetic flux for output, and is used as a core for current sensors and transformers. A current sensor is a sensor for measuring electric current. When current flows through a conductor, magnetic flux is induced in the core, and the magnitude of the magnetic field is used to measure the current value.

A transformer is a device for converting voltage and insulating between circuits; it consists of an input coil and an output coil wound independently on a single core, and when current flows in the input coil, voltage is output to the output coil by the nature of electromagnetic induction. The use of Permalloys, which have high magnetic permeability, makes it possible to downsize the transformer. 

3. Workability of Permalloys

Permalloys are flexibly deformable and have excellent workability. Like other metals, it can be processed by bending, cutting, pressing, and punching. However, nickel alloys, of which permalloys are a part, are representative of materials that are generally considered difficult to cut. For this reason, cutting permalloys requires a high level of technical skill.

Permalloys are widely used in magnetic shields, measuring instruments, magnetic heads, audio equipment, communication cables, etc., and are processed and used in a variety of shapes, including cylindrical, plate, ring, wire, and foil shapes, depending on the application.

What Is a Mobile Robot?

A mobile robot is a robot that can perform simple transportation tasks.

In recent years, mobile robots have been introduced in a great number of workplaces, but in the past, conveyance tasks such as moving products on production lines were mainly performed by human operators. However, as technology has developed, the need for automation has increased, and mobile robots have become widely used at many production sites, helping to reduce human resources and improve productivity.

As a result, mobile robots have become widely used in many production sites, freeing workers from the heavy and simple tasks of simply transporting goods, and providing greater benefits in terms of safety and quality. Recently, more and more robots are equipped with AI functions, and they themselves are able to determine the best route and transport packages to a predetermined location.

Uses of Mobile Robots

Mobile robots are widely used in factories, not only for transportation but also for replacing tasks traditionally performed by humans.

1. Automobile Parts Manufacturing Plants

Mobile robots are used to transport heavy parts and perform simple tasks that are prone to errors and omissions when performed by humans. Also, by combining automatic control devices, it is possible to program the start, stop, and movement of operations.

2. Semiconductor Factories

In semiconductor factories, the system can efficiently transport products in cramped spaces, avoiding congestion and obstacles. This helps to reduce human resources and time in the factory.

3. Food Factories

Production lines in food factories often change with the seasons or with the release of new products. By introducing Mobile Robot, the factory can flexibly respond to time-consuming production line changes without having to spend human resources and time. Some factories are also unmanned because they can pack bags, boxes, and apply labels.

4. Distribution Warehouses

Robot controllers are ideal for logistics factories where a lot of goods come and go. The robot’s current position and operating status can be monitored to ensure efficient transport and prevent errors.

Principle of Mobile Robot

Mobile robots vary in individual performance. In this article, we will describe four functions and principles of Mobile Robots dedicated to conveyance that do not require magnetic tape, etc.

1. Safe Traveling

The built-in laser scanner provides 360-degree visibility, allowing the robot to determine its own path and avoid obstacles to avoid collisions. In addition, sensors on both sides, back, and low front prevent collisions.

2. Robustness

By attaching a sturdy metal cover, etc., the robot can transport heavy loads. Some of the largest Mobile Robots can transport loads as heavy as 1.5 tons.

3. Monitoring Function

When multiple robots are used, their movements can be monitored and controlled in real time. Map information can be input to the robot, and instructions can be given to multiple robots at once using communication devices.

4. Safety Function

The power on/off button, as well as the emergency stop button, is provided for an emergency stop. Robots with carts and touch screens are also available.

Other Information on Mobile Robots

Mobile Robot Market

The market for mobile robots is becoming more and more active every year. This is due to the labor shortages faced by developed countries such as Japan and the need for social distance due to the new coronavirus that has recently been raging around the world, and the increasing number of companies around the world that are actively moving to manpower reduction.

The number of companies entering the market is increasing each year due to the flexibility and wider range of specifications that robots can offer, and it is expected that robots will be introduced in production sites other than food, semiconductor, and automotive fixture factories.

What Is a Production Printer?

A production printer is a large printer that prints commercial and in-house printed materials at high speed and with high accuracy.

They are characterized by their ability to handle various sizes of printed materials, as well as a wide range of paper thicknesses and materials. Production printers enable companies to produce vivid, colorful printed materials in-house and reduce costs for business cards, envelopes, clear files, and sales paper, which are often consumed.

Uses for Production Printers

Production printer applications include printing large quantities of presentation materials, high-speed printing of color photographs, business cards, brochures, invitations, envelopes with designs, printing of product packaging, posters for advertising, and clear files with designs.

Vivid printing can be done at high speed on a wide variety of printed materials. When selecting production printers, it is necessary to fully consider the necessary functions, etc., since these products are very expensive, costing about 10 million yen per unit.

Principle of Production Printers

Production printers are mainly composed of a paper feeder, a photoconductor drum, a fusing process unit, a binding system, and a device that transports the printed materials to the respective mechanisms. The paper feeder of production printers feeds a variety of print materials to the fusing process unit and other devices.

To accommodate a wide variety of printed materials, each printer uses air to vibrate and roll up the printed materials for smooth feeding at high speed.

In the photoconductor drum, light is converted into an electrical charge and toner is adsorbed by giving static electricity to the object to be printed. In the fusing process equipment, the toner transferred by the photoconductor drum is fixed by heat treatment. Again, the degree of fusing during heat treatment is changed to accommodate various types of printed materials.

In the bookbinding system, when the printed material needs to be closed, such as a pamphlet, it is bound by heat treatment or by punching holes.

Production Printers Market

In recent years, the market for production printers has been changing.

For example, printed materials (brochures, invitations, direct mail) as a means of reaching customers are being replaced by online advertisements that appear on portal sites and search engines as smartphones become more widespread. At the same time, the paper data output of bookkeeping documents related to corporate business transactions is being replaced by decentralized processing using multifunction office equipment or is even becoming unnecessary due to the trend toward paperless printing. Thus, the market for production printers has been shrinking for a while.

On the other hand, industrial-use high-speed inkjet printers, which have been introduced continuously since around 2010, have grown to account for one-third of the production printers market (figures according to Yano Research Institute Ltd.). The reason for this growth is that inkjet printers do not come into direct contact with paper or other materials, and can therefore print on cloth and cardboard, which were previously impossible to print on. The emergence of high-speed inkjet printers for industrial use has opened up new markets that production printers had not previously targeted, such as printing on clothing and small-lot packages for confectionery, and the market shrinkage trend is slowing.

Production Printers and POD

Print-on-demand (POD) is a technology that prints the required number of copies at the required time.

In the past, production printing was done by analog means (e.g., letterpress printing, as used for newspaper printing. It refers to the printing of large quantities of prints with the same content using analog means (e.g., letterpress, as used in newspaper printing, which offers superior image quality). In recent years, advances in digital technology and MEMS technology (micro-electro-mechanical systems) have brought POD-capable production printers to the market, with expressive capabilities that exceed those of printed materials such as posters in terms of image quality.

POD is also expected to contribute to market expansion in the future, as it allows printing customer names directly on brochures and direct mail, and printing advertising images tailored to customer preferences, one sheet at a time.