月: 2022年12月

What Is a Band Saw Blade?

A band saw blade is a tool in which the saw blade is shaped like a belt.

Band saw blades can be broadly classified into tabletop, stationary, and portable types.

Band saw blades are characterized by the single direction of rotation of the saw blade when cutting, which allows for a cleaner and quicker cutting surface compared to other tools used for cutting.

In addition, cutting with a band saw has the advantage of producing very few sparks during the operation and making a relatively small amount of noise.

Uses of Band Saw Blades

Uses of band saw blades are explained here by type.

The horizontal tabletop band saw blade is the most common shape and is used for cutting aluminum and metal pipes, wood such as plates and squares, and round bars.

A small number of tabletop shield-shaped band saw blades are used for cutting soft materials such as aluminum and wood.

Portable band saw blades are used for cutting objects directly where they cannot be moved or when working at heights.

Stationary band saw blades are large band saw blades and are used in industrial manufacturing.

Principle of Band Saw Blades

The following is an explanation of the principle of band saw blades by type.

Band saw blades are powered by an electric power source, often an AC power source, but there are also rechargeable band saw blades for portable use only.

By using durable metal or bimetal for the blade, the blade is resistant to spills and achieves high cutting performance.

Since the blade portion is shaped like a belt, high cutting capacity can be obtained by adjusting the appropriate tension.

The tabletop horizontal band saw blade is characterized by its ability to perform cutoff cutting, and its structure allows the blade to descend automatically by hydraulic pressure or its own weight, so it is possible to work without letting go of the blade.

The tabletop shield-shaped band saw blade can contour cut by pressing the blade directly against the object for more flexible work, such as curved or vertical cutting.

Portable band saw blades range from light ones for working at heights to heavy ones with casters for easy mobility.

Stationary band saw blades are used for cutting large objects in industrial applications, and therefore have a high cutting capacity and large band saw blades.

What Is Winding Machinery?

Winding machinery are machines that wind metal or enameled wire to produce various types of coil components. Winding machinery winds enameled wire into coil components in a fraction of the time that thread is automatically wound onto the bobbin of a sewing machine. The number and variety of coil parts are quite large, and the winding methods vary. Winding machinery plays an important role because the performance of enameled wire depends on the way it is wound.

Winding machinery comes in manual and automatic models, with the manual model being smaller. There are also different types of winding machines, such as single-axis and multi-axis.

Uses of Winding Machinery

Winding machinery is used to manufacture components such as relays, solenoids, ignition coils, edge-wise, and pickup coils. Winding machinery allows enameled wires to be wound evenly without tangling. The appropriate winding machinery is selected according to the type of winding (vertical, horizontal, etc.) and the thickness of the wire (thin or thick).

Winding machinery is also used to wind welding wire for automatic arc welding and motors for ceiling fans.

Principle of Winding Machinery

The principle of winding machinery is similar to the winding of thread on a sewing machine. Enameled wire is threaded through the winding machinery and switched on to start winding. When the winding is completed, the switch is turned off, and the enameled wire is cut with scissors. In fully automatic winding machinery, all coil components are installed and wound automatically. Many products are computer-controlled, so they are capable of various types of winding.

Winding machinery is selected according to the winding method used for each coil component.

• Spindle Winding
  Winds stepper coils, ignition coils, etc., using spindles.
• Toroidal Winding
  A method of winding a coil in the form of a ring, winding from the center of the ring outward.
• Perfectly Aligned Winding
  Motor stator coils, clutch coils, etc., are wound in perfect alignment, one wind at a time.
• Nozzle Winding
  This winding method can be used from the inside and is suitable for motor windings with inner winding.
• Flyer Winding
  The flyer rotates and winds. Suitable for air-core coils, chip coils, and motors.

What Is a Windlass?

A windlass is a device designed for winding sheet products such as film or hoses. It’s primarily used for winding sheets and similar products, streamlining handling and storage. By coiling long products onto a core, it enables compact handling without compromising the quality of the products.

Windlasses are crucial for optimizing material winding processes and enhancing organization and storage. These devices are ubiquitous in various industrial settings and everyday life, playing a vital role in efficient material handling and management.

Uses of Windlass

Windlasses have diverse applications:

• Yarn and Textile Production: Used in spinning and weaving mills to wind yarn, enhancing handling and processing.
• Wire and Cable Manufacturing: Windlasses coil long wires and cables, aiding in handling and storage.
• Fishing Tackle: Employed for winding fishing lines, maintaining organization, and preventing tangling.
• Chemical Products Manufacturing: Used in reeling sheet products like plastic films and adhesive tapes, ensuring constant winding force to avoid wrinkles.

Principle of Windlass

Windlasses consist of several components:

1. Frame

Provides structural support, typically made of steel or other metals.

2. Motor

Powers the device, selected based on material weight and winding speed. In the case of manual winding, the motor is omitted and a handle is attached instead.

3. Drum

The core component where materials are wound. Its design varies based on material characteristics. 

4. Control Unit

The winder is operated by a control unit. The controller adjusts the parameters of the winding process, such as winding speed and traverse control.

A constant tension must be maintained if the windlass is to wind the sheet product without wrinkling or sagging. However, since the roll diameter increases as the winding progresses, tension cannot be maintained simply by keeping the output of the motor on the take-up shaft constant.

To maintain constant tension during winding, open-loop or feedback control systems like a dancer roll are used.

Types of Windlass

Windlasses come in various forms:

• Turret Windlass: Features multiple winding shafts, automating the winding process.
• Bobbin Windlass: Ideal for winding linear products, ensuring uniform winding diameter and preventing product entanglement.

What Is a Differential Pressure Gauge?

A differential pressure gauge measures pressure differences in fluids. It assesses the pressure disparity between two distinct points, quantifying and displaying the difference. It typically features two ports: one measuring fluid pressure at a specific location and the other at a reference point. The gauge then displays the pressure difference.

Applications of Differential Pressure Gauges

Differential pressure gauges find applications across various sectors:

• Clean Rooms: Installed atop doors to maintain high internal pressure, preventing external contaminants.
• Liquid Level Measurement: Measures pressure difference at different levels in tanks and reservoirs, useful in boilers and pressure vessels.
• Gas Leak Detection: Monitors gas pipelines and tanks for abnormal pressure changes.
• Filter Monitoring: Measures pressure differences indicating filter clogging, prompting maintenance or replacement. Bug filters, for example, are often equipped with a differential pressure gauge, which is used to monitor the clogging of the filter cloth.

Principle of Differential Pressure Gauge

Differential pressure gauges vary in design. A common type, the manometer, utilizes hydrostatic pressure to gauge differences:

1. For Liquids:

Pressure differences are ascertained through liquid height and spring deformation. A glass tube filled with liquid alters height based on pressure differences, which can be read off a scale.

2. For Gas:

Gas pressure differences are measured by the deformation of a spring or diaphragm. This displacement is translated into a pressure difference, displayed digitally or via an analog scale.

Types of Differential Pressure Gauge

Besides manometers, there are other types:

1. Pitot Tube Type:

Utilizes fluid velocity pressure to measure pressure difference, estimating fluid velocity and flow rate.

2. Orifice Plate Type:

Measures flow velocity and rate through a plate in a pipeline, calculating pressure differences.

3. Differential Pressure Transmitter:

An electrical device converting pressure differences into analog or digital signals, using pressure sensors and integrated circuits for signal processing.

What Is a Differential Pressure Switch?

A differential pressure switch is a device designed to detect pressure differences in fluids and activate a switch accordingly. Commonly installed on pipes or tubes, it functions by comparing the pressure between two input ports: one with higher pressure input and the other with lower. The switch is calibrated to trigger at a predetermined pressure differential.

Upon exceeding the set pressure difference, the switch’s internal mechanism changes its state. For smaller measured pressure differences, it is sometimes known as a differential pressure switch.

Applications of Differential Pressure Switches

These switches have diverse applications in multiple industries:

• Fluid Supply and Discharge Control: Used in managing the operation of pumps based on fluid pressure differences.
• Filter Clogging and Pressure Drop Monitoring: They signal warnings or indicate the need for filter replacement when a specific pressure differential is detected, commonly seen in industrial settings.

Principle of Differential Pressure Switch

Differential pressure switches primarily utilize bellows or diaphragms. These components deform in response to pressure changes, with a spring mechanism to reset their position. The spring tension sets the switch’s operating pressure differential. The switches also contain internal electrical contacts that respond to diaphragm movements, altering the switch’s state. Protected by metal or plastic enclosures, these components are safeguarded from external elements.

How to Select a Differential Pressure Switch

Key factors to consider when selecting a differential pressure switch include:

• Contact Quantity and Type: Options range from single to dual-contact switches, with specific models for low-voltage applications.
• Pressure Range: Choose a switch that operates within the required minimum and maximum pressure settings.
• Diaphragm Material: Material choice depends on the measured fluid, with options like fluorine or nitrile rubber, and special treatments for specific uses.
• Connection Port: Ensure compatibility with system and piping, choosing from threaded or flanged types.

What Is a Refractometer?

A refractometer is a device for measuring the refractive index of a sample.

When the light source wavelength, temperature, and pressure are constant, the refractive index is unique to the substance and is used to identify and test the purity of the substance. The Brix sugar meter, which is used to measure the sugar content of fruit juices and beverages, is another type of refractometer that uses the effect of the concentration of sugar in the sample solution on the refractive index.

The refractometer requires precise sample preparation under stable temperature conditions because of the influence of temperature and sample concentration.

Uses of Refractometers

Refractometers can be used to quantitatively measure the refractive index of a substance, which is a measure of purity because it varies from substance to substance. While HPLC or GC analysis is required to determine purity in more detail, a refractometer is the best choice for quick and easy measurement.

1. Food Industry

Brix analyzers are used to measure the sugar content, salt content, nectar content, and other components of food products for quality control and production process management. The Brix Glycometer, which measures the sugar content of food products, measures the refractometer by placing fruit juice or beverages on the measuring section.

Since the refractive index correlates with the concentration of sugars (glucose, fructose, sucrose, etc.), the refractive index can be converted to Brix sugar content (unit: °Bx) and displayed.

2. Pharmaceutical Industry

The concentration, purity, and density of chemical substances are evaluated and used in the development of new drugs and for quality assurance.

3. Biological Research

Determines the composition of biological samples (blood, urine, etc.) for medical research and diagnostics.

4. Chemical Research

Used to monitor chemical reactions and analyze the composition of liquids.

5. Environmental Science

Water quality and oceanographic studies Used to investigate the properties of substances in water.

Principles of Refractometers

The following is an explanation of the principle of the “critical angle method” commonly used in refractometers as an example.

1. A light source emits D-rays in the sodium spectrum toward a prism.
2. When the light enters the sample through the prism, it is refracted.
3. The refracted light is captured by the detector, and the refractive index of the sample solution is displayed based on the angle of incidence and the angle of refraction.

When the light source wavelength, temperature, and pressure are constant, the refractive index is a material-specific value. In quality control of food and pharmaceutical products, this method is sometimes used for purity control, for example, by setting a control range for the refractive index of each item.

In addition to the critical angle method, the refractive index can also be measured by the minimum declination method and the V-block method. Since each of these methods has its characteristics, the measurement method should be selected according to the application.

Structure of Refractometers

A refractometer consists of a prism, a light source, and a detector. The light source and detector are located inside the instrument, while the prism is exposed on the instrument’s surface. The refractive index can be measured by placing a sample solution on the prism and refracting the substance.

Types of Refractometers

1. Liquid Refractometer

Used to measure the refractive index of liquids. The Brix sugar meter is also classified as a liquid refractometer.

The liquid sample is placed in a cell and the cell is attached to a refractometer. Liquid Refractometers are available in three measurement methods: minimum declination, sea angle, and V-block.

2. Solid Refractometer

Used to measure the refractive index of solid samples. It can measure the refractive indices of crystals, films, membranes, and fibers. It is mainly used in physical properties research and crystallography.

As with the liquid Refractometer, it can be used to measure in three different ways: the minimum declination method, the critical angle method, and the V-block method, but for film samples, it can only be used in the critical angle method.

3. Hand-Held Refractometer

Handheld and tabletop refractometers are available, and handheld refractometers are often used when the refractometer is brought into an agricultural field or factory.

Other Information on Refractometers

1. Standards

Measurement standards for refractometers are specified for each object. The main standards followed are the Japanese Industrial Standards (JIS), the American Society for Testing and Materials (ASTM), the ISO standards, and the Japanese Optical Glass Industrial Standards (JOGIS).

2. Refractive Index

Light travels straight through a uniform medium, but when it encounters a medium with different properties, it is reflected or refracted at the boundary. In a non-uniform medium, light rays are continuously bent.

The refractive index determines the trajectory of light rays and is the most important material constant in optics. The refractive index is expressed as “phase speed of light in vacuum/phase speed of light in material.

What Is a Conductivity Meter?

 

A conductivity meter is an instrument used to measure the electrical conductivity of a substance or solution. This measurement is critical in determining the ability of a material to conduct electric current. The device operates by passing an electric current through a sample and measuring the resulting voltage.

Applications of Conductivity Meter

Conductivity meters are essential in various fields:

• Water Quality Testing: They measure water conductivity to evaluate purity and contamination, essential for drinking water and environmental monitoring.
• Mining and Metallurgy: Conductivity meters assess metal presence in ores and control metal dissolution and refining processes.
• Electrolyte Quality Control: In electrolyte solutions like battery acid, they ensure performance and quality.
• Power Generation and Boilers: Used for measuring cooling for water turbines, generators, and other equipment in power plants and monitoring water impurities in boilers.

Principle of Conductivity Meter

Conductivity meters measure conductivity by evaluating the electrical current and voltage in a sample. When voltage is applied, ions and solutes in the sample carry an electrical charge, leading to a voltage drop. The meter calculates conductivity by comparing this voltage drop with the current. Advanced methods include four-electrode systems and multi-frequency current applications for comprehensive conductivity evaluation.

Types of Conductivity Meter

Conductivity meters come in various types:

• Contact Type: Direct contact with the sample, suitable for pure solutions and those without solids.
• Dielectric Type: Uses dielectric properties for measurement, allowing non-contact assessments even in corrosive or high ionic concentration solutions.

How to Select a Conductivity Meter

When selecting a conductivity meter, consider:

• Conductivity Range: Choose based on the conductivity range of your samples.
• Measurement Accuracy: Accuracy varies with the range; select according to your precision needs.
• Sample Characteristics: Ensure the meter is compatible with your sample’s temperature, pressure, and chemical composition.

Conductivity meters are integral in ensuring accuracy and consistency in various industrial and environmental applications.

What Is a Conductive Film?

Conductive film is a thin film made from materials like metals and conductive polymers that can conduct electricity. These films are typically transparent and can be applied to transparent substrates like glass or plastic, making them ideal for use in transparent electronic devices and displays. Their flexibility allows adaptation to curved surfaces and soft materials, broadening their application scope.

Uses of Conductive Film

Applications of conductive film include:

• Touch panels in displays to detect user interaction.
• Flexible displays, benefiting from the film’s flexibility and transparency.
• Solar panels, where these films collect and conduct electricity.
• Diverse sensors, leveraging the film’s conductivity changes in response to physical alterations.

Principle of Conductive Film

Conductive films are typically made from PET film combined with conductive polymers like polythiophene-based semiconductors or PEDOT-PSS. These polymers ensure that the film retains its transparency while being conductive. The resistivity of the film depends on the proportion of conductive materials used. Some films may include metal mesh or charge-carrying ions to enhance conductivity.

In some cases, films are made from materials that contain charge-carrying ions or charge carriers. In this type, ions and carriers move and conduct electricity when voltage is applied. A typical example is a conductive polymer film that contains an electrolyte.

How to Select Conductive Film

Selection criteria for conductive film include:

1. Conductivity

Choosing a film with the right level of conductivity for the intended application is crucial.

2. Transparency

Essential for applications like displays where clarity is paramount.

3. Dimensions and Shape

Ensuring the film fits the design requirements of the product.

Also, consider compliance with environmental standards and certifications where necessary.

Conductive film is key in a wide range of applications for its unique combination of conductivity and flexibility.

What Is a Waveguide?

A waveguide is a tube that passes electromagnetic waves in the vicinity of microwaves or millimeter waves.

In a broad sense, the term can be used for both sound waves and visible light and thus includes optical fibers, etc. However, it is generally used as the name of a tube for passing electromagnetic waves with wavelengths in the vicinity of microwaves and millimeter waves. It is a hollow tube structure with a square or circular cross section.

Microwaves are used in microwave ovens, etc., and are electromagnetic waves that are highly effective in warming objects. Because of their long wavelength, however, optical fibers cannot be used, and special microwave waveguides must be used to transmit the waves from the microwave source to the processing system.

Uses of Waveguides

Uses of waveguides are often for high-power microwave generators, radar antennas, and transmission of signals in the millimeter wave frequency band. For example, in the case of microwave ovens, a low-power microwave generator, such as a household microwave oven, has a magnetron installed inside the housing and can directly irradiate the microwaves.

However, at high power, the magnetron itself is destroyed by the microwaves, so the irradiation process must be carried out in a separate location. High-power microwaves can be supplied by connecting a waveguide to the processing chamber where the heating or other processing takes place.

Waveguides are also used in radar, where they serve as slot antennas for radio wave irradiation devices. As well, coaxial cables can be used for the evaluation of RF and other communication transmission, but in many cases, waveguides are used for sub THz applications in the millimeter wave band.

Principle of Waveguides

The principle of waveguide is based on the physical property that electromagnetic waves of the target frequency propagate inside the tube while forming propagation modes according to the shape of the tube. In the hollow-type structure often used in waveguides, there is no built-in conductor, so there is little internal loss, and it is possible to propagate electromagnetic waves of relatively high power.

As an example, electromagnetic waves with a frequency of 2.45 GHz often used in microwave ovens are also microwaves, and the wavelength of the electromagnetic waves in this microwave oven is 12.2 cm. To pass microwaves in a microwave oven, the diameter of the waveguide must be about the wavelength of 12.2 cm, and the longer the wavelength of the microwaves, the larger the diameter of the waveguide.

Thus, the design of the waveguide is based on the wavelength of the electromagnetic wave. Waveguides are generally rectangular in cross section, but there are also circular waveguides and ridge-shaped waveguides used for special purposes.

Other Information on Waveguides

1. Comparison With Coaxial Cable

Waveguides have often been used in wireless communication systems such as radar and horn antennas in air traffic control towers, but recently they are increasingly being used to develop millimeter wave applications in next-generation wireless communication systems such as millimeter wave radar in automobiles and 5G/beyond 5G. In the past, coaxial cables were used in the microwave band.

Compared to conventional coaxial cables in the microwave band, the following points can be cited as advantages:

• Transmission is possible with low loss, and the power resistance is excellent.
• Metal structure, stable in shape, easy to match, and less reflective.

However, in addition to advantages, the following disadvantages also exist:

• Narrow frequency bandwidth.
• Heavy and expensive.

When the frequency is microwaved, coaxial cables are used more frequently, partly because of the ease of handling cables and partly because the frequency bandwidth is lower than that of a millimeter wave. However, in the millimeter wave band, especially in the high frequency range, including D-band from 110 GHz, coaxial cables, except for some products, are inadequate in terms of characteristics, so waveguides are generally used in many cases.

2. Size of Waveguide Specifications

In the case of waveguides, it is necessary to select a waveguide size that is compatible with various application frequencies. In particular, in the case of a millimeter wave, it may not be possible to use a waveguide with a different flange standard. For your information, “WR-xxx” for waveguide size means “square waveguide,” and the number xxx indicates the inner width of the waveguide in one-hundredths of an inch.

What Is a Light Guide?

A light guide plate is an optical component that allows light sources, such as LEDs, to enter from the edge of the plate and emit light on the surface.

When the surface of the plate is smooth, the incident light repeatedly undergoes total reflection, and the light is emitted on the opposite side of the plate. By processing this smooth surface to change the direction of light, it is possible to make the surface light-emitting.

Light guides are mainly installed on the back of “transmissive LCDs” and are often used in the “backlight method” to illuminate the LCDs, requiring light guides with a high degree of uniformity to illuminate the LCDs evenly.

In recent years, demand for products using “reflective LCDs,” which consume less power and are lighter, has been increasing. Light guides used for reflective LCDs are installed in front of the LCDs in a “front light system,” so light guides with a high degree of transparency are required. However, light guides with high transparency are extremely difficult to process, so the number of manufacturers who can produce them is limited.

The development cycle of electronic devices is expected to shorten further in the future, and Light guides must also be developed in a short period to ensure the superiority of new products.

Uses of Light Guides

Backlight Method

Mainly used as lighting for “transmissive LCD products.” They are used as lighting for products such as LCD TVs and smartphones, as well as for store signboards and poster panels. Demand for general lighting such as ceiling lights is also increasing.

Front Light Method

This type of lighting is mainly used for “reflective LCD products.” It is used for electronic paper, wearable devices, and digital signage (electronic signage). As a new application of the front light method, its use as lighting for “image processing inspection equipment” is attracting attention. By using highly transparent light guides, it is possible to provide a wide field of view to the workpiece while ensuring uniform illumination of the entire area.

Light Guides Manufacturing Method

Light guides can be manufactured by a variety of manufacturers, depending on the purpose of use and quantity.

Injection Molding Method

This is a common method that has been used for a long time. For mass production, it is possible to manufacture at a low cost. However, the mold must be repeatedly modified until the optimum optical pattern is produced.

Main applications: LCD meters, amusement products, smartphones

Laser Processing Method

This is a surface emitting system that uses a laser processing machine to engrave “dots” or “grooves” on the surface of a plate. Many manufacturers are capable of processing, and since molds and plates are not required, manufacturing can be done at a low cost. It is often used for inexpensive products that do not require a high degree of uniformity.

Main applications: Backlight for store signboards, poster panels, shelves, ceiling lights

Screen Printing Method

This system uses a printing plate to print “reflective dots” on the surface of a board for reflection. Although a plate is required, it is less expensive than a molding die. Because of the limited mesh size of the plate, it is often used for inexpensive products that do not require a high degree of uniformity.

Main applications: Backlighting for store signboards, poster panels, shelves, ceiling lights

Inkjet Lens Printing Method

This is the newest method of light guide manufacturing. An inkjet printer is used to produce an “optical lens” on the surface of the plate. The diameter of the lens is extremely small, approximately 32 µm, enabling light distribution design with a high degree of uniformity. The greatest feature of this process is that the lenses themselves are transparent, making it possible to produce light guides with a high degree of transparency, which is difficult to achieve with other manufacturing methods. In addition, since inkjet printers are used and no molds or plates are needed, it is possible to respond to short delivery times and in small quantities. However, the number of manufacturers that can produce this product is limited, and it is not suitable for inexpensive product applications, such as backlighting for store signboards.

Since high-definition printing like that shown in the photo is possible, demand for stand-alone Light guides for use in in-store displays is also increasing.

Main applications: For electronic readers, amusement products, image inspection and processing equipment, pre-production prototypes, store displays

While there are a variety of manufacturing methods for light guides, in many cases, the manufacturing method that best suits the purpose has not been selected. If you are having trouble selecting a light guide, a good way to start is to request a sample prototype from the manufacturer and make a comparative evaluation.