月: 2023年1月

What Is a Trolley?

A trolley is a device used to transport products, raw materials, etc. It has wheels under a flat plate on which loads are loaded and pushed by a handle.

By loading cargo on the flat plate, more cargo can be loaded than if it were carried by hand, and once it starts moving, it can be moved smoothly because the resistance between the wheels and the ground is reduced.

While hand-pushed carts are the most common type of cart, some electric carts are also available to assist in work.

Uses of Trolleys

Trolleys are used everywhere to transport relatively lightweight loads.

The most common type is the single-sided trolleys with a handle on one side. In the transportation and retail industries, box trolleys are often used for moving and storing high loads, and double-sided trolleys with handles on both sides are used for transporting heavy loads.

Some trolleys are developed not for pushing as they are, but for towing with forklifts, etc. for the purpose of transporting heavy loads.

Principles of Trolleys

The behavior of trolleys can be explained by the equations of motion in physics.

When trolleys are loaded with a load and pushed, it will initially remain stationary due to the weight and the frictional force between the wheels and the ground. It starts moving when the applied force exceeds the starting resistance force.

Since the starting resistance force is proportional to the ground contact area of the wheel, the harder the wheel is that is less deformed, the less the resistance force becomes, and the larger the wheel is, the more the torque increases, allowing the wheel to move with less force. The design is made in accordance with the intended use.

Although trolleys can transport heavy loads, when the load is stacked high and the center of gravity is high (as indicated by the height of the handle), the moment of rotation around the center of gravity is activated, causing the load to collapse or topple over due to the difference in level or inclination of the location where it is used. The tread and wheelbase of the wheels are designed according to the expected weight, and the use of trolleys with stoppers is recommended on sloping terrain.

What Is a Woodworking Clamp?

A woodworking clamp is a tool used for securing wood to a jig or for gluing pieces of wood together.

Clamps are indispensable in woodworking; without them, progress is difficult. Attempting to work on materials without proper support can lead to poor workmanship and even injury.

Using clamps ensures clean and safe work, particularly when operating power tools that often require both hands.

Uses of Woodworking Clamps

Woodworking clamps are primarily used for fastening and gluing wood to jigs. Here are some key applications:

• Clamping materials to the workbench for cutting, grinding, or chamfering.
• When drilling holes, placing a waste board under the material and securing it with clamps prevents gaps and ensures a smooth finish.
• For gluing, use clamps to hold the edges together to prevent slipping until the glue sets.
• When assembling, temporarily secure the clamps using nails, screws, or adhesive bonds.

How to Choose a Woodworking Clamp

There are various types of woodworking clamps, each suited for different applications:

• “Quick bar clamps” are ideal for sawing and assembly work. Also known as “ratchet bar clamps,” they are operated with a handle and lever, easy to handle with one hand, making them suitable for beginners.
• “F-type clamps” are recommended for cutting with power tools like circular saws and for grinder processing. Also known as “sliding clamps,” they feature a screw on the handle for tightening and adjustable mouth width.
• “C-type clamps” are best for crimping small objects or for strong fastening. They provide high clamping force, but the metal part can dent or scratch the material.
• “Corner clamps” are used for holding corners of materials vertically, useful for making box corners and picture frames, especially for materials cut at 45 degrees.
• “Spring clamps,” similar to large clothespins, are used for gluing thin materials. They are also known as “hand clamps” and have a narrow opening.
• “Belt clamps” fasten materials like picture frames in one operation, tightening a square with a belt.
• “Pipe clamps” have fittings attached to a gas pipe, allowing for clamping materials of various widths. They provide strong clamping force, ideal for making large items.

What Is Forging Machinery?

Forging machinery is a machine used to shape or forge metal materials by applying pressure to them.

Forging machinery can be broadly divided into hammers and presses. These include air hammers and steam hammers that use compressed air or steam, as well as drop hammers that drop large hammers by gravity. Presses, on the other hand, are classified into hydraulic presses and mechanical presses based on the method of load generation.

While hammers can apply large pressure, it is difficult to control the load, making high-precision forging difficult. Mechanical presses are used, especially when precision forging is required.

Uses of Forging Machinery

Forging machinery is used in the manufacturing and processing of hardware, such as kitchen knives and pliers, as well as automotive and aircraft parts that require high-strength metal materials.

Forging machinery is used for automotive parts such as crankshafts, gears, tire wheels, and bearing races. In aircraft parts, they are often used for jet engine parts and fuselage frames.

Other industrial parts include bolts, couplings, and valves. Forging Machinery is used when high strength is required and parts are not easily deformed when heated.

Principle of Forging Machinery

Forging has long been used as a processing method to shape metal materials by striking them. The process by which forging increases the strength of metal is fairly well understood.

When metal is compressed and stretched sufficiently by forging, a crystalline structure called a metal flow line (forging flow line) is formed. This metal flow plays an important role, but castings that are not forged do not have metal flow and are not strong enough to withstand bending stresses.

In forged metal, metal flow follows the shape of the material, making the metal stronger and more durable. Forging Machinery strikes the metal with a hammer or press to produce metal flow.

In hammer forging, the weight of the ram or compressed air is used to impact the metal strongly. Presses, on the other hand, use hydraulic pressure to pressurize a cylinder forcefully or convert the rotational motion of a motor into linear motion by means of a crank.

Types of Forging Machinery

1. Hammer Forging Machinery

Forging hammers are forging machines mainly used in hot forging. There are pneumatic hammers, counterblow pneumatic hammers, spring hammers, etc.

Pneumatic Hammer
A pneumatic hammer is a machine that blows and shapes a workpiece by accelerating and dropping a driving unit called a ram by air pressure. It is characterized by its high impact energy.

Counterblow Air Hammer
The workpiece is pulled up from the jig at the same time as the ram drops and struck. It is characterized by increased pressure and low vibration.

SpringHammer
This is a small general-purpose hammer that uses the force of a spring. Compared to manual forging, it has higher productivity and less variation in the striking marks, but it requires a skilled operator.

2. Press Forging Machinery

Forging Machinery can be classified by power: mechanical presses, hydraulic presses, and servo presses.

Mechanical Presses
One of the mechanical presses is a press that applies pressure to a workpiece by converting the rotational motion of a flywheel into the sliding motion of a ram for power. The slide cannot be stopped at any given position, but the processing speed is high and productivity is excellent. Automated lines are possible. It is often used for mass-produced cold forging.

In addition to the flywheel type, there are other types of mechanical presses, such as crank presses, knuckle presses, and screw presses.

Hydraulic Presses
Hydraulic presses are machines that press workpieces using hydraulic or water pressure. They are widely used, from large products for small lots to small products for mass production.

Since the slide can be stopped at any position, prototypes and material deformation tests can be performed. The slow pressurization speed makes it unsuitable for hot forging of small parts that are prone to heat dissipation.

Hydraulic forging presses are the mainstream, but hydraulic forging presses are also used for hot forging of large products due to ease of maintenance, safety, and price. Forging Machinery is used for hot forging of large products such as turbines for thermal power generation and generator rotors.

Servo Presses
Servo forging presses use a servo motor to slide a ram directly. Because it is driven by a servomotor, precise control of pressurization and an amount of pressure is possible.

Servo presses can improve productivity by controlling the pressurizing speed and reduce yield by controlling the amount of pressurization. Forging of difficult-to-machine materials such as magnesium and complex shapes is also possible.

What Is a Volute Spring?

A volute spring is a spring made by winding a plate like a bamboo shoot.

The name “bamboo shoot spring” is derived from its shape, which resembles a bamboo shoot, and its ability to withstand a significant load in proportion to its volume.

A volute spring is made by winding up plates of hardened steel or stainless steel, shifting them little by little, and polishing both ends.

Usually, a wide range of plate thicknesses from 1mm to 30mm are used to manufacture volute springs.

Uses of Volute Springs

Volute springs are used in a wide range of applications, such as in small ball screw covers, and in large springs that absorb the shock of collisions in industrial equipment.

In an unusual case, a spring called a “bamboo shoot spring” is also used on bicycles.

This bamboo shoot spring is attached to the “quick release type” axle often used in cross bikes and mountain bikes. At first glance, it looks like a coil spring due to the narrow width of the plate material.

Characteristics of Volute Springs

Volute springs are known to have non-linearity in the load characteristic graph that expresses “load” versus “deflection”.

Non-linearity of the load characteristics of volute springs refers to a phenomenon in which the amount of deflection becomes smaller than the linearity of the load characteristics graph, even if the load is increased.

Generally, it is proven that the amount of deflection of a spring is proportional to the “load” and “effective number of turns”.

However, in the case of volute springs, as the load increases structurally, the wound plates gradually begin to adhere to each other, and the effective number of turns of the spring gradually decreases in effect, which is thought to break the linearity.

Volute springs can exert a substantial load relative to their volume, with a published record of 500 kN.

The rectangular plates used in volute springs are tapered to the appropriate dimensions in both width and thickness so that the ends of the plates (known as “sea wraps”) are horizontal and gradually thickened in the finished state.

What Are Locking Pliers?

Locking pliers, also known as “vise-grip pliers,” are a type of pliers that can be locked onto an object. This feature distinguishes them from regular pliers, which require continuous pressure to hold onto an object.

Unlike regular pliers, which necessitate constant hand pressure, locking pliers can be set to a locked position, enabling hands-free use during work. This function provides the convenience of maintaining a secure grip without continuous manual pressure.

Furthermore, the mouth’s opening width can be adjusted via an adjusting screw, accommodating a broader range of object sizes than standard pliers. This adjustability enhances their versatility for various applications.

Locking pliers are incredibly versatile tools, serving as pliers, clamps, and even as a makeshift monkey wrench.

Uses of Locking Pliers

Locking pliers are commonly used for gripping, turning, bending, twisting, and even cutting tasks.

Their design allows for usage at various angles, unlike standard pliers.

Due to their diverse shapes and sizes, they find applications in numerous fields such as plumbing, woodworking, metalworking, machining, and automotive maintenance.

Additionally, their robust gripping strength makes them ideal for temporary holding tasks, serving as makeshift clamps or vices to secure materials in place.

What Is a Storage Battery?

A storage battery is a mechanical device that stores electric power as chemical energy. Batteries include primary batteries, which can only be discharged and not recharged, and secondary batteries, which can be repeatedly charged and discharged. A storage battery refers to a secondary battery.

The need for storage batteries has been drawing attention, not only as a backup power source but also for their use in storing renewable energy. They also are cost-effective and energy-saving devices such as for averaging power use during the day.

Uses of Storage Batteries

Storage batteries are used in a wide range of applications, from home to industrial use.

For home use, they can be used in conjunction with solar power generation to save electricity. For example, solar power can be harnessed during the daytime and sold if there is a surplus. Even if electricity is not sold, it can be stored in batteries during the day, along with late-night power obtained at a discounted rate. This stored power can then be utilized during the night, after the sun has set, effectively saving electricity. In addition, even if a power outage occurs due to a disaster, the electricity in the storage batteries can be used.

For industrial use, storage batteries are also used as backup power sources for high-power applications and uninterruptible power supplies for instrumentation. The major difference between industrial use and household use is the electrical capacity.

Principles and Types of Storage Batteries

The principle of operation of storage batteries differs slightly from one type to another, but the mechanism of extracting electric power through a chemical reaction remains the same. Storage batteries consist of a positive electrode, a negative electrode, and an electrolyte that assists with the chemical reaction between the positive and negative electrodes.

1. Lead Storage Batteries

Lead storage batteries are the oldest of all storage batteries and are mainly used in car batteries and emergency backup power sources. They use lead dioxide for the positive electrode, lead for the negative electrode, and dilute sulfuric acid for the electrolyte. They are inexpensive, highly resistant to overcharging, and have a very long service life of approximately 17 years. Its low energy efficiency in charging and discharging is a disadvantage. 

2. Nickel-Metal Hydride Batteries

These batteries use nickel oxyhydroxide for the positive electrode, a hydrogen storage alloy for the negative electrode, and an alkaline solution, such as potassium hydroxide for the electrolyte. Before lithium-ion batteries, they were used as batteries for mobile devices and are still used in hybrid cars and railroad ground storage facilities. They are characterized by their resistance to over-discharge and over-charge and their ability to be rapidly charged and discharged, but their large self-discharge rate and short lifespan of about 5 to 7 years are their disadvantages.

3. Lithium-Ion Batteries

These batteries use lithium-containing metal oxide for the positive electrode, carbon material for the negative electrode, and organic electrolyte for the electrolyte. They are widely used as batteries for electronic devices used in daily life, such as notebook computers and smartphones, and in recent years, they have also been adopted as batteries for electric vehicles. They are characterized by their high energy density and ability to charge and discharge rapidly. They also have a relatively long service life of 6 to 10 years, but their cost is higher than other batteries. 

4. Sodium Sulfur (NaS) Batteries

Also called NaS batteries, these batteries use sulfur for the positive electrode, sodium for the negative electrode, and β-alumina for the electrolyte, and are used as backup power sources for large-scale facilities such as factories. They are also known as NAS batteries and are used as backup power sources for large-scale facilities such as factories. They feature almost no self-discharge, excellent charge-discharge efficiency, and energy density. They offer a long service life of about 15 years and are attracting considerable attention as industrial batteries. In addition, cost reductions can be expected because of the abundant resources of electrode materials. However, the operating temperature is 300°C, so the high temperature must be maintained with a heater, and the electrode material is a hazardous material, so safety is a major issue.

Other new batteries, such as redox flow batteries, in which the electrolyte tank and cell stack can be installed separately, are also emerging.

What Is a Water Storage Tank?

A water storage tank, as the name implies, is a facility designed to store water. When used for holding tap water, it is often referred to as a receiving tank.

Typically, tanks are located underground or on the first floor of buildings where water is extensively used.

In standard households, water is accessible directly from the tap. However, facilities that consume large amounts of water simultaneously, or buildings with three or more floors, such as condominiums, often require water storage tanks. This is because the direct water supply from pipes may be inadequate.

Uses of Water Storage Tanks

Water storage tanks are primarily used for storing drinking water and for other daily water supply needs.

They also serve in supplying water for various industrial purposes to factories and businesses and as fire prevention water tanks in firefighting systems.

Water storage tanks are broadly categorized into receiving tanks (for tap water), high-set tanks (for rooftop installation), and pressure tanks that are connected to water supply pumps, based on their use, installation location, and method of water supply.

Principle of Water Storage Tanks

These tanks are constructed from materials such as concrete, stainless steel, or Fiber Reinforced Plastic (FRP).

A crucial requirement for water storage tanks is adequate volume, approximately half the daily usage. Their seismic resilience is also vital to withstand earthquakes and prevent damage or collapse.

Moreover, high-set water tanks are designed to supply water from a receiving tank to a rooftop tank using a pump. The water is then distributed to each floor, utilizing the pressure generated by the elevation difference.

The maintenance of water storage tanks, crucial for drinking and domestic use, is the responsibility of the building administrator. These tanks must be cleaned at least once a year to ensure sanitary conditions.

Building managers are required to annually inspect the sanitary conditions of water supply facilities, mainly focusing on the water storage tanks and associated pumps, to prevent any issues.

Recently, to avoid water supply disruptions during cleaning or repairs, many buildings have adopted a two-tank system with a bulkhead for construction or multiple interconnected water storage tanks.

What Is a Superalloy?

Superalloy is a general term for alloys that have been developed to maintain the required properties even at temperatures of 800°C or higher, and are metals with excellent heat resistance, high hardness, and oxidation resistance.

Since its first development, development has continued, and many alloys with excellent heat resistance have been introduced.

Currently, there are three main types of alloys under development: nickel-based Ni-base alloys, cobalt-based Co-base alloys, and iron-based Fe-base alloys.

Furthermore, development of superalloy is not limited to the three base alloys, but also includes the addition of substances such as molybdenum, tungsten, and titanium.

Uses of Superalloys

Iron-based Fe-based alloys are well known for their use in jet and rocket engines because of their superior mechanical strength among superalloys.

Nickel-based superalloys are also used in turbochargers and micro gas turbines because of their superior mechanical strength, similar to Fe-based alloys.

In addition, cobalt-based co-base alloys have slightly lower mechanical strength and are used in gas turbines for static blades and in the roadbeds of high-temperature furnaces, etc. Superalloys are also used and studied in various fields.

Characteristics of Superalloys

Before the development of superalloy, stainless steel and heat-resistant steel were known as metals with excellent heat resistance, but the temperature at which they could maintain their properties was said to be about 500℃.

Originally, metals with excellent heat resistance were assumed to have a high melting point. Among the major metals, tungsten has the highest melting point at 3422°C, followed by molybdenum, niobium, titanium, iron, cobalt, and nickel.

Titanium, which is at the top of the list, has excellent corrosion resistance at room temperature, but it is extremely susceptible to oxidation at high temperatures, making it impossible to maintain its properties.

Superalloys are said to have been developed by changing the composition of nickel, iron, and cobalt, which have relatively high melting points and are compatible with additives, as a base.

Superalloys are being developed to achieve both corrosion resistance at high temperatures and oxidation resistance and strength, with the aim of further improving their properties by changing the amounts of various substances in the mixture.

What Is Corner Clamp?

Corner Clamps are clamps that hold materials at right angles to each other. They are used for temporary fixing and adhesive bonding when assembling materials at right angles, such as in the production of picture frames and panels and gluing the corners of wooden boxes.

Corner Clamps can be used to fix materials with edges cut at 45° or 90° at right angles to each other. They are important in the production of wooden frames and boxes, as misaligned corners can adversely affect the finished product.

Uses of Corner Clamps

Corner Clamps are used in a wide range of applications, from general DIY to usage in professional workplaces. In particular, they are often used for assembly and fabrication work at sites such as woodworking production sites.

Corner Clamps are used to secure materials at right angles. The basic function is simply to clamp the material to be fixed. It assists in operations such as gluing materials together, driving screws into them, or processing them.

It simply fixes materials at right angles, but if the corner angle shifts even slightly, it will affect the finished product more than expected. It is a simple tool, but it plays an important role in the work process.

Principle of Corner Clamp

Corner Clamps use screws or springs to fix materials to be fixed at right angles. When using a screw to fix a material, turn the screw to widen the mouth opening, clamp the material, and turn the screw to tighten it.

For spring-loaded clamps, pull the handle to widen the opening and clamp the material. The spring type applies pressure according to the strength of the spring.

Types of Corner Clamps

Corner Clamps are available in three types: the single-handle type, which uses one handle to tighten screws; the double-handle type, which uses two handles to tighten screws at 90° to each material; and the right-angle ruler type, which uses an L-shaped ruler clamped by a clamp.

1. Single-Handled Type

The single-hand type has a screw or spring inside the right-angled mouth opening that clamps the material. Since there is only one handle for tightening the material, the tightening force is weaker than the double-handled type, but only one screw tightening operation is required, which shortens the working time.

This type is suitable for making small items such as picture frames and shelves, and for improving work efficiency. If the handle axis can be adjusted to the left or right, it can be used for materials of different widths.

2. Double-Handled Type

The double-handle type has one clamp per side on the outside of the right-angled opening that clamps the material, and since two handles are used for clamping, the work takes twice as long as with a single-handle type, but the clamping force is stronger. Therefore, this type is suitable for processing large materials and for construction sites. 

3. Right Angle Ruler Type

This type is L-shaped like a right-angle ruler. The body does not have a clamp to fix the material, so a C-shaped clamp, L-shaped clamp, or spring clamp is used separately to fix the material. The main unit has a scale on it for easy measurement of length and angle.

Materials include ABS resin and aluminum alloy, and there are also different sizes. Besides the above three types, belt clamps can also be used as corner fixation.

How to Select Corner Clamps

1. Maximum Opening Size

Corner Clamps range in size from about 10 mm to 200 mm in maximum mouth opening size. Corner clamps are tightened by screws to secure the material, so the maximum opening size should be larger than the width of the material to be secured. 

2. Material

Aluminum and alloys are the most common materials used for corner clamps. However, if you need to clamp materials that you do not want to clamp too tightly, such as soft materials, resin corner clamps are an option.

3. Other

When fastening large pieces of wood or other materials, those fastened with double-handle type screws can be fastened securely. It is convenient to have several sets of 2 or 4 clamps.

What Is a Bar Clamp?

A Bar Clamp is a clamp that basically consists of a bar and two jaws, and holds the material between the jaws fixed on one end of the bar and the jaws sliding on the bar.

A clamp, also called a fastener, is a tool used to secure a material to a workbench or other surface.

Bar Clamps, also called quick bar clamps or ratchet bar clamps, are used to clamp a material between the jaws and a lever attached to the sliding jaw, which is operated to squeeze the jaw into position. They can be used with one hand and are quick and easy to use, even for beginners.

Usage of Bar Clamps

Bar Clamps are used in a wide range of applications, from general DIY to professional assembly work in civil engineering and construction, furniture manufacturing, sheet metal, and steel industry. By holding materials firmly in place, they improve the accuracy and efficiency of work.

For example, bar clamps are used in many DIY applications, such as clamping box-shaped boards in woodworking to hold them in place until the glue cures, or clamping flat boards side by side to compress them and aid in gluing them together.

In addition to bar clamps, there are many other types of clamps, including C-type, G-type, L-type, and spring-type clamps.

Each has its own characteristics, but bar clamps are especially used to secure long (or wide) materials. Although they are slightly less strong than C-type clamps and other screw-type clamps, they are superior in that they can be used with one hand.

Principle of Bar Clamps

Bar Clamps have a fixed jaw at the end of one bar, and the sliding jaw on the bar is moved to secure the material. Most ratchet bar clamps apply pressure by squeezing a lever on the sliding jaw multiple times, but there are also types that tighten screws by turning a handle or by knocking down a lever.

In ratchet bar clamps, the jaws are slid by pressing the unlock button to clamp the material, and the lever is squeezed several times to apply pressure to hold it in place. When removing the clamp, the pressure can be released at once by pressing the unlock button again.

Bar Clamp Features

Ratchet bar clamps are easy to handle, even for beginners, because materials can be clamped with one hand. If you have several of them, you can work efficiently even when working alone.

Bar Clamps can be used in the usual way of clamping materials by clamping them between the jaws and applying force inward.

Conversely, bar clamps can also be used for attaching to a bar with two jaws facing outward and applying force in the direction of pushing and spreading to secure the material.

How to Select a Bar Clamp

To select a bar clamp, check whether the maximum clamping force, maximum opening size, and material are suitable for the material to be processed.

1. Maximum Opening Size

Select the maximum opening size that corresponds to the length and width dimensions of the material to be processed. For long or wide materials, use the one with a long lever and a large opening.

The thickness of the material to be processed should also be taken into consideration when fixing it to the workbench or when using it against the material to be processed. Selecting a lever with a protective cap such as rubber on the jaws has the advantage of not leaving marks and preventing slipping, but it is slightly inferior in terms of durability of the material.

Also, if the gripping area is shallow, the clamp may not be able to grip the material to be processed, depending on the width and thickness of the material.

2. Material

There are two main types of clamp materials: plastic and metal. Plastic is used for clamps with relatively low clamping force, while die-cast aluminum is used for clamps with high clamping force. Selection is based on the operating environment and frequency of use. 

3. Maximum Tightening Force

Each bar clamp has a maximum clamping force, which is indicated in the catalog. It is important to use bar clamps within the range of this maximum tightening force.