月: 2023年1月

What Is a Power Monitor?

A power monitor is a system that supports energy-saving activities by measuring the amount of electricity used.

Whereas in the past power meters were inspected visually, a power monitor can automatically measure power usage in multiple locations, enabling efficient and accurate power measurement.

The basic function of the power monitor is to measure and monitor the amount of electricity used constantly. The system also monitors the amount of electricity used at regular intervals and generates an alarm when it is expected to exceed the target value. It can also take emergency measures, such as shutting down the least important electrical equipment in order. Some systems not only monitor power use but also provide feedback on the monitored data to control power usage.

Uses of Power Monitors

Power monitors are used to monitor and control power usage in a variety of locations, including buildings, factories, power generation facilities, and small stores.

Power monitors in office buildings monitor power on a floor-by-floor basis to identify areas of inefficient power use and control power used for air conditioning and lighting to conserve energy.

Power monitors in factories monitor power for each production line and collectively monitor the relationship between equipment operation status and power usage, not only saving energy by improving the efficiency of production equipment, but also monitoring equipment abnormalities.

Principle of Power Monitors

The basic configuration of a power monitor includes an electricity meter that measures the amount of electricity used on site, a wired or wireless system that connects the power system and the power management computer, and power monitoring software. This basic configuration can be combined with IoT to expand to a remote power monitors.

Some power monitors have a function that monitors the average power consumption (power demand) over a 30-minute period. It then predicts the power consumption if the current power consumption continues, and generates an alarm when the power consumption is predicted to exceed the contracted power consumption or target power consumption. This improves awareness of energy conservation and leads to cost savings by reducing power use.

Another benefit is that visualization of the power monitor results, clarifies the status of power usage, making it easier to devise power reduction measures.

Power monitoring systems were originally introduced to various locations to reduce the cost of electricity, but now have the added objective of environmental protection. Reducing power consumption leads to a reduction in carbon dioxide emissions from power generation. For this reason, some power monitors have the ability to convert the amount of carbon dioxide emitted by a business activity from the amount of electricity it consumes.

What Is Coating Machinery?

Coating machinery is a machine that performs the coating operation when applying a coating material to a surface. The coated material can be paper, plastic film, nonwoven fabric, aluminum foil, or many other materials. The coating material can be an adhesive or a coating agent.

Coating machinery use two main functional technologies, “coating” and “solidification,” and the “wetting” factor between the material to be coated and the coating material has a significant impact on the coating process.

Therefore, coating machinery may require various innovations depending on the purpose.

Uses of Coating Machinery

Coating machinery is used in a wide range of fields, including optics, electronics, office supplies, and everyday products.

They are particularly popular in the electronics field, where they are used for flexible substrates, battery electrodes, conductive films, insulating tapes, and various electronic components.

In addition, coating machinery is also used for silicon film and ceramic sheets.

Features of Coating Machines

The purpose of coating machinery is to adhere the coated material to the substrate and to add functions, including surface treatment.

Various types of coating machinery are manufactured as follows:

• Roll Coater
  Typical coating machinery used for sheets, etc.
• Coating Robot
  Used in automobile production lines. Nowadays, automation has progressed and multi-axis robots are well known.
• Spray Coater
  Spray coaters are used for spray coating on the surface of materials such as glass.
• Spin Coater
  Spin coaters use centrifugal force to apply the coating, and are used for semiconductor wafers that require a thin film.
• Dispensers
  Suitable for dispensing minute and precise amounts of material. A typical example is the dispensing of cream solder.
• Inkjet Coater
  Inkjet coaters enable high-definition printing without the use of plates and are indispensable in the field of electronics to produce fine patterns on substrates.
• Screen Printing
  Screen printing enables high-definition patterning using screen masks, and can be configured in a variety of settings to meet the needs of each application.

What Is Painting Machinery?

Painting machinery is the equipment used for spraying paint.

Conventionally, when applying paint, uneven, three-dimensional areas are covered with a brush, while flat areas are covered with a roller.

However, the larger the area to be painted, the more workers are required and the more time is needed to apply the paint, resulting in more labor hours.

In such cases, the use of painting machinery can reduce the number of labor hours required for painting, and since the paint can be applied more evenly than with brushes or rollers, the surface can be painted cleanly.

Uses of Painting Machinery

Painting machinery is mainly used to paint civil engineering structures such as buildings, exterior walls, and bridges.

Since the price per unit is high for a machine, they are used for painting large areas.

The machine can be used to apply a variety of paints, from general paints for construction to heavy-duty anti-corrosion paints for use in harsh environments.

The main precaution in use is to clean the inside of the equipment with a dedicated cleaning agent, as paint residue left inside the equipment after painting may cause problems the next time the equipment is used.

In recent years, painting machinery has also been sprayed with a stripping agent to remove old paint during renovations.

Principle of Painting Machinery

The principle of painting machinery differs depending on the type.

Diaphragm Type Airless Coating Machines

Diaphragm airless coating machines use electricity or an engine to spray paint, and do not use a compressor.

Two nozzles, one for spraying and the other for sucking up the paint, come out from the main body of the machine. The nozzle for sucking up the paint is placed in the container containing the paint.

When the equipment is turned on, it applies high pressure to the paint, which is then used to draw the paint up. A fine filter at the tip of the nozzle prevents paint clumps from entering the equipment.

The sucked-up paint is then ejected from the spray nozzle and applied. The advantage of this method is that it does not use air, so paint is not likely to be scattered around the equipment when spraying.

Pneumatic Painting Machinery Using Compressor

Pneumatic painting machinery using a compressor is also available. This type of machine sprays paint onto compressed air.

The pneumatic type allows for a more uniform coating of the painted surface. However, more paint will be sprayed onto the surrounding area.

What Is a Whetstone?

A whetstone is, in the broadest sense, a tool, such as “a tool for cutting and polishing rocks and metals.”

A whetstone is widely used in a variety of forms, from household to industrial applications.

For home use, a whetstone is commonly used to sharpen kitchen knives, often found in rectangular or block-shaped.

Industrial whetstone is often disk-shaped wheels with a mounting hole in the center that is attached to a power tool.

Uses of Whetstones

Whetstones are used in the following applications.

1. Cutting whetstones
   Cutting whetstones are often used in the plumbing industry.
   A cutter wheel, which is a disk-shaped whetstone, is attached to a pipe cutting machine called a tube cutter.
   The whetstones are rotated to cut the required length of piping work.
2. Abrasive cloth paper (sandpaper)
   This is an abrasive tool made by bonding abrasives to cardboard, cloth, or other material with an adhesive.

Principle of Whetstones

There are various types of bonding agents used in whetstones, depending on the application.

The most commonly used resinoid is made by a process called the “bakelite method.”

Next, the principle of how whetstones grind workpieces is explained.

• Normal Grinding Process
  In normal grinding, when the sharpness of the abrasive grains is worn, the grinding process becomes dull, the abrasive grains drop off and new grains appear on the surface.

  This ensures the necessary grinding force at all times.
  In this state, chips do not penetrate between the abrasive grains, so the surface roughness of the workpiece is excellent, and high quality can be obtained.

• Improper Grinding
  If the bond of the whetstones is too soft for a hard workpiece, the abrasive grains will not be able to withstand the workpiece and will break.

  If this happens, the grinding surface will become rough, and the finished surface roughness will deteriorate.

  Conversely, when grinding soft workpieces such as aluminum or copper, chips can get between the grains and deteriorate the sharpness of the workpiece.

  Resistance during grinding increases, resulting in a rougher finished surface.

What Is a Floodlight?

A floodlight is a device that has a generator and illuminates light.

Generally, the word “machine” is used for devices that have a part that is driven by itself. Typical examples are generators and electric motors. Heat exchangers and circuit breakers are also examples.

When the word “spotlight” is used, it refers to a lighting part attached to a building or a battery-powered lighting device. In contrast, the term “floodlight” refers to a floodlighting device that includes a generator or other drive unit.

Uses of Floodlights

Floodlights are mainly used for construction or work in dark areas.

The illumination intensity for work is roughly defined by some standards, and even for rough work, the illumination intensity of the work area should be about 200 lux (lx). Insufficient illumination means workers cannot see their surroundings or the surrounding area, which can put them in danger. It is the duty of the prime contractor to ensure the safety of the work area, and in the event of an accident or injury, the prime contractor will be held responsible.

The prime contractor provides floodlights for the purpose of ensuring illumination of the work area.

Principle of Floodlights

Floodlight consists of a fuel tank, a generator, and an illuminator.

The fuel tank contains the fuel used by the generator. Generally, kerosene, or light oil, is used. In rare cases, gasoline may be used. The fuel tank is designed to hold at least 8 hours of fuel so that the fuel does not run out during the work.

In the generator section, fuel from the fuel tank is used to turn a generator to generate electricity to supply the lighting section. The generator is an engine generator, which is simple in structure and easy to downsize. In Japan, 100V or 200V is used as the power supply voltage, and in most cases, a circuit breaker is installed to protect the generator from overcurrents.

In recent years, LED floodlights have become the most common type of lighting. A voltage is applied to the light-emitting diode to produce light. For lighting that requires the use of a generator, large floodlights (400W-800W fluorescent equivalent) are used. Balloon floodlights are also used for 360-degree all-round illumination.

What Is a Coaxial Connector?

A coaxial connector is designed for use with coaxial cables, offering a reliable connection in electronic equipment and communication systems. They excel in shielding signals from electromagnetic interference and noise, thus minimizing signal loss. The effectiveness of a coaxial cable and its connector largely depends on proper shielding and grounding.

Uses of Coaxial Connectors

Coaxial connectors are integral to various applications across multiple industries, thanks to their durable design and superior signal protection capabilities:

• Television: Used for connecting TV receivers to antennas or satellite dishes, ensuring high-quality signal transmission for clear audio and visual reception.
• Radio Communication: Essential for connecting antennas to communication equipment, minimizing signal degradation for reliable transmissions in amateur radio and aircraft communications.
• Computer Networks: In networking, they maintain signal stability over long distances, surpassing the typical range limitations of LAN cables.
• Manufacturing Industry: Employed in distributed control systems and bus communication in industrial settings, as well as in remote monitoring cameras for video signal transmission.

Principle of Coaxial Connectors

Coaxial connectors are designed to maintain signal integrity, featuring components such as the connector body, inner conductor, center contact, and outer conductor for effective electromagnetic shielding.

Types of Coaxial Connectors

Diverse in design, coaxial connectors cater to specific needs and applications:

• RFC Connector: Features a bayonet locking mechanism, ideal for high-frequency signal transmission in cameras and monitors.
• N-Type Connector: Suited for high-frequency and broadband communications, commonly used in base stations and wireless communication systems.
• SMA Connector: Compact design for high-frequency applications, popular in satellite and wireless communications.
• F-Type Connector: Primarily used for TV antenna connections, cable TV, and satellite broadcasting, offering a low-cost and user-friendly solution.

Whether for television, radio communication, networking, or industrial applications, coaxial connectors provide a secure and efficient means of maintaining signal quality and integrity.

What Is a Copper Clad Laminate?

A copper clad laminate, also known as CCL, is made by laminating resin-impregnated sheets onto a base material such as paper or glass, then applying pressure and heat treatment to produce a laminate with copper foil on both sides.

It is used in a wide variety of printed wiring boards and electronic circuit modules. Electronic components such as ICs and chip capacitors are placed by forming patterned circuits on the surface and inner layers and connecting multilayer wiring with vias. 

Uses of Copper Clad Laminates

Copper clad laminates are usually standardized in their final form as printed circuit boards, with the most widely known and universally used being FR-4, which is a glass epoxy substrate.

FR-4 substrates have excellent high-frequency characteristics and mechanical strength. They are used in a wide range of applications, including information equipment such as PCs, home appliances, mobile terminals, OA equipment, and industrial machinery.

FR-5 substrates with excellent heat resistance are used for in-vehicle applications that require high reliability.

Principle of Copper Clad Laminates

Copper clad laminates (CCLs) are made by impregnating a cloth made of woven fibers called glass cloth, which has high insulation properties, with resin. Therefore, it can be said that the composition of the copper clad laminates is the most important factor in the characteristics of a printed circuit board.

There are two main types of copper clad laminates: 3-layer CCL and 2-layer CCL.

The 3-layer CCL is the most widely used today because it is inexpensive and has stable characteristics and quality. Epoxy and acrylic adhesives are used as bonding agents. The lamination method is the most common manufacturing method.

Compared to 3-layer CCL, 2-layer CCL has various manufacturing methods other than lamination, such as casting, sputtering, and plating, but the cost tends to be higher.

However, the cost tends to be higher, but the quality and characteristics are superior to the cost. It is generally purchased as a core material (base material) from chemical material manufacturers who are mainly contracted to manufacture copper clad laminates.

What Is a Heat-Treating Furnace?

A heat-treating furnace is used to enhance the structure and properties of metals through controlled heating and cooling processes. These furnaces play a critical role in various manufacturing sectors by altering the physical and sometimes chemical properties of materials to achieve desired engineering outcomes.

Uses of Heat-Treating Furnaces

Heat-treating furnaces are pivotal in industries ranging from food processing, where they are used for sterilization, to the automotive sector, supporting the production of highly rigid components. The versatility of heat-treating furnaces allows for their application in improving the durability, strength, and performance of metal parts.

Principle of Heat-Treating Furnaces

The core operations of heat-treating furnaces include quenching, tempering, normalizing, and plating of steel. These processes, facilitated by either incinerator or electric heating methods, hinge on precise temperature and time control to ensure uniform product quality. The distinction between heating methods lies in their fuel source and heating accuracy, with electric furnaces providing pinpoint heating capabilities.

Structure of Heat-Treating Furnaces

Heat treating involves a meticulous set of heating and cooling stages, with the equipment type varying based on the specific heat treatment process. Batch and continuous types represent the two primary categories of heat-treating furnaces, each designed to accommodate different production volumes and operational needs.

Types of Heat-Treating Furnaces

1. Forging Furnace

Materials such as steel bars are heated to an appropriate temperature to make them plastic before forging.

2. Rolling Furnace

Billets, slabs, and billets are heated to a plastic state and rolled into products such as steel shapes, bars, wire rods, and steel plates.

3. Standardizing Furnace

Quenching furnaces are used to improve the mechanical properties and machinability of steel by homogenizing the microstructure of steel that has become non-uniform during casting and forging.

4. Annealing Furnace

Removes internal stresses produced by cold working. Unlike quenching, the material is heated and then cooled slowly in the furnace.

5. Quenching Furnace

Hardens steel to make it wear-resistant. After heating, the steel is quenched in a water or oil bath.

6. Tempering Furnace

Tempering furnace toughens steel that has become brittle during quenching and remove residual stresses to prevent quench cracking. The quenched steel is heated to 700°C or lower and cooled in air.

7. Carburizing Furnace

Hardens the steel surface and imparts wear resistance. The steel is heated in a carburizing endothermic transformation gas for a certain period and then quenched to a temperature slightly higher than the austenite transformation temperature to prevent distortion.

8. Aluminum Heat-Treating Furnace

Aluminum heat treatment furnace removes distortions caused by machining and cooling shrinkage of castings and ensures proper mechanical properties by homogenizing the microstructure.

What Is a Fuel Cell?

A fuel cell is a device that utilizes the electrical energy generated when hydrogen and oxygen react to produce water. Compared to the use of fossil fuels, the environmental impact is extremely low. Due to its superior energy efficiency, it is expected to find a variety of applications.

In addition to hydrogen itself, fossil fuels such as natural gas, LPG, and methanol can be used as an energy source by reforming them with a catalyst.

Uses of Fuel Cells

When fuel cells were first developed, they were used in spacecraft as a device that could simultaneously generate electricity and hydrogen.

Fuel cell-based household generators are installed to assist power generation during times of peak electricity use, and use city gas as a source of hydrogen for power generation.

Another area attracting attention is fuel cell vehicles, which have various advantages such as long cruising range, low environmental impact, etc. Fuel cell vehicles that do not need to be recharged are already on the market.

Principle of Fuel Cells

There are four types of fuel cells, depending on the type of electrolyte used. The polymer electrolyte type and the solid oxide type are the most popular types in use today and are expected to become more popular in the future.

Solid polymer electrolyte fuel cells are characterized by the use of a fluoropolymer-based cation exchange membrane as the electrolyte, and the use of methanol or city gas as the fuel, in addition to pure hydrogen. Because of their relatively simple structure and compact size, they are used in many applications, including household generators and fuel cell vehicles. However, research is currently underway to reduce the use of platinum catalysts, which are expensive.

Solid oxide fuel cells are characterized by the use of ceramics as the electrolyte, and like the polymer electrolyte type, they use pure hydrogen, methanol, or city gas as fuel. The structure is simpler than that of the polymer electrolyte type and theoretically more efficient, and expensive platinum catalysts are not required. Verification and improvements are underway.

Advantages of Fuel Cells

Fuel cells have the following advantages:

① High power generation efficiency:
In the case of thermal power generation, heat from burning fuel is used to generate steam, which turns a turbine to produce electricity. Energy loss occurs as the chemical energy of the fuel is converted to electrical energy via thermal and kinetic energy. In addition, energy is also lost in the transmission of electricity from the power plant. On the other hand, residential-use fuel cells have extremely high power generation efficiency because they convert chemical energy directly into electrical energy without transmission loss.

② Stable energy source:
Hydrogen used in fuel cells can be obtained from various raw materials such as LP gas, natural gas, petroleum, methanol, and biomass, thus ensuring a stable supply of fuel.

③ Low environmental impact:
When fuel is burned, as in thermal power generation, not only carbon dioxide but also nitrogen oxides, sulfur oxides, and other air pollutants are produced. On the other hand, fuel cells produce only water during power generation, making them environmentally friendly.

④ Extremely quiet:
Fuel cells do not require a turbine, etc. Since fuel cells do not require turbines, etc., and electricity is obtained only through chemical reactions, they are very quiet in operation and generate almost no vibration.

Although fuel cells have these excellent characteristics, they currently have some issues such as high cost and short life span.

What Is Adhesive Tape?

Adhesive tape is a material with an adhesive layer coated on one side. Unlike tube-based adhesives, adhesive tape offers immediate bonding strength and can be removed without damaging the bonded surface. This flexibility makes it a preferred choice over traditional adhesives in various applications.

Uses of Adhesive Tape

Adhesive tape finds applications across all industrial sectors. Its primary use is for bonding materials together. In construction, it’s used for masking, and in manufacturing, it’s employed for temporary assembly of parts due to its easy removability. Adhesive tapes are also used for electrical insulation and protecting circuit boards, with the tape materials and adhesive types selected based on specific requirements. While most commercially available tapes fall under the category of adhesive tapes, gummed tapes activated with water are specifically used for industrial purposes.

Principle of Adhesive Tape

Adhesive tapes work by creating intermolecular forces between the tape’s adhesive and the target surface. These forces are effective only at very close ranges. Normally, microscopic surface irregularities prevent two substances from sticking together, but the adhesive on the tape fills these gaps, enabling the intermolecular forces to act effectively.

While traditional adhesives rely on chemical bonding and curing for a permanent bond, adhesives in tapes often use reversible intermolecular forces, allowing for peeling off without residue. Different types of adhesives are used in tapes, such as acrylic adhesives for their transparency and durability, silicone adhesives for their wide temperature range and easy bubble release, and urethane adhesives for re-adhesiveness.