月: 2023年1月

What Is an Optical Encoder?

An optical encoder is a type of encoder that utilizes an optical sensor to detect and measure physical quantities such as linear axis movement and rotation angle. This device converts position information into electrical signals through the interaction of light with a coded pattern on a disk.

Uses of Optical Encoders

Due to their high accuracy, resolution, and speed, optical encoders are integral in controlling servo motors, elevator motors, through-axis motors, and high-speed rotating motors in industrial equipment. They are particularly advantageous in environments with strong magnetic fields, such as MRI equipment and linear motor-type actuators.

Structure of Optical Encoders

The construction of an optical encoder involves:

1. Light Emitting Element (LED)

An infrared LED is commonly used as the light source in optical encoders, though colored LEDs or laser diodes may be employed for enhanced performance and resolution.

2. Lens

A lens focuses the emitted light into a parallel beam, ensuring accurate detection by the optical sensor.

3. Code Wheel

The code wheel, which can be made from metal, resin, or glass, features slits or patterns that modulate the light beam. The material choice is dictated by application requirements, balancing factors like cost, precision, and environmental resistance.

4. Photodetectors

Photodiodes or phototransistors capture the modulated light and convert it into electrical signals. These sensors are fabricated from semiconductor materials optimized for light detection.

Types of Optical Encoders

Optical encoders are categorized into:

1. Transmissive Type

This configuration positions the light source and sensor on opposite sides of the code wheel, detecting light that passes through the slits.

2. Reflective Type

Here, the light source and sensor are located on the same side, with light reflected from the code wheel’s surface being detected.

Principle of Optical Encoders

Optical encoders generate pulse signals by modulating light through or off the code wheel’s pattern. The frequency of these pulses correlates with the movement speed, while the phase difference between the two signals indicates rotation direction.

How to Select Optical Encoders

Selection considerations include the encoder’s resolution, which is limited by the physical dimensions of the code wheel’s slits, and environmental factors such as dust and oil, which can interfere with light transmission. Optical encoders also tend to have higher power requirements due to the continuous operation of the light source.

What Is a Magnetic Encoder?

A magnetic encoder is a position sensor that utilizes magnetic sensors to detect the position and movement of an object. It operates by converting changes in magnetic field distribution into electrical signals, representing physical quantities like linear displacement or rotational angle.

Encoders come in two main types: linear, for measuring straight-line motion, and rotary, for detecting rotational movement, with rotary encoders being more prevalent in applications involving motors.

Uses of Magnetic Encoders

Magnetic encoders excel in industrial settings, offering robust resistance to contaminants such as oil, water, and dust, as well as to harsh conditions like high temperatures and mechanical vibrations. They’re ideal for machine tools, industrial machinery, and environments prone to dust or liquid exposure.

These encoders are preferred over optical types for their compact size, lower part count, and reduced power consumption, making them suitable for applications where space efficiency and energy savings are priorities.

Principle of Magnetic Encoders

Magnetic encoders can provide both incremental and absolute output. Incremental output relays position relative to a start point, while absolute output indicates the exact position at any time. The unique capability of magnetic encoders to easily output absolute angles stems from the direct correspondence of voltage waveforms to absolute angles.

Key components of a magnetic encoder include a magnetic sensor and a permanent magnet mounted on the moving part.

1. Magnetic Sensor

These sensors, typically Hall or magnetoresistive (MR) elements, detect changes in magnetic fields. Hall elements use the Hall effect to generate a voltage proportional to magnetic flux density, while MR elements change resistance in response to magnetic field strength.

2. Permanent Magnet

Attached to the moving object, the permanent magnet’s position changes with motion, altering the magnetic field’s distribution. This change in flux density is converted by the magnetic sensor into electrical signals, providing position information.

Features of Magnetic Encoders

While magnetic encoders are effective in many applications, they can be sensitive to magnetic interference, especially near electric motors, and generally offer a narrower operating temperature range. Their accuracy and resolution may not match that of optical or capacitive encoders, but they are less affected by environmental contaminants.

Structures of Magnetic Encoders

The magnetic sensor, often a Hall element, is typically fabricated from semiconductor materials like indium arsenide, gallium arsenide, or silicon, each offering distinct advantages in terms of sensitivity and temperature stability.

Permanent magnets in magnetic encoders are usually disk-shaped, with material choices including ferrite, neodymium, and samarium-cobalt, selected based on cost, size, weight, and temperature performance requirements.

What Is a Rigid-Flex PCB?

A Rigid-Flex PCB (Printed Circuit Board) is a type of printed circuit board. It has both rigid and flexible characteristics.

Printed circuit boards are components used to electrically connect electronic devices. They are responsible for transmitting signals and power, and allows wiring connections while fixing the position of each component. It is mounted as a built-in component of various electronic devices and is an indispensable component.

Features of Rigid-Flex PCB

Printed circuit boards are classified into two types: rigid and flexible.

Rigid boards are made of insulators, which are rigid and can withstand automated transport and facilitate component positioning. While they are strong, they are not flexible.

Flexible substrates are made of thin film and can be bent repeatedly. They can be mounted on components with weight limitations and are suitable for use in moving parts. The material itself is also an insulator.

A Rigid-Flex PCB is a composite board that combines a rigid circuit board and flexible circuit board. It was originally developed for use in space aircraft, where compactness was required. Prior to its development, multiple boards were connected by unstable wires, resulting in frequent defects and failures.

Principle of Rigid-Flex PCBs

The rigid part where components are mounted has a structure in which all layers of the flexible layer for three-dimensional wiring and the rigid layer for circuit formation are overlapped.

Although connectors are normally required to connect between the boards, the concept of connecting the outer and inner layers with through holes eliminates the height and weight of connectors.

The flexible part consists of only flexible layers. However, as the flexibility is impaired when the number of layers increases, the layers are separated by one or two layers. The total number of layers can be adjusted according to the desired application, and design proposals are generally made by each manufacturer.

Flexible substrates alone require careful work in mounting due to their thinness. The rigid board takes care of the base strength, making it possible to use existing mounting equipment.

The structure allows connection with a single lead wire, which has been confirmed to suppress noise generation. The omission of components has made it possible to realize smaller, lighter, and thinner devices, greatly expanding the range of applicable devices.

Uses of Rigid-Flex PCB

Rigid flexible substrates are available in various shapes, such as folding type, flying tail type, and book binder type, and can be used in a variety of ways depending on the conditions of the installation location.

Due to the wide range of substrate shape adjustment, rigid flexible substrates are widely used in devices that require compactness, light weight, and high reliability, such as home game consoles, cell phones, medical equipment, smart devices, storage devices, wearable devices, and communication base stations.

Other Information on Rigid-Flex PCB

1. Rigid-Flex PCB Issues

The process is more complicated than the manufacturing of rigid substrates or flexible substrates alone. Via positions need to be adjusted, and minute checks are required from the design stage.
The number of manufacturers is also limited, and the manufacturing cost is high.

2. Future Prospects

Recently, the printed circuit board market has been expanding due to improvements in communication technology and increased sales of electronic devices.

Standards that enable high-speed communications have a significant impact on infrastructure facilities, and higher-performance printed circuit boards are required. Furthermore, with the rise of AI technology, various industries intend to promote the use of IT. The diplomatic relations and circumstances of each country are also relevant, and the demand for these products is global.

Rigid flexible substrates are also being mounted in an increasing number of devices due to their characteristics, and a review of manufacturing efficiency is required.

What Is Insulation Board?

Insulation boards are building and industrial materials designed to block the transmission of heat.

In addition to thermal insulation, insulation board has various features, such as heat resistance, water resistance, chemical resistance, impact resistance, sound insulation, dustproofing, and adhesiveness. They are used in a wide variety of applications and locations depending on their thermal resistance and related functions.

In addition, insulation board, which can be easily cut with a cutter, are often used for self-renovation for insulation purposes, and some are sold at general home improvement stores.

Uses of Insulation Board

In the construction industry, insulation board is used for insulation purposes in reinforced concrete and wood construction sites. They are used inside roofs and walls, as bases for interior finishes, and as RC cast-in-place insulation using insulation board that bond strongly to concrete.

In industry, insulation board are also used in factories to ensure safety around hot equipment, such as heat presses, heaters, industrial furnaces, and combustion equipment.

Insulation board is also used in a wide variety of other applications, including as alternatives to cardboard and plywood, cushioning materials, and partitioning boards.

Characteristics of Insulation Board

Insulation board materials include cement-based, calcium silicate-based, and resin-based materials with low thermal conductivity to which fillers such as glass fiber are added.

• Rosna Board:
  This insulation board consists of multiple layers of sheets of thermosetting resin to which glass fiber or other fillers are added. It has a heat resistance temperature of 400°C and is effective in insulating under high temperatures. It also has the advantage of minimizing thermal expansion and deformation due to pressure, and has minimal distortion even when used continuously for long periods of time.
• MIOLEX:
  This is a highly versatile insulation board based on glass fiber. In addition to its basic properties of heat insulation, it has various other properties, such as pressure resistance, impact resistance, durability, insulation, and workability. Heat resistance temperatures range from 200 to 500°C, depending on the grade.
• BESTHERMO:
  This rigid insulation board is made by laminating sheets of glass fiber and solidifying them with an inorganic binder or resin. The heat resistance temperature is 200-300°C. It has a high thermal insulation performance at a low price.

There are also various other types of insulation board, such as insulation board made of rigid urethane and gypsum board, and insulation board made of a heat insulator made of phenol resin, which is a type of thermosetting resin, and gypsum board.

In addition to properties such as thermal insulation, heat resistance, and flame retardant properties, insulation board for building applications are required to be free of asbestos, chlorofluorocarbons, formaldehyde, etc.

What Is a Full Color 3D Printer?

A full-color 3D printer is a manufacturing machine that uses the inkjet method to create multi-colors when layering molding materials in a two-dimensional cross-sectional shape to create a three-dimensional model based on 3D data. By combining conventional thermal lamination and optical modeling technologies with color inkjet printer technology, it is possible to produce full-color models in thousands to millions of colors.

ABS resin and acrylic resin are used as molding materials. The advantage of this technology is that it does not require a mold, and coloring is done directly in the process of creating a three-dimensional model using color ink.

For example, rather than showing a photograph to explain a product, it is more powerful and persuasive to let the audience hold a real color 3D image in their hands.

Uses of Full-Color 3D Printers

Full-color 3D printers do not make a mold for manufacturing. Rather, they create a three-dimensional image directly by layering and curing thin layers of molding material little by little based on the 3D data of the object to be modeled. This enables prompt prototyping, shortening the development period, improving development efficiency, and reducing costs. It is especially suited for high-mix, low-volume production.

Low-cost, easy-to-operate tabletop products that specialize in small modeling products have also been introduced. These products are powerful in fostering creativity in school education, for example. The advantages are increased by using color. In addition, it is easy to examine designs, pursue colors, and check usability during product development by holding the actual product in one’s hand.

Principle of Full-Color 3D Printers

There are several types of 3D printer principles, but in particular, color can be achieved by combining the thermal melting and laminating method and the optical molding method with inkjet, which is the principle of full-color 3D printers. In this method, ink of each color is ejected from multiple ink nozzles to add color to a thin layer of modeling material.

The thermal melting and stacking method is a modeling method in which thermally melted modeling material is extruded through nozzles, stacked, and cooled. The 3D data of the modeling object is used to create the desired shape. Materials such as PLA (polylactic acid), ABS, PC (polycarbonate), and nylon can be used as thermoplastic resin. Materials that can absorb color inks are required. Color ink is injected using color inkjet printer technology.

In the optical molding method, the resin is solidified one layer at a time by irradiating the molding material extruded from the nozzle with a UV laser. The surface is characterized by smoothness and high definition, and photo-curable epoxy resins and acrylic resins are used as molding materials. Color inks are also made from acrylic resins and light-cured to ensure strength.

What Is a Digital Signal Processor (DSP)?

A DSP is a series of arithmetic processing devices (processors) that perform digital signal processing.

It can analyze input audio and video data, temperature, acceleration, and other information at high speed and output it in digital or analog format.

A DSP is equipped with independent “program memory” and “data memory,” and data is transferred between them.

In recent years, multiprocessor configurations have been used to perform more complex operations, such as big data processing.

Uses of DSPs

DSPs are used in many products that require high-speed, high-precision signal processing performance.

Because of their ability to modulate and demodulate signals, perform Fourier transforms, and filter at high speeds, they are used in a wide range of applications. This includes personal computers, portable electric fields, digital AV equipment, and copy machines.

For example, DSPs are used in the voice recognition functions of smartphones and in image processing in the medical field.

DSPs are also used to reduce the load generated by power circuits in servers and other devices through digital control using DSPs.

Features of DSPs

Signal processing methods that previously used separate hardware have been used. However, with the advent of DSPs, a significant improvement in signal processing speed has been realized.

DSPs can perform complex operations at higher speeds than general-purpose microprocessors.

The DSPs are equipped with a high-speed AD converter, and the input data is transferred to the memory inside the DSPs.

The memory includes program memory and data memory, with the micro-processing unit (MPU) acting as an intermediary between them.

Each memory and MPU are connected by a bus (signal line), and data is transferred between memories through the bus, enabling processing operations such as sum-of-products.

Program memory stores the program used for data processing, and data memory stores the data to be processed.

The processed data is then output as digital data or analog data after DA conversion.

DSPs are currently being developed that can perform arithmetic processing in a fraction of a nanosecond (about 100 nanoseconds), including all of these processes.

What Is a Product Lifecycle Management Service?

Product lifecycle management (PLM) service is a comprehensive system designed to manage and optimize the entire lifecycle of a product from its inception through design and manufacturing, to service and disposal. It serves as a central hub for managing vital information and processes across different stages of product development, thereby enhancing product quality, development speed, and efficiency.

PLM services also play a crucial role in ensuring standardization and compliance with industry regulations.

Uses of Product Lifecycle Management Services

PLM services are invaluable across various industries, particularly those looking to strengthen their manufacturing processes and product management:

1. Electrical Equipment Manufacturers

Electrical equipment manufacturers leverage PLM to automate and refine design and production processes for both mass-produced and bespoke products.

2. Precision Equipment Manufacturers

PLM aids precision equipment manufacturers in managing maintenance parts efficiently, significantly reducing the time spent on parts lists and data management.

Moreover, PLM is increasingly applied in infrastructure equipment and plant maintenance, enhancing maintenance efficiency and equipment stability through operational monitoring and management.

Principle of Product Lifecycle Management Services

PLM systems centralize and streamline the management of the entire product lifecycle:

1. Data Management

At its core, PLM involves centralizing all product-related data, from design and manufacturing to sales and maintenance, enabling easy data access, reuse, and efficient communication during design modifications.

2. Process Management

PLM offers tools for managing the workflows of product development, including project and resource management, allowing for real-time task progress tracking and resource allocation.

3. Collaboration

PLM supports collaboration among various internal and external stakeholders, ensuring that all parties have access to the latest information and facilitating seamless information exchange.

4. Regulatory Compliance

Especially crucial in regulated industries, PLM helps ensure products meet all relevant regulations and standards, aiding in the generation of necessary compliance documentation.

Additional Information on Product Lifecycle Management Services

The Emergence of Product Lifecycle Management Services

The concept of PLM evolved from the need to manage the growing complexity and volume of data in product manufacturing. Originating from product data management (PDM), which focused on managing technical data, the scope of PLM expanded to include data sharing across all departments involved in the product lifecycle, responding to the global diversification of customer needs. PLM integrates information across design, production, procurement, logistics, sales, and maintenance, enhancing design efficiency through AI and facilitating system integration via standard programming languages.

What Is a Biodegradable Film?

A biodegradable film is a type of plastic that is ultimately decomposed to the molecular level by the action of microorganisms, resulting in water and carbon dioxide.

In general, plastics are synthetic polymers derived from petroleum, which are difficult to decompose in the natural world.

Therefore, conventional plastics that are buried in the soil or dumped into the ocean remain for a long time without returning to nature. This is becoming a serious environmental problem.

Biodegradable film, on the other hand, is decomposed by microorganisms that exist in the natural world. It is attracting attention as a plastic that can be recycled as a resource.

Uses of Biodegradable Film

Biodegradable films are mainly used for agricultural and civil engineering materials, food waste collection bags, and food container packaging. Some examples are shown below:

1. Mulch Sheets for Agriculture

Biodegradable film is used in agricultural mulch sheets. Agricultural mulch sheets are used to cover field beds and are effective in regulating soil temperature, retaining moisture, and controlling weeds and diseases. The use of biodegradable film in agricultural mulch sheets can greatly reduce the labor required to collect and dispose of used mulch sheets.

2. Food Waste Collection Bags

Biodegradable film is also attracting attention as an alternative to food waste collection bags. If biodegradable film is used as food waste collection bags and processed directly in composting and methane gas fermentation facilities, food waste can be recycled without waste.

3. Marking Tape

Marking tape is mainly used to mark trees in mountain forests. Commonly known as “red tape,” it is used for hazard avoidance, course signage, landmarking, and patrol purposes. The use of biodegradable film eliminates the need to remove it and does not affect the trees.

4. Vegetable Broadcasting Film

Vegetable broadcast film is used to protect the quality of vegetables. This form of packaging is essential for the sale and transportation of vegetables and consumes a lot of plastic. By incorporating biodegradable film as an alternative to existing plastics, you can conduct your business in an environmentally friendly and ecological manner.

Characteristics of Biodegradable Film

The raw materials for biodegradable film can be broadly classified into petroleum-derived biodegradable plastics and plant-derived biodegradable plastics. Polyvinyl alcohol (PVA) is the most common petroleum-derived material, while polylactic acid (PLA) is the most common plant-derived material.

Although biodegradable film is considered to have a low environmental impact, it is not necessary to replace all plastic products with biodegradable film. The priority of replacement is considered based on whether biodegradability is necessary for plastic products that have an environmental impact.

The criteria used to determine this are whether the product is durable or non-durable and whether there is sufficient recovery of the product. High priority is given to non-durable materials that have not been recovered to a great extent.

Typical examples are fishing lines and fish nets, which account for about 41% of litter by weight. If these materials are made biodegradable, even if they are released into the environment, they will be decomposed by microorganisms in the ocean, enabling resource recycling.

Types of Biodegradable Film

In general, plastics are classified into thermoplastics and thermosetting plastics.

However, biodegradable plastics include only thermoplastics.

This is because the film must decompose at a faster rate. Chemical structures that can be biodegradable include aliphatic polyesters and aliphatic polyamides, all of which are thermoplastics.

Plastics that are biodegradable include the following types:

1. PLA

PLA is a plant-derived plastic called polylactic acid and is classified as a bioplastic. It is mainly composed of starch from corn, sugar beets, potatoes, etc., and is biodegradable.

2. Cellulose Acetate (Diacetate)

Cellulose acetate is made from wood-derived fibers and cotton. It is produced by esterification of the extracted cellulose with acetic acid. It is valued as a biomass resource because it is ultimately decomposed into water and carbon dioxide.

What Is a Pipe Heater?

A pipe heater is a heater that heats the liquid flowing inside a pipe to prevent it from freezing. It is also known as an anti-freeze heater or anti-freeze strip.

A pipe heater is used especially for water pipes and is indispensable in cold climates where temperatures are below freezing. When water pipes freeze, not only does the water supply become unavailable, but the volume of water expands as it freezes. This can deform the pipes, or in the worst-case scenario, cause them to burst. A pipe heater is used to prevent freezing by heating water pipes.

Uses of Pipe Heaters

Pipe heaters are often used in cold regions to prevent water pipes from freezing.

In particular, water pipes that are not buried underground but exposed to the ground must be protected from freezing by pipe heaters.

At this time, if the appropriate one is not selected depending on the material of the water pipe, it may end up damaging the pipe.

In the past, water pipes were mainly made of metals such as copper pipes, but in recent years they have been replaced by PVC and polyethylene pipes and other resin-based materials. Pipe heaters have also been improved in line with these changes in the materials used for water pipes.

Structure of Pipe Heaters

Pipe heaters consist of a heating element and a power cable.

Heating Element and Power Cable

The heating element is made of nichrome wire, etc. Joule heat is generated when an electric current is applied through the power cable. The power cable may come with an energizing lamp or a power lamp to confirm that the heater is not disconnected.

A band-shaped heating element portion, like a flat cable, is wrapped around a water pipe to heat the water in the pipe. By wrapping a heat-retaining tape over the wrapped heating element, the heating element and water pipe can be firmly fixed and the pipe can be efficiently heated.

Combination With Pipe Heaters

Pipe heaters are often used in combination with thermostats. Using a thermostat has two advantages: it allows temperature control and saves on electricity costs by heating only when necessary.

Thermostat Detection Methods

There are two types of thermostats: the outside temperature sensing type and the pipe temperature sensing type.

The outside temperature sensing type reacts to the outside temperature and does not need to be attached to the piping, making it easy to install, but it may continue to heat the water excessively, even if the water inside is sufficiently warm.

On the other hand, the piping temperature sensing type measures the pipe temperature, so there is no need to worry about excessive heating. However, the piping and the thermostat must be tightly adhered to one other, and careful attention must be paid to the installation.

How to Select Pipe Heaters

There are many types of piping heaters available, but the heater must be selected, along with the material and length of the piping to be installed.

Another criterion for selecting a pipe heater is whether the power cable comes with an energizing lamp, a power light, an energy consumption indicator monitor, or a thermostat.

One thing to keep in mind is the material of the piping and the way the heating element is coated. For example, if the piping is made of resin, such as cross-linked polyethylene pipe, and the heating element is coated with soft polyvinyl chloride, the plasticizer will migrate and cause the piping to become brittle.

Therefore, be sure to select a product that has countermeasures for the covering of the heating element.

Self-Control of Pipe Heaters

Self-controlled heaters without thermostats have become popular in recent years. This type of heater does not require the use of a thermostat and will not fail due to abnormal heating or burnout of the heating element. The heating element is designed to heat in accordance with the ambient temperature automatically.

There are also heaters available that are configured in parallel circuits, allowing for cutting and other processing on site. Self-controlling heating resistors are used as heating elements.

Furthermore, the heater can be operated economically with energy savings due to fewer attached devices, and it also has excellent quietness.

However, electricity costs are incurred because current continues to flow while the unit is connected to a power source.