月: 2023年3月

What Is a Welding Machine?

A welding machine (welder) is a generic term for welding machines that perform welding (melting and joining materials such as metals).

Welding machines include arc welders and laser welders, which perform welding only, as well as welding robots, which are equipped with welding machines and automate the welding process.

The welding methods used by Welding Machines are broadly divided into four types: “arc welding,” “gas welding,” “resistance welding,” and “laser welding.” There are several types of welding machines according to each welding method, especially arc welding machines, such as “covered arc welding machine”, “MIG/MAG welding machine”, “TIG welding machine”, and a “plasma welding machine”.

Uses of Welding Machine

Welding machines are widely used at sites where metal products are manufactured by processing, joining, and assembling metal materials, construction sites, automobile manufacturing plants, and other sites where products are manufactured by joining metal to metal materials.

They are used in automobile factories for welding bodies and frames in the production line, in ship factories for welding steel plates and frames of hulls, and in other situations where welding is performed by automatic welding robots.

In addition to large products and manufacturing plants, automatic, semi-automatic, and manual Welding Machines of various sizes are used in steel and can manufacturing plants, construction sites for steel rebar work, and other applications.

Welding machines are usually dedicated to different welding methods.

Principle of Welding Machine

Welding is defined as “the operation of bringing two or more base materials together by heat, pressure, or both so that there is continuity between the base materials to be joined.” Welding machines are used to perform this welding process and are available in a variety of configurations to accommodate different welding methods.

For example, a stand-alone welding machine, such as a manual welder, consists of a power supply unit to generate the electric current that serves as the heat source, a welding torch at the tip of the weld, a wire supply unit to supply the welding torch with the consumable filler, and a cylinder and hose, to supply the shielding gas.

Laser welding machines consist of a laser oscillator to generate laser light, a laser focusing lens, and an assist gas supply cylinder and hose. In addition to manual welding machines, there are also automatic welding machines that move the bed with the welding base metal left, right, up, and down as programmed to move the welding point automatically.

In the case of automatic welding robots, there are machines in which a robot arm with a welding torch attached moves to the position programmed by teaching, etc., and welds, and machines that can automatically move and rotate the base material to be welded and the direction of the product to be welded, and perform welding operations automatically and continuously.

There are also machines like CAM (Computer Aided Manufacturing) that automate welding machines by using 3D CAD models and programming the welding position, welding speed, etc.

By using these automated welding machines, complex and various welding operations can be automated, enabling stable and high-quality welding work.

What Is a Bare Crimp Terminal?

A crimp terminal is a component that connects an electrical wire to an electrical device.

Mechanical pressure is applied by passing the end of the electrical wire through the crimp to connect the crimp terminal firmly to the wire. Connection to electrical equipment is made by screwing the terminal connection part of the crimp terminal to the terminal board.

Bare crimp terminals are a type of crimp terminal that does not have an insulation coating. Compared to crimp terminals with insulation coating, bare crimp terminals have the advantage of being less expensive and shorter working hours. However, they also have the disadvantage of having to be insulated after installation, depending on where they are installed.

Uses of Bare Crimp Terminals

Connecting electrical wires to electrical equipment is often done by soldering, which requires a certain degree of soldering skill. In contrast, the connection with crimp terminals has the advantage of being relatively simple.

In addition, soldering is done in a designated place, such as a workshop, whereas connection work using crimp terminals can be done anywhere. Because they can be used on-site, they are often used for wiring on switchboards.

Among crimp terminals, bare crimp terminals are generally used to connect single electrical wires.

Principle of Bare Crimp Terminals

There are many varieties of bare crimp terminals, depending on the combination of wire and screw, and they have a unified name such as “R2-4”.

The first letter indicates the shape of the terminal connection: “R” for round terminals (R-type) and “Y” for open terminals (Y-type); the first of the two numbers indicates the cross-sectional area of the wire (mm2) and the second number indicates the screw diameter (mm).

There is a range of wire sizes that can actually be used in relation to the cross-sectional area of the wire in the product name. If the wire is smaller than the range, the wire may fall out. If the wire is larger than the range, it will not fit into the crimp terminal and cannot be crimped.

There are special tools for connecting crimp terminals and wires, depending on the type of crimp terminal. When crimping bare crimp terminals, be sure to use a tool dedicated to bare crimp terminals.

Crimping tools come in several sizes. After selecting the appropriate size for the terminal, set the bare crimp terminal on the end of the tool, insert the wire with the end sheath removed into the crimp section, and grip the tool firmly to complete the crimp.

What Is a Cooling System?

Cooling Systems are devices, equipment, or electronic equipment that are used to reduce temperature increases. Cooling Systems can be broadly classified into two types: water-cooled, which uses water to cool, and air-cooled, which uses air to cool.

Among the water-cooled types, there are two types: one uses industrial water and the other uses a chiller system that recirculates water that has been heated through the equipment by cooling it again.

Air-cooled systems absorb heat and dissipate it to the atmosphere through contact with heat-conductive metal or air, or use an electronic device called a Peltier element to transfer heat.

Uses of Cooling Systems

Air-cooled heat exchangers are used in cooling systems of petroleum complexes and waste incineration plants, where large amounts of heat are generated. An air-cooled heat exchanger is cooled by flowing the fluid to be cooled and blowing air with a fan.

Water-cooled heat exchangers are used to efficiently cool metal parts. By drilling holes in the parts to be cooled and passing cooling water through them, the heat of the metal parts can be taken away directly. They are used for camera noise reduction and brazing machines that generate high temperatures locally.

Peltier elements may be used in areas where water or air cannot be circulated or where cooling to below 0°C is desired.

Principle of Cooling System

Cooling Systems using Peltier elements can cool objects down to below 0°C (32°F).

Peltier elements cool by utilizing the thermoelectric effect, a phenomenon in which heat is absorbed and dissipated at the metal junction when two different metals are connected in series, and an electric current is applied to them. Since the direction of heat flow can be controlled by the direction of current applied to the Peltier element, it can be used not only for cooling but also as a heat source.

Peltier elements can take away a large amount of heat by stacking multiple layers, but it is also important to dissipate the heat taken away efficiently. In general, heat is dissipated using aluminum heat-dissipating fins and heat exhaust fans. However, in order to improve efficiency, the number of units that use heat pipes and heat conductive sheets in combination is increasing. Not only the heat absorption power of the Peltier but also the amount of heat that can be exhausted is important.

Recently, flexible Peltier elements have been developed that can adhere to curved surfaces for efficient cooling.

What Is an Electronic Leak Detector?

An Electronic Leak Detector is a device that emits a sound or signal to alert the user in the event of an electrical leakage.

Electrical wiring may be subject to insulation deterioration due to the insulation coating peeling off as a result of disasters or age-related deterioration. When this occurs, sparking between the exposed core wire and the building frame generates heat, and wiring with an organic insulation coating can easily catch fire.

Electrical fires are often caused by the above causes. Electronic Leak Detectors are installed for the purpose of preventing such fires.

Usage of Electronic Leak Detectors

Electronic Leak Detector installation standards for buildings are generally using lath mortar.

Lath mortar is a structure in which mortar is spread around a metal mesh called metal lath. Thin metal mesh has a low allowable current and low grounding resistance, which increases the risk of fire.

Even when lath mortar is used, the installation may be exempted if the contract current is low or the total floor area is small.

Principle of Electronic Leak Detector

Electronic Leak Detectors are designed to detect ground-fault currents and to alarm when a certain power system is not normally supplied with power.

When a power system is feeding power normally, the sum of the currents on the distribution lines is always zero. This is true for both three-phase and single-phase systems. In electrical engineering, this is called a balanced state. In a balanced state, the sum of the magnetic fields around the wiring feeding a single system is zero, and the change in the currents around the system due to the magnetic fields is 0A. 

However, when a ground fault occurs and a ground fault current flows, the equilibrium state is disturbed and the sum of the magnetic fields of all phases is no longer 0. ZCT is a device that clamps all phases of wiring together and detects currents flowing out of equilibrium.

Electronic Leak Detectors receive the earth fault current value from the ZCT, and if the value exceeds a predetermined threshold value, the alarm is triggered. Since it only emits an alarm, it has no interrupting capability against leakage current. For leakage current fire protection, a separate switchgear or RCD must be installed.

What Is Transport Management Software?

Transport management software (TMS) centralizes the management of delivery-related information to achieve efficient dispatch and delivery of goods. It optimizes delivery plans considering various destinations and bases, allowing for real-time tracking of vehicle locations.

As logistics volumes expand, the need for more efficient transportation operations—such as optimal truck allocation and delivery cost reduction—becomes critical. TMS offers a comprehensive solution by managing all transportation and delivery operations within a unified system.

Typically part of a logistics management system, TMS works in conjunction with warehouse management systems (WMS) to streamline the entire logistics process.

Uses of Transport Management Software

TMS aims to enhance delivery efficiency by consolidating transportation and delivery tasks. It addresses the growing need for more effective delivery operations amid increasing logistics volume and driver shortages. By generating optimal dispatch plans and managing loads and routes, TMS reduces logistics costs and worker workload.

Principles of Transport Management Software

Key functionalities of TMS include:

1. Dispatch Management

It generates optimal delivery plans by considering factors such as destinations, product costs, and available vehicles, improving route efficiency.

2. Transportation and Delivery Management

Real-time GPS tracking of vehicles and products provides current delivery statuses and estimated arrival times.

3. Transportation Cost Calculation

The system calculates all transportation-related costs, including wages and fees.

4. Performance Management

Automatically generates driving reports and records, managing driving behavior and contributing to operational improvements.

5. Vehicle Management

Manages fleet-related operations, including vehicle lease statuses and associated expenses.

TMS offers flexibility to handle non-routine tasks and adapt to unforeseen challenges such as traffic congestion.

How to Select Transport Management Software

Key considerations when choosing a TMS include:

1. Functionality

Ensure the system meets your specific shipping operation needs. Focus on functionalities crucial to your business, like delivery planning and customer information management.

2. Customizability and Linkage

The system should be customizable to fit your business requirements and capable of integrating with existing systems, enhancing overall functionality.

3. Operability

Confirm the software’s ease of use, ensuring an intuitive user interface that minimizes errors across all user levels, from experienced staff to newcomers.

What Is a Logistics Management System?

A logistics management system manages logistics processes and inventory of raw materials and products. It encompasses warehouse management systems (WMS) for warehouse operations and transportation management systems (TMS) for shipping and delivery, addressing the increased complexity and volume of goods handled in modern logistics.

Uses of Logistics Management Systems

Logistics management systems aim to streamline operations, enhance logistics services, and cut costs by digitalizing the management of logistics-related information. They are increasingly adopted for on-site management due to their ability to handle the growing complexity and volume of logistics operations, moving beyond traditional Sales Management Systems.

Principles of Logistics Management Systems

Logistics management systems typically include WMS for inventory and warehouse operations, and TMS for transportation and delivery, leveraging technology to reduce manual labor, minimize errors, and improve operational efficiency.

1. Warehouse Management System

WMS enhances warehouse operations through inventory management, shipping, and labeling, utilizing barcode readers and scanners to streamline processes and link with other systems for comprehensive asset management.

2. Transportation Management System

TMS optimizes transportation and delivery, including vehicle allocation, route planning, and cost calculation, integrating data from WMS to plan efficiently and manage driver performance.

How to Choose a Logistics Management System

Selecting a logistics management system requires consideration of business-specific functionalities, cost-effectiveness, usability, support, and scalability to ensure it meets current and future business needs.

1. Functions That Match the Characteristics of Your Business

Select a system with features tailored to your logistics operations, such as route optimization for businesses handling their deliveries.

2. Usage Fees and Cost Effectiveness

Assess the system’s costs against its potential for cost reduction and return on investment to choose a cost-effective solution.

3. Operability and Ease of Use of the System

Ensure the system is user-friendly to minimize employee stress and errors, potentially through demos or trials.

4. Support System

Opt for a system with robust support available round the clock, especially for operations running 24/7.

5. System Scalability and Customizability

Choose a system that can grow and adapt to your business, considering integration capabilities with other systems to enhance management functions.

What Is a Materials Management System?

A materials management system, also known as BOM (bill of material) system, is a system that not only manages parts but also manages the bill of materials used to manufacture and manage products, and provides appropriate information related to the parts to various departments.

Depending on the management method, there are two main types of materials management system: integrated materials management system and application-specific materials management system. An integrated materials management system has the advantage that it is less likely to cause discrepancies between departments, since the bill of materials is managed centrally across departments.

However, the disadvantage is that the usage of the bill of materials generally differs from one department to another, making it difficult for certain departments to utilize the system in some cases. On the other hand, materials management system by application have the advantage that the system can be easily utilized in each department because the BOM is created and managed specifically for a particular department. However, since the system does not use a unified bill of materials among departments, there is a risk of inconsistency among departments.

Usage of Materials Management Systems

The main use of materials management system is to manage a bill of materials, inventory status of parts, warehousing history, and ordering status in real time. By centralizing information previously managed on paper or in other systems, materials management system enables efficient management of parts.

BOM is an important document used in various departments, such as design, production, and purchasing. Although the same bill of materials should normally be used across departments, in practice, different departments often use different bills of materials for their own management, resulting in issues such as design changes in one department not being reflected in another department’s bill of materials.

In recent years, manufacturing processes have become more complex, and the use of BOMs across multiple departments has increased, so efficient management of parts and BOMs is required. In many cases, parts and bills of materials are managed electronically in Excel and other formats. However, general electronic management has left problems, such as input errors (e.g., double entry) and design changes that are not reflected.

With the introduction of materials management system, changes to the BOM can be made in real time and can be easily shared by other departments.

Materials Management System Functions

Typical functions of a materials management system are as follows:

1. BOM (Bill of Materials) Management Function

A materials management system can manage BOMs, which has the advantage of clarifying the location and contents of BOMs, and preventing inconsistencies between BOMs when multiple BOMs are used. In addition, existing BOMs can be easily referenced when creating new BOMs. 

2. BOM (Bill of Materials) Update Function

When design changes are made, the BOM can be automatically updated based on the details of the changes. This facilitates information sharing among departments and unification of BOM content, especially when changes are managed across multiple departments or when the changes affect multiple BOMs.

3. Inventory Management Function

An actual materials management system can be used to manage actual parts. By linking parts to processes, it is possible to estimate in advance which process each part will be used in, whether parts are in surplus or shortage, and the construction period until completion.

4. Product Management Function

Products can also be managed. By linking products to their respective bills of materials and drawings, it is possible to check parts and drawings by product name.

The functions required will vary depending on how the BOM is managed. Selecting a materials management system after clarifying in advance which functions are important to you will make it easier to implement the system.

How to Select a Materials Management Systems

1. Functionality

Since the way to manage the bill of materials varies from company to company, it is necessary to confirm in advance whether the materials management system has the necessary functions before selecting a system. For example, there are functions such as automatic ordering, inventory control, and warehouse management, etc. It is important to review from the business process point of view which system will be used for the business and which functions will be linked with other systems.

2. Ease of Use

Materials management systems are often handled not only by personnel familiar with the business but also by temporary workers and young employees in some companies. Therefore, we check whether the system has a simple user interface that can be operated smoothly and whether it is accompanied by intuitive operability.