月: 2024年1月

What Is a 3D Printer Metal Material?

3D printer metal material refers to the materials used in the manufacturing of metal parts through 3D printing technology.

3D printing technology enables the efficient production of parts with complex shapes and internal structures, allowing for the realization of designs and structures that were challenging with conventional manufacturing methods. This expands the possibilities for new products and designs. By minimizing material waste compared to machining or subtractive methods, it is also possible to reduce material costs.

Additionally, the high degree of design freedom makes it suitable for the fabrication of custom parts and prototypes. The ability to implement design changes quickly enables rapid prototype development and design optimization.

However, it is generally more expensive than other materials, so consideration must be given not only to the cost of the material itself but also to the operational costs of 3D printing equipment and post-processing costs.

Uses of 3D Printer Metal Material

The uses of 3D printer metal material include:

1. Aerospace Industry

3D printing of metal components plays a crucial role in the aerospace industry. It allows for the manufacturing of parts, such as engine components and fuel injectors, that operate under high-temperature and high-pressure conditions. The use of 3D printing enables the realization of complex internal cooling channels and high-efficiency designs that were challenging with traditional manufacturing methods.

2. Automotive Industry

In the automotive industry, the use of metal 3D-printed parts can enhance vehicle performance. The fabrication of components like suspension parts using a 3D printer allows for the production of complex-shaped and structured parts, enabling lightweight and high-strength designs that contribute to improved fuel efficiency.

3. Medical Devices

In the medical field, 3D printers are widely used for the production of custom medical devices. Examples include artificial joints and custom implants. The ability to manufacture parts tailored to the patient’s characteristics improves compatibility.

4. Energy Industry

In energy-related industries, 3D printers are used to manufacture parts that can withstand high-temperature and high-pressure environments. Components like cooling parts and fuel rods for nuclear power plants are 3D-printed, enhancing safety and reliability. Turbine blades for gas turbine engines are also frequently manufactured using 3D printers.

Characteristics of 3D Printer Metal Material

3D printer metal materials often have high strength. This allows them to be used in high-load environments and applications with stringent requirements. Being metallic, these materials typically exhibit excellent durability and long lifespans.

Furthermore, the use of 3D printer metal materials enables the fabrication of complex internal structures, contributing to the lightweighting of components. It allows for the production of intricate cooling channels, lattice structures, internal voids, and other features that would be challenging with conventional manufacturing methods. This, in turn, contributes to improved fuel efficiency in industries such as aerospace and automotive.

Moreover, the efficiency of manufacturing individual parts through 3D printing is a notable advantage. In the medical field, designing and manufacturing patient-specific parts using various materials is possible.

However, proper process control and quality management are crucial. Additionally, due to the high costs associated with manufacturing metal 3D-printed parts, it is essential to focus on producing high-value products.

Types of 3D Printer Metal Material

3D printer metal materials are primarily manufactured from metals and metal alloys, and the types include:

1. Stainless Steel

Stainless steel is a common 3D printer metal material known for its corrosion resistance and excellent strength. Various types of stainless steel, such as SUS304 and SUS316L, are used for 3D printing. Its stable physical properties, even in high-temperature environments, make it advantageous for applications like industrial machinery and automotive components.

2. Aluminum Alloy

Aluminum alloys are lightweight yet offer high strength, making them suitable for applications in the aerospace and automotive industries. They are frequently used for manufacturing cooling components, allowing the production of complex-shaped parts.

3. Titanium Alloy

Titanium alloys are extremely lightweight with excellent durability and corrosion resistance. Widely used in fields like medical devices and biomechanics, they offer advantages in the production of artificial joints and dental implants.

4. Nickel Alloy

Nickel alloys possess properties that withstand high-temperature environments, making them suitable for industries such as gas turbine engines and aviation engines. They are characterized by high durability and corrosion resistance.

5. Copper Alloy

Copper alloys have high thermal conductivity, making them suitable for electronic devices and cooling components. Components like electronic cases and conductive parts are manufactured using 3D printing technology.

What Is a T Nut?

A T Nut refers to a fastening component with a T-shaped cross-section, designed to be inserted into a T-shaped groove to securely fasten parts together.

Nuts, when used in pairs with bolts or screws, fasten two or more components together. While there are various types of nuts, such as hex nuts, cap nuts, wing nuts, etc., the T Nut, when viewed horizontally with the through-hole for the bolt on the upper and lower faces, appears T-shaped.

The distinctive feature of T Nuts is their ability to securely fix fastening components in a precise position, making them commonly used in machine tools. Here, we will focus on explaining T Nuts, also known as jaw nuts, used to secure jaws to chucks in machine tools like lathes.

Uses of T Nut

T Nuts are utilized by inserting them into the T-shaped grooves of machine tools to securely fix components in a precise position.

In machine tools like lathes, jaws, such as dead centers or hard centers, are attached to the chuck to secure the workpiece. The jaws grip and hold the workpiece according to the tightening of the chuck.

Usually, a sufficient number of T Nuts accompany each chuck. When attaching jaws to the chuck, T Nuts are initially bolted to the jaws. Subsequently, T Nuts are inserted into the groove of the chuck, and bolts are further tightened to secure them.

In manufacturing settings, where jaws are frequently changed during the processing of a single workpiece, and since chucks typically have three jaws, the time spent on setup increases if T Nuts are replaced each time jaws are changed. To address this, a solution is to prepare the required number of T Nuts for the anticipated number of chucks in advance. Each T Nut is pre-attached to its respective jaw, streamlining the process of jaw replacement.

Principles of T Nut

Generally, T Nuts are used in locations subjected to vibration, or impact, where nuts are prone to loosening due to vibration or impact, and in places requiring high-precision fastening.

When fixing jaws to the chuck using T Nuts, bolts pass through holes in the jaws, and the bolts are threaded into the T Nuts. The jaws have a slender shape when viewed from above, with two holes arranged side by side. With T Nuts engaging at two points, there is no play or wobbling after fastening.

Jaws equipped with T Nuts are inserted into the T groove on the chuck, and further securing is achieved by tightening bolts. Chucks can have a part with a T groove called the master jaw, which receives the T Nut (jaw nut), or some chucks may have T grooves directly machined without using a master jaw.

Using a master jaw makes T Nut installation easier, improving attachment accuracy. However, the cost of the chuck increases, and the price of the master jaw adds to the overall cost.

On the other hand, directly coupling T Nuts to the chuck can help control the overall cost, but it makes T Nut installation more challenging and may compromise precision.

How to Choose T Nut

In lathes, preventing core runout of the workpiece and achieving high-precision machining require the accurate attachment of jaws to the chuck. During machining, the chuck rotates at high speed, and the force and vibration from impacting the workpiece with a cutting tool are transmitted.

T Nuts and master jaws absorb these forces, maintaining accurate jaw attachment. The available jaws, T Nuts, and master jaws vary from one chuck manufacturer to another.

When selecting T Nuts, it is essential to choose those that match the chuck and master jaw you intend to use.

Jaws come in two types: dead centers and hard centers. Dead centers, especially used for finishing processes, are consumables and often require frequent replacement. However, T Nuts and bolts, as long as their sizes are compatible, do not need frequent replacement.

However, if the threads of nuts or bolts are damaged or if there is debris caught in the threads, there is a risk of reduced precision. In such cases, replacement may be necessary, emphasizing the importance of having spare parts on hand.

What Is a Dead Center?

A Dead Center is a fixture attached to the tip of chucks in machine tools such as lathes to secure workpieces.

In machine tools like lathes, the workpiece is held in place by jaws attached to the tip of the chuck to rotate the workpiece. There are two types of jaws: hard centers and dead centers.

Hard centers, hardened through heat treatment, are used in the roughing stages due to their hardness, making them difficult to shape. On the other hand, dead centers are made of non-heat-treated metal, allowing for easy shaping, and are used in the finishing stages. They can create a contact surface shape tailored to the shape of the workpiece, securing even irregularly shaped workpieces like those with a star-shaped cross-section.

Uses of Dead Center

Dead Centers are used in machine tools such as lathes to process workpieces in the finishing stages or when working on workpieces with special shapes.

They are employed in various machine tools, including general lathes, milling machines, NC lathes, drill presses, machining centers, etc. In these machine tools, the workpiece is clamped between the chuck and the immersed jaws. If we liken the relationship between the chuck and the jaws to the human hand, the chuck is the palm, and the jaws act as the fingers.

While there are two types of jaws, hard centers, and dead centers, dead centers can shape jaws that fit each workpiece securely. Therefore, hard centers are used in the roughing stage, and dead centers are used in the finishing stage.

Additionally, when dealing with workpieces with special cross-sectional shapes or when conventional-shaped jaws cannot grip and hold conical-shaped workpieces effectively, customized dead centers are shaped to match the workpiece’s shape, allowing both roughing and finishing processes to be carried out using dead centers.

Principles of Dead Center

The shapes and sizes of workpieces handled by machine tools like lathes vary widely. Therefore, by replacing the jaws attached to the chuck, one machine can process workpieces of various shapes and sizes.

Jaws of a certain shape and size are provided as standard for each chuck. However, it is impossible to provide standard jaws that fit perfectly with all workpiece sizes and shapes. Therefore, dead centers that can be shaped to fit the workpiece are often used.

While hard centers, which have undergone hardening treatment, are challenging to process after hardening, dead centers, not subjected to hardening, are easy to shape. As a result, they can firmly grip the workpiece, preventing core runout and enabling higher precision processing.

Types of Dead Centers

Dead centers are classified into standard centers, small-diameter centers, high centers, wide centers, etc., based on their shape and purpose.

Standard centers are the dead centers that come with the chuck when purchased, with the lowest height becoming the standard. Small-diameter centers are dead centers designed to grip small-diameter workpieces. High centers are dead centers with greater height than others, used not only to match the material’s shape but also to prevent interference between the chuck and tools. Wide centers have a width wider than the standard, used for gripping large workpieces.

Additionally, there are custom-order dead centers that can be adjusted in height, width, length, shape, etc. Dead centers are often considered consumables since they are often cut along with the workpiece during cutting.

How to Choose Dead Center

When choosing a dead center, paying attention to the following points is crucial.

1. Material

Dead centers are generally made of iron or aluminum, and the choice depends on the material of the workpiece. Although iron is widely used today, different materials may be chosen based on specific requirements or non-ferrous metal processing.

Also, in cases where the working environment or the material being processed is highly corrosive, it is important to choose a dead center made of a corrosion-resistant material.

2. Hardness

Hardness is directly related to the durability and lifespan of the dead center. Higher hardness improves wear resistance, but it may also make the dead center brittle. Therefore, it is necessary to select the appropriate hardness according to the workpiece and cutting conditions. For example, dead centers with high hardness are suitable for high-speed cutting or processing of hard materials.

Additionally, the hardness of dead centers can be altered by heat treatment. Proper heat treatment during the manufacturing process is crucial to ensure accurate and consistent hardness.

3. Shape and Size

The shape and size of dead centers must be suitable for the shape of the target object. For instance, three-jaw chucks may be suitable for cylindrical workpieces, but for asymmetrical shapes or complex parts, special-shaped dead centers may be required.

If the dead center’s shape is symmetrical, the force during processing is evenly distributed, ensuring stable holding. It is essential to be mindful when changing the target object, as using dead centers that are too large or too small can lead to unstable holding, adversely affecting the quality of the processed item.

4. Wear Resistance

Since dead centers are subjected to friction and cutting forces, sufficient wear resistance is crucial.

In cases where high rotational speeds or strong cutting forces are involved, dead centers with low wear resistance will deteriorate quickly, resulting in a shorter lifespan. Surface treatments or coatings may be applied to improve wear resistance. Dead centers made of materials with high wear resistance withstand prolonged use, reducing the frequency of maintenance.

What Is a Switching Transformer?

A Switching Transformer is an essential component in power supplies, particularly in the predominant Switching Power Supplies.

Switching Power Supplies generate a pseudo-high-frequency alternating current internally, achieving compact and highly efficient power conversion and transmission through high-frequency operations.

Optimizing the transformer allows for the design of a power supply with minimal heat generation and noise. It stands as the most crucial component in the construction of Switching Power Supplies.

Uses of Switching Transformer

Switching Transformers are used, as the name suggests, in Switching Power Supplies.

Since Switching Power Supplies are employed in various electrical products, Switching Transformers find application in a wide range of electrical devices.

These include household appliances such as TVs, and air conditioners, communication devices like routers and gateways, information equipment like photocopiers and computers, industrial machinery like semiconductor manufacturing equipment, processing equipment, robots, and more.

Principles of Switching Transformer

Similar to other transformers, a Switching Transformer converts electrical energy into magnetic energy and facilitates the transmission of power.

The transferred magnetic energy is then reconverted into electrical energy to supply power to electronic devices. By increasing the frequency, transformers can be made smaller.

In addition to power transmission, Switching Transformers also incorporate a protective function (isolation) by interrupting unnecessary power to ensure the safe use of electronic products.

Concerning core materials, as power conversion occurs at high frequencies, suitable magnetic materials for rapidly changing magnetic flux are needed. Depending on the frequency band, magnetic materials like ferrite and dust are used selectively, with ferrite being commonly used in Switching Power Supplies.

How to Choose Switching Transformer

To match the Switching Transformer with the intended Switching Power Supply, the transformer must be custom-designed.

As this process can be quite complex and challenging, it usually involves discussions with the transformer manufacturer to finalize the design. The following steps are summarized in a flowchart style:

1. Determine the specifications of the power supply (input/output voltage, output power, circuit configuration, selection of control IC, oscillation frequency).
2. Choose the desired transformer shape from the transformer manufacturer’s catalog.
3. Size depends on the circuit configuration and oscillation frequency, so consultation with the manufacturer to decide is advisable.
4. When high insulation is required, using a larger transformer compared to power requirements is recommended (consult with the manufacturer).
5. Regarding pin assignment, constraints exist based on the layout of the circuit board and manufacturing constraints for the transformer. Consultation with the manufacturer is necessary for decision-making.

Furthermore, applicable safety standards vary depending on the destination and application. Transformers need to be designed to comply with these standards.

Since transformers are highly customized components, discussing with the manufacturer during the conceptual stage is advisable. Achieving optimization involves repeated prototyping and verification.

Finding a manufacturer with whom discussions are easy is a shortcut to optimal design.

What Is an Indicator Gauge?

An Indicator Gauge refers to an instrument that converts physical quantities such as temperature, pressure, flow, and weight into a readable form and displays them for human interpretation.

In various locations, including factories, machinery, and equipment in motion, monitoring various physical quantities such as temperature, humidity, flow, weight, and rotational speed is essential. Measurements of physical quantities are performed by sensors specific to each purpose, and the measured values are transmitted in electrical form.

There are analog indicator gauges and digital indicator gauges. They receive electrical signals from sensors and convert the values into a format understandable by humans for display. Additionally, some instruments, known as indicator controllers, not only display values but also have adjustment functions to bring parameters like temperature and humidity closer to target values. Sometimes, the term “indicator gauge” may also include indicator controllers.

Uses of Indicator Gauge

Indicator gauges are widely used in various locations, including factories and facilities, to monitor physical quantities of machinery in operation. Especially in facilities such as power plants, substations, and plants, numerous indicator gauges are embedded in control panels to monitor equipment conditions intensively. They are also utilized on ships to monitor the status of engines, boilers, etc., and even the electricity meters installed in residential houses are a type of indicator gauge.

The displayed physical quantities vary widely. In factories, they are used to display and monitor the temperature, pressure, and flow of gases and liquids, as well as the power and speed of machinery. Additionally, they are employed for the display and monitoring of various physical quantities such as humidity, illumination, sound volume, weight, and distance.

Indicator gauges also serve the role of notifying when monitored physical quantities reach a warning level. Analog types typically use a red-colored portion of the scale to indicate the warning range when the needle touches it. Digital types, on the other hand, present a warning level, and when the measured value reaches that level, they alert through alarms or lights. An indicator gauge with an alarm function is also referred to as an indicator alarm gauge.

Principles of Indicator Gauge

Indicator gauges include analog and digital types, each with different principles.

1. Analog Indicator Gauge

Analog indicator gauges, also known as analog electric meters, quantitatively indicate the input electrical quantity using the amplitude of needle deflection. They do not require an external power source and consist of driving, controlling, and braking mechanisms.

The driving mechanism generates a driving torque corresponding to the input electrical quantity, causing the needle on the meter to move. The controlling mechanism generates a controlling torque in the opposite direction to the driving torque using mechanisms like springs. The point where the driving torque and controlling torque balance is where the needle indicates the value. The braking mechanism suppresses needle oscillation, ensuring the needle stops promptly at the equilibrium point.

Analog indicator gauges are classified into various types based on the principles of their driving mechanisms, such as movable coil type, rectifier type, current force type, induction type, electrostatic type, thermoelectric type, and movable iron piece type.

The most commonly used indicator gauge is the movable coil type. In this type, a movable coil is placed within the magnetic field created by a permanent magnet, similar to the principle of a motor. When current flows through the movable coil, its interaction with the magnetic field causes the coil to tilt. The tilt of the coil is balanced by the force of the spring (braking mechanism), and the point where it stops indicates the value of the current. Movable coil-type meters excel in frequency characteristics and are commonly used in DC voltage and current measurements.

2. Digital Indicator Gauge

Digital indicator gauges convert the measured value into an electrical current, digitally convert it using an A-D converter, and then count the generated pulses to display the result as a numerical value.

Most products come with various additional features, such as alarm functions. For instance, they may store measured values in internal memory over a certain period, displaying changes in values over time in a graph.

Moreover, digital indicator gauges can perform multiple measurements with one device, process data at intervals, and display individual measurement results. Since the output is a digital signal, it can be sent to a network. By collecting results from multiple digital indicator gauges into one computer, monitoring the entire facility becomes possible. In many cases, software for the PC side is provided to establish a PC and network for digital indicator gauges.

How to Choose Indicator Gauge

The current mainstream of indicator gauges is digital. Various digital indicator gauges with multiple additional features are commercially available. When choosing a digital indicator gauge, it is advisable to verify that the basic specifications and environmental resistance meet the requirements and then select a product with convenient features tailored to the usage scenario.

On the other hand, analog indicator gauges have advantages such as not requiring a power source, excellent durability, and reliability, and are suitable for intuitive readings. The way the needle deflects allows for analog diagnostics, such as assessing the condition of machinery based on needle movement.

What Is a Letter Case?

A Letter Case is an envelope designed for organizing and storing postal items and letters using features such as clear files.

It is often referred to as a Letter Pack or cardboard envelope. These envelopes commonly use glossy cardboard on the surface and include space for writing the recipient’s address and name. The use of Letter Cases facilitates the secure mailing of important documents.

Moreover, they serve the role of protecting postal items and letters from unauthorized access by others. By storing documents inside and sealing them, it prevents individuals, including delivery personnel, from accessing the documents. This ensures the safe mailing of confidential documents and personal letters.

Using glossy cardboard helps protect postal items from elements like rain or snow. This role in shielding postal documents from damage enhances the reliability of postal services.

Uses of Letter Case

The primary uses of Letter Cases include the following:

1. Sending Business Documents

Specific examples of using Letter Cases for sending business-related documents and papers include invoices, estimates, presentation materials, and more. Envelopes often feature printed company logos, addresses, and sender information.

2. Sending Catalogs and Brochures

They are also utilized for sending business-related materials such as product catalogs and service brochures. Addresses are typically printed on the envelopes, and the materials are sent through postal services, reducing the need for personnel to move back and forth and enhancing the overall presentation.

3. Sending Photos and Artwork

Letter Cases are employed for storing and sending photos taken at events and artwork. As Letter Cases are often made from sturdy cardboard, they protect photos from rain or snow during transportation. The protection of sent photos or artwork contributes to improving the reliability of postal deliveries.

Principles of Letter Case

Letter Cases are manufactured by assembling cut pieces of thick paper in a flat design using glue or other adhesives. Following the design of the envelope, panels on the front and back of the envelope and the flap are cut out. The cut panels are then folded into the shape of the envelope.

The adhesive is applied to the folded flap portion of the envelope, often using rubber or self-adhesive glue. When the adhesive surfaces come into contact, they compress, sealing the envelope.

As needed, the envelope may undergo printing and design processes, including elements like company logos or postal code frames. Subsequently, the quality of printing and the sealing properties of the adhesive are checked before completion.

How to Choose Letter Case

When selecting a Letter Case, the following critical factors should be considered:

1. Size and Shape

The size of the Letter Case should be chosen based on the dimensions of the items to be stored inside. Common sizes include A4 (210mm x 297mm) and A5 (148mm x 210mm). Selecting an appropriate size is crucial, especially when sending larger documents.

While rectangular shapes are common, square or special-shaped envelopes are also available. Choosing a shape that complements the design of the document or material being sent is important.

2. Quality of Thick Paper

Letter Cases are made from various materials. Considering the texture and durability, selecting the right material is crucial. Common materials include craft paper, recycled paper, glossy paper, and more.

The weight of the thick paper affects the robustness and appearance of the envelope. Heavier paper provides sturdiness and a luxurious feel, while lighter paper can help manage costs.

3. Color and Design

Letter Cases are available in various color options. For business documents, white, cream, or light tones are often preferred. Colorful designs may be chosen for items like invitations.

What Is a Waterproof Box?

A Waterproof Box refers to a storage case for electrical equipment and similar devices equipped with protective features such as waterproofing and dust resistance.

When installing electrical equipment or distribution panels indoors or outdoors, it is essential to place them in robust cases to protect them from waterproofing, and dust prevention, and to prevent unintended contact by unauthorized personnel.

These boxes typically feature characteristics such as the ability to be fixed in the installation location, wiring outlets connected to the equipment, doors, and locks for opening and closing, allowing users to choose an appropriate one based on usage conditions. Moreover, some manufacturers produce Waterproof Boxes tailored to specific requirements.

Uses of Waterproof Box

Waterproof Boxes are utilized for the long-term protection of electrical equipment such as distribution panels, wireless devices, breakers, meters, and associated cables.

Outdoors, they are commonly mounted on utility poles or building walls. For instance, Waterproof Boxes enclosing control panels for traffic lights are often seen mounted on signal poles. Additionally, related equipment is stored beneath the lower part of antennas used for mobile phone relay stations.

Indoors, in places like factories, Waterproof Boxes are used to safeguard equipment such as monitoring devices and control systems from unintended manipulation. Depending on the location, they can also protect electrical equipment from water droplets and dust scattered by machinery.

Thus, Waterproof Boxes serve a broad range of purposes beyond waterproofing and dust protection. They are employed to shield equipment from malfunctions, damage, incorrect operations, pranks, and more.

Principles of Waterproof Box

Waterproof Boxes include a platform for securing equipment, doors or lids for opening and closing to operate stored equipment, locks, and screw holes for securing the Waterproof Box itself. Additionally, separate holes are provided for power cords, signal cables used in electrical equipment, and, in some cases, conduits for passing water or air.

Due to the prolonged protection required for internal equipment, both protection and airtightness are demanded. Various standards have been established worldwide for Waterproof Boxes, and certification tests based on these standards are conducted.

One well-known standard is the Ingress Protection (IP) standard established by the International Electrotechnical Commission (IEC). The IP standard expresses dust resistance and waterproofing capabilities with two digits following “IP.” The left digit represents the dust resistance rating, and the right digit represents the waterproofing rating. Higher numbers indicate greater protective performance.

Common Waterproof Boxes seek both dust resistance and waterproofing capabilities, and you might see markings like “IP34” indicating both ratings. If a certification for either dust resistance or waterproofing is not obtained, it is represented with an “x.” For example, if it lacks dust protection certification, it might be expressed as IPx7, emphasizing only waterproofing capability.

Types of Waterproof Boxes

Waterproof Boxes come in two main types: those made of resin (plastic) and those made of metal.

Resin boxes are suitable for applications where wireless data communication devices like IoT devices are used, as they allow radio waves to pass through. They offer high waterproofing, are lightweight, and are easy to process. Metal Waterproof Boxes, made from materials like stainless steel, aluminum, or coated steel to prevent rust, are used when robustness is especially required, such as for control panels of traffic lights for security reasons.

Shapes and sizes vary, ranging from small key cases that can hold a few keys to large boxes that can accommodate large distribution panels. The location and size of cable holes also vary, with some having holes in two places for passing cables in both directions.

Products with additional features include those with transparent plastic doors for viewing instruments inside without opening the door and those with a ground terminal for connecting an earth wire.

How to Choose a Waterproof Box

When selecting a Waterproof Box, it is crucial to confirm the required waterproofing and dust resistance capabilities.

Depending on the usage location, there may be regulations specifying the use of standards, so choosing a product that meets these standards is necessary.

Moreover, there are cases where you can purchase pre-made products from e-commerce sites and cases where you might opt for custom-made solutions. If you are looking for the ideal protective performance and shape, or if you want to add unique features, or if you cannot find a commercially available product that meets your criteria, custom-made Waterproof Boxes can be created upon request.

What Is a Wireless Sensor?

A Wireless Sensor refers to a sensor that monitors pressure, temperature, vibration, and other conditions in facilities such as factories, transmitting the results via wireless communication.

In factories, various conditions such as the pressure of compressed air flowing through pipes for stable operation, temperatures of various liquids and gases, and vibrations of machinery are monitored. Sensors for this purpose are installed throughout the facility, constantly checking the measured data.

Using Wireless Sensors eliminates the need for wiring throughout the factory, enabling the collection of data from a wide range into one location. This allows for the visualization of overall operational status, facilitating more efficient and accurate facility management.

Uses of Wireless Sensor

Wireless Sensors are used for inspection and monitoring of factory equipment, as well as in various other locations such as environmental monitoring, buildings, commercial facilities, and homes.

In factories, products integrating sensors and transmitters are used to measure the pressure of gases, including air in pipes, the temperature of gases, liquids, and machinery, and the vibration of machinery. Multi-type Wireless Sensors combining pressure and temperature sensors are also utilized.

Principles of Wireless Sensor

1. Signal Transmission

A Wireless Sensor typically equips a transmitter with various sensors, transmitting signals wirelessly. Communication for Wireless Sensors involves using communication standards such as LoRa, ZigBee, Bluetooth, or other weak radio waves, as well as infrared communication.

LoRa (Long Range) is an international standard for Low Power Wide Area (LPWA) wireless communication with characteristics of wide coverage, long-distance, low speed, and low power consumption. Wireless Sensors using LoRa can achieve communication of approximately 1km independently and about 2km with a relay.

ZigBee is a communication standard designed for building wireless sensor networks. While it has a short transmission distance and low speed, it is inexpensive, consumes little power, and is suitable for use in ultra-small devices powered by batteries.

Bluetooth also has limited communication distance. Most commercial smartphones and computers support Bluetooth. Therefore, using these devices as relay stations makes it easy to send data to a Wide Area Network (WAN).

2. Power Supply

Wireless Sensors require power to operate, and many products are battery-powered. Wireless Sensors using wireless power supplies send power wirelessly using methods such as microwaves, and the sensor converts it into electricity. This is suitable for sensors in locations where continuous data sampling is required. However, it requires a nearby power supply device, and there may be issues with radio wave interference with other factory equipment.

Other methods include those that convert light into electricity, receive power via USB or other wired methods, and transmit data wirelessly.

How to Choose Wireless Sensor

When installing Wireless Sensors in a factory, it is essential to confirm the usage environment and radio wave conditions. From a DX perspective, considerations about how to build a Wireless Sensor network are also necessary for productivity improvement.

1. Usage Environment

In a factory with various operating devices and many radio waves and vibrations, it is necessary to consider whether the radio waves emitted by the network, including sensors and relays, will affect surrounding devices, or if the radio wave signals from sensors will be influenced by radio waves emitted by surrounding devices. Additionally, attention should be paid to variations in the reach of radio waves based on facility layout.

2. Consideration for Network Construction

When building a Wireless Sensor network in a factory, expectations for improved productivity through DX can be achieved. To achieve sufficient effectiveness, careful consideration of the construction procedure of the system and the content of the application to be used is required.

Other Information on Wireless Sensor

Advantages of Wireless Sensor

Introducing wireless sensors instead of wired ones has several advantages.

Firstly, the need for cable routing is eliminated, making it easier to install sensors in multiple locations and providing flexibility for layout changes. This is useful in locations where inspection points are far away or difficult to access, such as at heights or in confined spaces.

Moreover, by using numerous Wireless Sensors to collect monitoring data from equipment throughout the factory into one location, the construction of a Wireless Sensor network enables the streamlining, rationalization, and visualization of facility management. This is known as Digital Transformation (DX) in factories, utilizing digital technology to improve business processes and increase productivity in the manufacturing industry.

What Is a Rubber Injection Molding Machine?

A Rubber Injection Molding Machine is a mechanical device used for the injection molding of elastic materials such as rubber and elastomers.

The machine heats rubber or elastomer materials, injects them at high pressure through a nozzle, and molds products. This process allows for the manufacturing of components and products with highly precise and complex shapes and details. It contributes to improved quality consistency and reduction of defective products.

Moreover, the injection molding process is relatively fast, enabling the production of a large quantity of parts in a short period. This enhances productivity and cost-effectiveness. With precise control over process parameters, it is possible to ensure the reproducibility and consistency of components.

However, regular maintenance and cleaning are necessary. Machine components, nozzles, and molds must be kept clean. Additionally, due to the use of high-pressure and high-temperature processes, safety measures are crucial.

Uses of Rubber Injection Molding Machine

Rubber Injection Molding Machines find a wide range of applications for molding rubber and elastomer materials. The primary uses include:

1. Automotive Industry

Rubber Injection Molding Machines are widely used in the manufacturing of automobile tires. They mold rubber according to the tread pattern and size of the tire, providing wear resistance and high friction.

Moreover, rubber injection molding machines are used to manufacture seals and gaskets for automobiles. These seals and gaskets are crucial for preventing leaks of liquids or gases in engine components.

2. Electronics Industry

In the electronics manufacturing industry, Rubber Injection Molding Machines are employed to produce various components. Waterproof rubber gaskets are used to ensure the waterproofing of electronic devices, preventing water and moisture from entering. They are also frequently used in the production of silicone rubber keypads for keyboards.

3. Construction Industry

In the construction industry, Rubber Injection Molding Machines are used to manufacture parts necessary for sealing and waterproofing buildings and structures. Rubber gaskets are used in building materials such as windows and roofs, ensuring air tightness and water resistance. Additionally, silicone rubber gaskets contribute to maintaining air tightness both inside and outside buildings, improving energy efficiency.

Principles of Rubber Injection Molding Machine

A Rubber Injection Molding Machine is equipped with an injection device for supplying rubber or elastomer materials. This device fills the hopper with rubber particles or pellets, and a screw or plunger is used to inject the material into the injection cylinder.

The rubber material inside the injection cylinder is initially heated by high-temperature heaters. The temperature of the material can be controlled according to the type of material and the requirements of the product. Once the material reaches a softened state at a high temperature, it is ready for injection.

When the material is in the injection-ready state, it is injected at high pressure through the nozzle into the mold. The mold consists of two molds with the desired product shape, and the injected material fills the mold. The rubber material inside the mold is compressed into shape under high pressure and rapidly cooled using a cooling agent to harden.

Once the material in the mold has completely hardened, the molded product is extracted. The extracted product undergoes finishing processes such as removing excess material.

How to Choose a Rubber Injection Molding Machine

When choosing a Rubber Injection Molding Machine, the following considerations are essential:

1. Injection Capacity

The measurement range refers to the range of weight or mass that can be measured. It is crucial to confirm that the weight of the target object falls within the Weight Checker’s measurement range. Considering the minimum and maximum weights of the target object is essential.

2. Injection Pressure

Injection pressure indicates the pressure at which rubber material is injected from the injection cylinder to the mold. It affects injection speed and filling capacity and is crucial for high-viscosity materials or products with complex shapes.

3. Heating Temperature

Heating temperature indicates the temperature at which rubber or elastomer materials are heated. The required heating temperature varies depending on the type of material. Accurate control of the heating temperature is a crucial factor in ensuring product quality.

What Is a Weight Checker?

A Weight Checker is a device used to measure and manage weight in various applications such as manufacturing processes and logistics.

It enables the accurate measurement of the weight of products or materials, facilitating the detection of defective items and allowing for quality control. Since products with inaccurate weights may lead to quality issues and customer dissatisfaction, precise weight checking contributes to overall quality improvement.

Additionally, it helps prevent the excessive use of raw materials, allowing for efficient production. Accurate measurements contribute to reducing waste and the quantity of defective products, ensuring the delivery of consistent products.

Uses of Weight Checker

Weight Checkers find applications in various industries based on the needs of weight management. The primary uses include:

1. Manufacturing Industry

Quality control is crucial in the manufacturing industry. Weight Checkers accurately measure the weight of products during the manufacturing process, ensuring they meet specified standards. For example, in the paper industry, they manage the weight of paper, maintaining consistency in quality.

2. Food Industry

In the food industry, Weight Checkers are used to measure the weight of ingredients and products, enabling quality control. They are employed in applications such as accurately weighing dough for bread and cakes. In food packaging, it is essential to package products in the correct quantity. Weight Checkers confirm the accurate fill quantity in packages, ensuring consumers receive products as indicated.

3. Research

Scientific research requires precise measurements of the weight of samples and substances. Weight Checkers are employed to ensure reliability and successful experiments in various scientific fields, including chemistry experiments and biological research.

Principles of Weight Checker

The principle of a Weight Checker involves measuring physical quantities related to the mass or gravity of an object and expressing the measurement results as weight or mass. The weight of everything is proportional to its mass and occurs due to Earth’s gravity, and all Weight Checkers utilize this fundamental physical principle.

Changes in physical variables such as strain or pressure are observed, and these changes are interpreted as weight. Data from sensors are acquired as electrical signals and converted into weight through calculations or processing. The results are then digitally displayed or transmitted to control systems for further use.

Due to the often high precision required in measuring weight, Weight Checkers require regular calibration and adjustment. The sensor output is calibrated accurately compared to standard masses or weights.

How to Choose a Weight Checker

When selecting a Weight Checker, the following criteria are primarily considered:

1. Measurement Range

The measurement range refers to the range of weight or mass that can be measured. It is crucial to confirm that the weight of the target object falls within the Weight Checker’s measurement range. Considering the minimum and maximum weights of the target object is essential.

2. Measurement Accuracy

Measurement accuracy indicates how precisely a Weight Checker can measure weight. Higher accuracy results in more precise measurements. In industrial applications, accuracy is crucial, especially in influencing quality control and cost reduction.

3. Output Method

Considering how information obtained through measurement is captured is important. Common output methods include analog output and digital output. Since some products only indicate weight data, selection should be based on the specific application requirements.