日本ロック List of Products and Services

We would like to introduce a technical case related to our wear monitoring sensors. We received a request from an automotive parts manufacturer regarding the development of a sensor to monitor wear in automotive sliding parts. The new sensor for automotive use faced very stringent testing conditions, including exposure to 700°C and submersion at 500°C, with many challenging factors, and there were no companies willing to cooperate in the development. In response, we developed solutions from scratch, including the selection of circuit components, an alternative method for mounting electronic components instead of soldering, and the selection of housing materials that can withstand 700°C. Although the sensing method was changed and the product was not commercialized, the development reached nearly completion. 【Case Study】 ■ Concerns - Extremely stringent testing conditions regarding heat resistance, including exposure to 700°C and submersion at 500°C - Many challenging factors, with no companies willing to cooperate in the development ■ Response - Development of an alternative method for mounting electronic components instead of soldering - Development from scratch, including the selection of housing materials that can withstand 700°C *For more details, please refer to the PDF document or feel free to contact us.

• Sensors
• Safety Sensors
• Mechanical Design

We would like to introduce a technical case related to the bus bar that constitutes our automotive ECU. A request came from a vehicle electronics manufacturer to change part of the circuit of the automotive ECU from a printed circuit board to a bus bar. There were many challenges, such as the shape of the soldered parts and the thin-walled molding of the connection to the printed circuit board, making development difficult with conventional press and molding manufacturers. Therefore, we addressed this through the network of our cooperative association (Nissokai). We designed while holding discussions with press, molding, and mold manufacturers, and created a prototype to verify actual mass production feasibility. They expressed their satisfaction, stating that it was very helpful in creating the mass production model. 【Case Study】 ■ Concerns - Change the configuration of part of the ECU circuit from a printed circuit board to a bus bar - Many challenges such as the shape of the soldered parts and thin-walled molding of the connection to the printed circuit board - Development was difficult with conventional press and molding manufacturers ■ Response - Addressed through the network of our cooperative association (Nissokai) - Designed while holding discussions with press, molding, and mold manufacturers - Created a prototype to verify actual mass production feasibility *For more details, please refer to the PDF document or feel free to contact us.

• Other Auto Parts
• Circuit board design and manufacturing
• Mechanical Design

We would like to introduce a technical case related to our operational display board. We received a request from an authorized dealer of imported motorcycles to create a control board for a lamp that displays the condition of the transmission and vehicle speed of a training motorcycle. Since it is a CAN-equipped vehicle, even adding just one lamp would change the current, leading to a judgment of abnormality and causing the engine to stop. Additionally, there was a concern about not being able to allocate much development budget for CAN analysis work. Our company analyzed the CAN signals and completed the control board in a very short period. As a result, we were able to keep the development costs within budget. It was discovered that interrupting the CAN was not easy but possible, and the customer was pleased to see the potential for developing other products. 【Case Study】 ■ Concerns - Since it is a CAN-equipped vehicle, even adding just one lamp would change the current, leading to a judgment of abnormality and causing the engine to stop. - The number of units to be produced is limited to just two for the time being, and the budget is also constrained. - There is a limitation on how much development budget can be allocated for CAN analysis work. ■ Response - Analyzed the CAN signals and completed the control board in a very short period. *For more details, please refer to the PDF document or feel free to contact us.

• Circuit board design and manufacturing
• Contract manufacturing

We would like to introduce a technical case study regarding our satellite switch (intelligent switch). We received an inquiry from an automotive electrical manufacturer stating that they prioritized the design of the switch mechanism and had no space to accommodate a light guide lens, resulting in areas where the lighting barely illuminated. Although there is a specialized department for optical design, they found it impossible to address the issue even with simulation software, and they were in a bind as the mass production timeline was approaching. In response, we utilized our know-how in edge light design to redesign the light guide lens. We were able to complete the process from conceptual examination to evaluation with minimal steps. 【Case Study】 ■ Concerns - The switch mechanism was prioritized in design, leaving no space for a light guide lens. - There were areas where the lighting did not illuminate evenly, or barely illuminated at all. - The conditions were so poor that it was impossible to address the issue even with simulation software. - They were in a bind as the mass production timeline was approaching. ■ Response - Redesigned the light guide lens using our know-how in edge light design. - Completed the process from conceptual examination to prototype, tuning, mass production design, and evaluation with minimal steps. *For more details, please refer to the PDF document or feel free to contact us.

• lens
• Mechanical Design

We would like to introduce a technical case study regarding our special-purpose sensors. We received a request from an industrial machinery manufacturer for the small-scale production of sensors used in special-purpose construction machinery. Due to the very low production quantity of only 100 units per year, every company declined the request, and there was no company willing to accept the order, so they asked for assistance. While the typical production for automotive parts is around 10,000 units per month, this was not the standard for this case. Our company specializes in small-batch, diverse production, so we proceeded with the manufacturing. We were able to accept the small order and deliver high-quality products, which made the client very happy. 【Case Study】 ■ Concerns - The production quantity is very low at only 100 units per year. - Every company declined, and there was no company willing to accept the order. ■ Response - While the typical production for automotive parts is around 10,000 units per month, this was not the standard for this case. - Our company specializes in small-batch, diverse production. *For more details, please refer to the PDF document or feel free to contact us.

• Sensors
• Contract manufacturing

We would like to introduce a case study regarding the cost-effective solution for our waterproof toggle switch. A manufacturer of industrial equipment requested a waterproof version of the toggle switch. There are very few waterproof toggle switches available, and overseas products tend to be expensive. Additionally, developing a new product would incur enormous initial costs. In response, we developed the "waterproof toggle switch" as our own product. It features a larger knob, allows for 2-3 position operation, and offers the freedom to choose between momentary and alternate functions. Furthermore, it can also accommodate lighting and indicators, allowing for diverse applications in its design. This product can be adopted for small-scale production, significantly reducing initial and product costs. [Case Study] ■ Concerns - In industrial applications, waterproof specifications are often required. - Overseas products are costly. - Developing a new product incurs enormous initial costs. ■ Response - Developed the "waterproof toggle switch" as our own product. - Features a larger knob, allows for 2-3 position operation, and offers freedom of choice between momentary and alternate functions. - Design accommodates lighting and indicators, allowing for diverse applications. *For more details, please refer to the PDF document or feel free to contact us.

• switch
• Other machine elements
• Mechanical Design

We would like to introduce a cost response case regarding shifter escutcheons from our company. A manufacturer of automotive shifters (shift lever devices) requested to uniformly illuminate five operational position indicators on the top surface of the shifter with a single bulb. However, there were constraints that prevented the installation of a light guide lens inside, and the conventional technology required 14 printing processes, making it very expensive. Therefore, we utilized the reflection from the resin surface. Additionally, we reviewed the dimming printing process and cut unnecessary steps by 50%, achieving labor reduction and increased efficiency. As a result, we were able to meet the target cost and reduce the factors contributing to variability. Our customers were pleased with the stable quality of the product. [Case Study] ■ Concerns - Desire to uniformly illuminate five operational position indicators with a single bulb - Inability to install a light guide lens inside - Conventional technology requires 14 printing processes and is very expensive ■ Response - Utilized the reflection from the resin surface - Reviewed the dimming printing process from the beginning - Cut unnecessary steps by 50% to reduce labor and increase efficiency *For more details, please refer to the PDF document or feel free to contact us.

• Electrical equipment parts
• Processing Contract

We would like to introduce a cost response case related to our electronic circuit components. We received a request from a powertrain system manufacturer for new electronic circuit components to be incorporated into their powertrain. It was essential to establish a production system that posed no quality issues, and they also desired a cost advantage. In response, we addressed this by sourcing overseas in Leading Competitive Countries (LCC). We established a Chinese subsidiary, "Chuanggai Electronic Trading (Shanghai) Co., Ltd.," and implemented production in China under our management to achieve both quality and cost balance. As a result, we were pleased to achieve the target price. [Case Study] ■ Concerns - New electronic circuit components to be incorporated into the powertrain - It is essential to establish a production system that poses no quality issues - Desire for a cost advantage ■ Response - Overseas sourcing in LCC - Established the Chinese subsidiary "Chuanggai Electronic Trading (Shanghai) Co., Ltd." - Implemented production in China under management to achieve both quality and cost balance *For more details, please refer to the PDF document or feel free to contact us.

• Other electronic parts
• Other contract services

We would like to introduce a case study regarding the quality response of our automotive cigarette lighter illumination ring. A trading company dealing in automotive electrical components requested that the existing product only illuminated about half of the bulb side, and they wanted to achieve uniform illumination around the ring with just one bulb. They also wanted to keep costs as low as possible since it is a generic/shared component. Achieving uniform illumination around the ring with a single light source is quite challenging, but based on our experience with audio and navigation lighting, we developed the product. We simplified the structure and successfully reduced costs by changing from a conventional three-color molding to a two-color molding. As a result, we were able to deliver a product that met quality expectations, and they were pleased that we could also achieve a VA effect. [Case Study] ■ Concerns - They wanted to achieve uniform illumination around the ring with just one bulb. - The existing product only illuminated about half of the bulb side. - They wanted to keep costs as low as possible since it is a generic/shared component. ■ Response - Product development based on experience with audio and navigation ring lighting. - Simplified the structure and reduced costs by changing from three-color molding to two-color molding. *For more details, please refer to the PDF document or feel free to contact us.

• Other Auto Parts
• Processing Contract

This product is a combination switch for industrial machinery such as forklifts, wheel loaders, and dump trucks. Similar to automotive combination switches, it is mounted behind the steering wheel and has functions that are almost the same as those in cars, including switches for lights, wipers, hazard lights, and parking. Additionally, it accommodates specifications unique to industrial machinery, such as FNR switches and retarder levers. Compared to automotive combination switches, it has several times the strength and is designed for more severe conditions regarding waterproofing and dustproofing. 【Features】 ■ Accommodates specifications unique to industrial machinery ■ Also referred to as "combi switch" ■ Almost the same functions as automotive combination switches ■ High strength and designed for severe conditions regarding waterproofing and dustproofing *For more details, please refer to the PDF document or feel free to contact us.

• Switching Power Supply
• switch

It is common to use incandescent bulbs with a power of 5W to 10W, commonly referred to as "makura bulbs," which are tubular light bulbs. The reasons for using makura bulbs are that they allow for thin fixture designs, are inexpensive, and make bulb replacement easy. In terms of appearance, they have a polycarbonate lens and a switch for changing settings.

• others

The requirements for assembly precision and design aspects for vehicles are very strict, but technically, they are not such a high hurdle. The area where our technology can be most effectively demonstrated is in the nighttime illumination of position displays.

• others