[Case Study] Full Inspection of Steel Balls through Mass Production
We are manufacturing steel balls, but magnetization of the steel balls has occurred! Here is a case study of installing guide sensors on the line conveyor!
We manufacture approximately 40,000 iron balls with a diameter of 10φ every day, and among them, defective products (magnetized iron balls) are mixed in. Currently, only random sampling inspections are conducted, which allows defective products to escape. There was a request for "monitoring of magnetized iron balls on the automated line" and "to maintain a detection distance of 30mm between the detection object and the sensor due to the line structure." We installed the guide sensor "GS-116" manufactured by Makome Research Institute on the line conveyor, enabling the detection of the magnetic field of the iron balls and their expulsion (although this depends on the strength of the magnetic field). As a result of our improvements, we achieved a loss amount of zero for full inspections during the occurrence of defective products. *For more details, please refer to the PDF document or feel free to contact us.
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【Case Summary (Partial)】 ■Trouble Case (Request) - Monitoring of magnetized iron balls on an automated line - Due to the line structure, a detection distance of 30mm is desired between the detected object and the sensor ■Trouble Situation and Loss - When defective products are found, a full inspection of approximately 20,000 units is required - Time loss for full inspection: 358,000 yen per lot ■Points of Improvement and Expected Customer Benefits - Although it is listed as a guide sensor for AGVs (automated guided vehicles), the GS-116 supports 16-bit parallel switching output - It can detect magnetic fields with 16-bit resolution, enabling monitoring of magnetized iron balls - The GS-116 can detect up to 40mm, allowing for installation on conveyors ■Effects and Benefits of Improvement - A line is established that stops immediately in case of abnormalities - A line system that can automatically discharge defective products when they occur is realized *For more details, please refer to the PDF document or feel free to contact us.
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For more details, please refer to the PDF document or feel free to contact us.
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Utilizing our original technology of saturable coils, we offer a fundamentally simple magnetic detection element technology that provides high precision and long-term stability even under adverse conditions. We have received strong support from a wide range of industries, including unmanned transport carts, industrial equipment, labor-saving machines, material handling, machine tools, injection molding machines, civil engineering and construction robots, food machinery, industrial machinery, nuclear facilities, and ships. We also excel in sensors for motorsports such as F1 and Moto GP, tilt meters for construction machinery, and magnetic sensors used for ultra-high precision measurements in scientific fields. Some of our products are also used in applications like multi-story parking and golf cart guidance sensors. All of our products are developed and manufactured 100% in Japan, with over 80% of our product lineup being custom-made based on individual customer requests. We have many custom options available, including waterproof, explosion-proof, heat-resistant, water-resistant, and radiation-resistant specifications. If you have any issues related to sensing or measurement, please feel free to consult us. IoT Platform: Our sales and technical staff are fully committed to addressing everything from minor customizations of existing products to proposing new detection principles. You can also rely on us for assistance with improvements. Our standard products come with a reassuring 3-year warranty. Location: Ina, Nagano Prefecture. Published on Ipros Monozukuri.
