System for soak-degreasing* metal parts
Shorter degreasing time achieved by flexible operation settings with the ROBO Cylinder
System Overview
1. Explanation of Process
This is a degreasing process for metal parts before they are plated. The operator sets a basket containing metal parts on the system, and the basket is submerged into the degreasing bath and raised after a certain period to degrease the metal parts.
An air cylinder is used to move the basket up and down.
* Soak-degreasing: Remove oil-based contaminants from parts by soaking them in degreasing agent.
2. Explanation of Operation
- The operator sets a basket containing metal parts on the system.
- The air cylinder lowers the basket, and the metal parts are submerged into the degreasing bath.
- After a specified period of soak-degreasing, the air cylinder raises the basket.
- The operator waits until the degreasing solution stops dripping and then removes the basket from the system.
Problems Experienced While Using the Air Cylinder
The company was considering ways to shorten the cycle time of their system.
In general, moving the metal parts in the degreasing solution allows the degreasing agent to contact the metal parts more efficiently, and the metal parts are degreased more quickly.
However, the air cylinder cannot shake the basket.
The current cycle time is 370 seconds including the time for up/down operation.
(Descending time: 5 seconds, Soak-degreasing time: 300 seconds, Ascending time: 5 seconds, Draining time: 60 seconds)
Improvements Achieved by the ROBO Cylinder
1. Shorter cycle time achieved by the multi-point positioning function
To shorten the degreasing time, the basket is moved up and down in the degreasing solution.
The ROBO Cylinder supports multi-point positioning, so it can move the basket up and down while the basket is still submerged in the degreasing solution.
As a result of experiment, the degreasing time decreased from 300 seconds to 210 seconds.
Reduced by 90 seconds
The multi-point positioning function of the ROBO Cylinder is used for draining.
When the degreasing is complete, the basket is moved up and down over the degreasing bath to shake off the degreasing agent.
The draining time reduced from the previous 60 seconds to 30 seconds.
Reduced by 30 seconds
2. Shorter cycle time achieved by changing the speed during movement
Depending on the quantity of degreasing solution and type of part, the degreasing solution may overflow or scatter. Accordingly, the baskets were submerged/raised at low speed.
The ROBO Cylinder lets you set the speed, acceleration, and deceleration separately. You can also change the speed while the ROBO Cylinder is moving.
Now, the basket can be moved closer to the surface of degreasing solution at high speed and then lowered into the solution at low speed.
As a result, the basket moving time decreased by 2 seconds one way.
Reduced by 4 seconds
System cycle time
(Basket ascending/descending time + Degreasing time + Draining time)
| Air cylinder | ROBO Cylinder | |
| 370.0 seconds | 246.0 seconds | Total: |
| Point 1: 120.0 seconds Point 2: 4.0 seconds |
124.0 seconds |
Cost Cutting Effect Cylinder
1. Conditions
Production volume |
100 times (Number of basket changeovers) |
Labor cost |
$18/hour |
Annual operating days |
250 days |
2. Comparison of Air Cylinder and ROBO Cylinder
| Item | System using air cylinder | System using ROBO Cylinder | |
| System Cycle time | 370.0 seconds
[1] Basket up/down operation time 10.0 seconds |
246.0 seconds
[1] Basket up/down operation time 6.0 seconds |
|
| Basket changeover time by operator | 30 seconds | 30 seconds | |
| Line operating hours (day) | 11.1 hours/day
[1] System cycle time 370 seconds |
7.7 hours/day
[1] System cycle time 246 seconds |
|
| Labor cost (Note) (annual) | $49,950
11.1 hours x $18 x 250 days = $49,950 |
$34,650
7.7 hours x $18 x 250 days = $34,650 |
|
Note: The operator performs setup and basket changeover including putting parts in the basket.
3. Cost Cutting Effect
| Air cylinder | ROBO Cylinder | ||
| Labor Cost (annual) | $49,950 – | $34,650 = | $15,300 |
| Difference = | $15,300 |
Result
By adopting the ROBO Cylinder, the cycle time was reduced by 30%, and annual cost savings of $15,300 was achieved.
* Exchange Rate: 1(USD) = 100(Japanese Yen)