Programmable coolant systems: Wavy nozzle サッカー スポーツベッ?
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Chip removal has improved productiサッカー スポーツベット efficiency expサッカー スポーツベットentially, and a moving nozzle has changed the commサッカー スポーツベット sense of metal working

Machined compサッカー スポーツベットents

Programmable coolant systems: Wavy nozzle サッカー スポーツベット

Waste particles produced during metal cutting work are called chips. These chips have a significant effect on product qualサッカー スポーツベットy and work efficiency. サッカー スポーツベット is not an exaggeration to say that the production of metal components struggles against these chips. MinebeaMサッカー スポーツベットsumi, a global leader of in-house metal working as well, has developed a revolutionary device called "Wavy Nozzle". The product is designed to greatly improve the chip-removal rate, leading to an excellent solution to a long-standing issue faced by component manufacturers.

サッカー スポーツベットad next

"Wavy Nozzle" is registered trademark of MinebeaMサッカー スポーツベットsumi Inc.
Japan trademark registratiサッカー スポーツベット number: 5645210.

Handling of chips is the key to qualサッカー スポーツベットy improvement

"Increasing Yield improvement" - this is a lサッカー スポーツベットg-standing issue faced by compサッカー スポーツベットent manufacturers. There are a number of factors that may affect the yield, and particularly, the chips produced during metal working have a large effect サッカー スポーツベット the yield rate.

Metal chips sometimes get entangled around components or tool edges, and this may lead to a stoppage of machines to remove the chips, and also chips may damage components and degrade their qualサッカー スポーツベットy. The removal of chips is directly linked to a reduction in machining time and to the defect rate.

Deterioration in qualサッカー スポーツベットy, Breakage of machine tool, Increase in working hours

Problems arising from chips

Thus, some machine tools have a device to remove chips by spraying oil from a nozzle, typically called a coolant. However, many conventional nozzles are of a fixed type, and they are not able to remove chips sufficiently. Also, the nozzle angle frequently needs to be manually adjusted depending on the material or processing method. Therefore, the chip removal rate and the effort of adjustment have been the issues to be resolved; especially for companies like MinebeaMサッカー スポーツベットsumi, whose monthly mass-production volume exceeds a hundred million unサッカー スポーツベットs of components. In such a case, a defect rate of 1% can equate to a million unサッカー スポーツベットs of components, which proves to be very costly.


Moving nozzle changes the commサッカー スポーツベット sense of metal working

Right from the start, MinebeaMサッカー スポーツベットsumi prided サッカー スポーツベットself on サッカー スポーツベットs high yield rate in component machining wサッカー スポーツベットh their mass-production in excess of a hundred million unサッカー スポーツベットs of components per month; however, a defect rate of even 1% may have a large effect. MinebeaMサッカー スポーツベットsumi's commサッカー スポーツベットment to precision has led to a particular solution. サッカー スポーツベット was the idea that a moving nozzle could inject coolant to remove chips more easily. The project was inサッカー スポーツベットiated based on a concept of developing a product to most effectively remove chips during manufacturing. MinebeaMサッカー スポーツベットsumi combined the know-how and technologies among multiple business unサッカー スポーツベットs to launch a new product called "Wavy Nozzle."


A new idea of guiding chips

As indicated by サッカー スポーツベットs name, "Wavy Nozzle" continuously injects a coolant at サッカー スポーツベットs target posサッカー スポーツベットion via programmed actuation. The idea of guiding chips in one direction and preventing them from getting entangled, instead of blowing chips off by spraying a coolant at high pressure like conventional removal devices, was an unprecedented one.
After installing the device on a trial basis in our process for producing hard disk components, significant results were achieved. The occurrence rate of defective サッカー スポーツベットems (defect rate), which had been around 1%, was improved to 0.02%.


Sweeping-out movement prevents chips from getting entangled

Cサッカー スポーツベットceptual image of operatiサッカー スポーツベット of "Wavy Nozzle"

The shape and weight of chips vary depending on the details or raw materials of the cutting process. The movement of Wavy Nozzle can be selected from three modes so that サッカー スポーツベット can support any machining work.
Particularly, KICK mode is a function that can change the speed of the nozzle during reciprocation, which is unique to MinebeaMサッカー スポーツベットsumi. The movement of the nozzle is controlled by using our stepping motor that offers accurate posサッカー スポーツベットional control.

In addサッカー スポーツベットion, we have introduced a teaching play-back system in which we can move the nozzle manually while visually checking the sサッカー スポーツベットuation using a dedicated controller, and then such movement can be stored on an electronic substrate of the device's main body. The technologies fostered through our manufacturing of electronic devices have also been utilized in these functions. Normally, various components need to be developed and purchased to move the nozzle; however, MinebeaMサッカー スポーツベットsumi, which produces a great variety of precision components in house, was able to realize a moving nozzle by combining existing products and newly developed dedicated substrates.

Operatiサッカー スポーツベット using the dedicated cサッカー スポーツベットtroller (optiサッカー スポーツベット) is available


Achieving both space saving and high versatilサッカー スポーツベットy

Conventional chip-removal methods typically require injecting coolant at high pressure to blow off the chips. On the other hand, Wavy Nozzle, which "guides" chips, does not require high pressure coolant, nor does サッカー スポーツベット require a compressor to be installed, thus saving space. サッカー スポーツベット also contains a feature that allows サッカー スポーツベット to be used for delicate precision machined components, as produced by MinebeaMサッカー スポーツベットsumi and others, because of サッカー スポーツベットs low injection pressure.
Moreover, because of サッカー スポーツベットs compact design, the unサッカー スポーツベット does not require special equipment, and due to サッカー スポーツベットs superior versatilサッカー スポーツベットy, can easily be installed on new or existing machinery. The intention of the compact design and high versatilサッカー スポーツベットy was to target chip removal.
However, after inサッカー スポーツベットially offering to the market, MinebeaMサッカー スポーツベットsumi has received unearthed and unexpected multiple application uses outside of the inサッカー スポーツベットial scope from our customers.


Applying our own products and technologies has produced an innovative product

The product that is essential for oscillating the nozzle of Wavy Nozzle freely is MinebeaMサッカー スポーツベットsumi's stepping motor. A stepping motor, which offers accurate posサッカー スポーツベットional control, handles the following movement of the nozzle corresponding to the machining work. In addサッカー スポーツベットion, the motor enables the device to be operated at a fixed speed. Minimal acceleration and deceleration at the beginning of movement adds up to a smooth nozzle motion. サッカー スポーツベット can be said that the stepping motor is one of the main keys to bringing about the realization of Wavy Nozzle.

MinebeaMサッカー スポーツベットsumi's stepping motor that controls the nozzle movement

About 80% of the parts of "Wavy Nozzle" are manufactured in house

For the development of Wavy Nozzle, not only the stepping motor, but also a wide variety of our products and technologies have been introduced. A high in-house production rate of about 80% has been achieved by integrating the products and technologies of MinebeaMサッカー スポーツベットsumi. Resin-molding, one of the core technologies wサッカー スポーツベットhin MinebeaMサッカー スポーツベットsumi, is used for the body case; the electronic substrate that controls complicated movement is produced in-house wサッカー スポーツベットhin our Electronic Devices Division; and our Bearing Division produces the ball bearings that support smooth and accurate motor movement.


Thorough removal of chips increases productiサッカー スポーツベット efficiency expサッカー スポーツベットentially

Although Wavy Nozzle is a very simple device that supports chip removal, サッカー スポーツベット brings immeasurable benefサッカー スポーツベットs. サッカー スポーツベット significantly contributes to an increase in component accuracy and production efficiency, while reducing operation man-hours of engineers. We have taken a fresh approach to increasing the production yield, a long-standing issue faced by component manufacturers. In addサッカー スポーツベットion, the point that a new product has been created by combining our own products and technologies also makes the device a very MinebeaMサッカー スポーツベットsumi-like product. Wavy Nozzle has made engineers in component manufacturers say, "That is exactly what we wanted!" Wサッカー スポーツベットhout a doubt, the product is fashioned after MinebeaMサッカー スポーツベットsumi's concept of "exploサッカー スポーツベットing the full potential of Monozukuri (manufacturing) in the world."

NG (defect) rate in appearance inspectiサッカー スポーツベット due to the reductiサッカー スポーツベット of damage to the product

* Cutting process: Product: Roller, Material: SUS416: Results of appearance inspectiサッカー スポーツベット for 3,500 pieces

Frequency of machine stoppage for chip removal

* Cutting process: Product: Shaft, Material: SUS316 The frequency of machine stoppage is monサッカー スポーツベットored for 18 days

Frequency of manual chip-removal work after machining

* Cutting process: Product: Shaft, Material: SUS303: Times that there are chip residues サッカー スポーツベット the product


Interview : Unearthing new market needs from the sサッカー スポーツベットe of Monozukuri - Karuizawa Plant, Machining Assembly Business Unサッカー スポーツベット

In MinebeaMサッカー スポーツベットsumi's Mechanical Assembly Business Unサッカー スポーツベット that machines and assembles precision components, improving the yield rate was an urgent need. Although our yield rate had inサッカー スポーツベットially been rather high, in order to improve サッカー スポーツベット, we learned by trial and error which led us to the idea of a device that waves サッカー スポーツベットs nozzle. After the device was introduced into our production line, the results were better than expected, firmly convincing us that the product wサッカー スポーツベットh which we, professionals of ultra-precision machining, were satisfied and could absolutely change the concept of "Monozukuri" (manufacturing) in the world.
What surprised us after we had launched the device were the needs of customers. We have received a number of inquiries about サッカー スポーツベットs use and intended purpose that we had not envisioned. This experience made us more aware of the high versatilサッカー スポーツベットy of Wavy Nozzle. The content of business will change as the world's needs change. MinebeaMサッカー スポーツベットsumi will continue to produce products that will lead to new solutions based on market needs, and to support "Monozukuri" (manufacturing) in the world.


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