wakayama city, wakayama report - sodick€¦ · machining center, 5-axis processing machine, etc....

High precision components for horizontal knitting machines supporting clothing from around the world“Whole garments” are woven three-dimensionally directly from whole garment knitting machines. The cutting and sewing processes are greatly shortened.

*V-LINE® is a registered trademark of Sodick Co., Ltd. *The export of Sodick’s products and its related technologies (including software applications) is regulated under Japan’s Foreign Exchange and Foreign Trade Control Law. In addition, because some of these products may be subject to re-export controls under the Export Administration Regulations (EAR) of the United States; please contact Sodick before offering or exporting these products overseas. *Photos include images created from 3D model. Options may be included. *The external appearances and specifications are subject to change without prior notice due to ongoing research. *The content is current as of January, 2019.

The parent company, Shima Fine Press’ knitting machine is a proprietary technology capable of seamlessly knitting “whole garments” of even complex one-

piece shapes, holding 60% of the worldwide market share. It has gained worldwide recognition for both its functionality and for not breaking even when used

for long periods of time; Shima Fine Press provides the high-precision parts necessary for this horizontal knitting machine. Outside the realm of horizontal

knitting machines, the company continuously supports the global garment industry with blanking (FB) and ultra precise injection molding technology.

Sodick User Report We hear the voice of customers who use Sodick products.

Shima Fine Press Co., Ltd.Wakayama City, Wakayama

Head office 357 Kozaki, Wakayama City, WakayamaRepresentative Sadao Nishimura, Managing DirectorNumber of employees

110 people

Possessed equipment

Large number of Fine blanking press machine, Injection molding machine, Wire-cut EDM, Die-sinker EDM,Machining center, 5-axis processing machine, etc.

Business activities

Uses techniques such as fine blanking and injection molding to manufacture horizontal knitting machine parts such as needle plates

S9118800.2019.01<01>©Sodick Co.,Ltd.2018 Printed in Japan

3121, Nakamachidai, Tsuzuki-ku, Yokohama,

Kanagawa 224-8522 Japan

TEL: (045) 9423111

Sodick Co., Ltd.https://www.sodick.co.jp/en/

2019 W I N T E RREPORT

SodickNew Technology

Information Overview

New Product

High-speed BuildingMetal 3D Printer

LPM325

New Product

Linear motor driveHigh speed, ultra precisionDie-sinker EDM

AP30L

New Product

Linear motor driveNano Machining Center

AZ275nano

New Product

Linear motor driveHigh speed, ultra precisionLarge wire-cut EDM

AL800P

Users who offer the latest machining examples

Togo Engineering Corporation

Niigata Precision Co., Ltd.

Mutoh Seimitsu Co., Ltd.

M.I.C. Co., Ltd.

Sanko Kasei Co., Ltd.

Shibata-Gosei Co., Ltd.

Supports clothing from around the worldHigh-precision components for horizon-tal knitting machines

Shima Fine Press Co., Ltd.Sodick User Report

Japan: Tokyo

Using machines to their utmost limitsThe company was founded in 1980. Not satisfied with European parts that were adopted at the time, the company aspired to make these parts in-house. President Sadao Nishimura, transferred from Shima Seiki at age 29, said “I had zero mold and molding know-how. What I knew was that we needed to make high-precision parts and that we need high-precision machines to make them”. So he was very particular with the equipment. The theory is, “you can't make a 1000-part machine by lining up a bunch of 100-part machines”.

Use only the best machinesAccording to this policy, we have collected all of the finest machines. However, as President Nishimura said, “What is most important is not just the machine, but mastery of the machine”. “Considering the safety factor, it is common to use machines in ranges that are slightly lower than the champion data from the manufacturer's catalog. But we do things differently. We master our machines so that we can use them at the utmost limit levels defined in the manufacturer's catalog. That’s know-how”. To ensure that the engineers are aware of this, they choose their own machines themselves.The highest grade machines, and the ambition to master them. This posture was probably the reason. The reason why we produced the FB mold only half a year from our establishment. Eight years later we began injection molding, thinking “there are machines that make molds, so we can make plastic molds.” Although we started this way, the parts we handle now are more sophisticated. For example, the main needle plate component that is indispensable for knitting machine control is composed of a hardened material with a thickness of 1 - 2 mm and a length of 200 - 250 mm. This part which uses thousands of pins will produce 80,000 of these per day. We also manufacture special parts with resin. There is a part that cuts the film of new material such as cloth and carbon fiber according to certain dimensions; place the film on this part and it will adhere to and cut it. In order to cut cleanly, we needed to place 8,100 pins in a square of about 100 mm and it took several months to produce this mold.

Automate things well as soon as possibleSome may think that because we are a subsidiary, it is easier for us to make high quality products, but it is actually the opposite. Because we are a subsidiary, the demands are more severe. For this reason, we are making things less expensively through automation. For example, it used to take two hours to polish the tip portion in the needle plate but in collaboration with specialist manufacturers, we were able to develop a breakthrough method to polish it in around 10 seconds. Also, we have been working on automation measures to process any debris stuck inside the molds.

Without challenge, there is no growthThere are endless challenges to develop devices and new technology. Recently, considering that “including post-processing, lasers are faster for most parts,” we have begun to make parts using laser processing. Also, we are bringing in a 650t class molding machine this year, and construction of large size parts is in progress. In addition, while we have not taken any definite action, we are considering using injection molding machine developed by Sodick for aluminum.

“Even if you are productive and profitable, without attempting new challenges, you cannot grow,” says President Nishimura, who serves as a source of company growth.

Linear motor driven wire-cut EDM, die-sinker EDM

A needle plate, indispensable for the control of knitting machine. An important part that we constantly manufacture.

A part that cuts fabric film according to dimensions. Highly difficult parts lined with thousands of pins are handled from die manufac-turing to resin molding.

* WHOLE GARMENT is a registered trademark of Shima Seiki Manufacturing, Ltd.

Linear motor drive Nano Machining Center

High-speed BuildingMetal 3D Printer

AZ275nanoLPM325 NEWNEW

Active Vibration-free System "Counter Table Mechanism"

Suppresses vibrations to the maximum during the cutting process by the cancel axis which is driven in the opposite phase from the machining table

Newly developed and manufactured in-house Built-in high performance amplifier

Higher acceleration machining is possible which reduces the machining time

Ultra High-speed Spindle

Maximum rotation speed 120,000 min-1

Realized highly precise and highly efficient high-speed milling excellence at the nano level

New NC unit developed and manufactured in-houseLN4AZ

Improved machining accuracy by superfine subdivisions of the control unit

Main Specifications

Maximum molded object dimensions (width x depth x height) 250 x 250 x 250 mm

Maximum load weight 120kg

Maximum laser output 500 W

Machine dimensions (width x length x height) 1630 x 2525 x 2020 mm (Including peripherals)

Main Specifications

Each axis stroke (X x Y x Z) 300 x 250 x 100mm

Machining area (width x depth) 275 x 170mm

Main spindle rotation speed 20,000 ~ 120,000 min-1

Maximum quantity of machining material 5kg

New High-Speed Air Spindle Machining Bio-related mold parts 49 consecutive concave R2 hemispheresHemispherical Mirror Finish

This is a Nano Machining Center of a unique structure which demonstrates the superiority of high-speed milling machining to the fullest by a built-in cancel axis

which is driven in the opposite phase from the machining table and a high-speed spindle with a maximum rotation speed of 120,000 min-1.

This is a high-speed building Metal 3D Printer equipped with a 3D building function that has a greatly improved building

speed which is required for the entry model of a Metal 3D Printer, and a reference surface machining function for secondary

machining.

Equipped with a 500 W Fiber Laser

Implements high-speed, high-quality metal 3D printing

High-speed Metal 3D Building Function

Improved fume recovery efficiency with an ideal building chamber layout

Reference surface machining function for secondary machining

New NC unit developed and

manufactured in-house

RM4RP

Space-saving Design

Machine, power supply and peripheral devices Integrated structure

High-speed layered modeling in parallel mode Fluid pump impeller

MRS: Optional

*The machining results are based on environment specified by us.

Maintains stable run-out accuracy and exhibits excellent rotational quality, in a wide rotational speed range of 20,000 ~ 120,000 min-1

Convex shape Concave shape

Producing convex and concave shape with cemented carbide

1st 22nd 49thMax valley depth Pv

71 nm 61 nm 97 nm

Surface roughness Ra

9.9 nm 10.0 nm 17.7 nm

Laser sintering Base surface machining Total

32 hr 56 min 1 hr 28 min 34 hr 24 min

Machining Tools UsedBall end mill R0.1 Guide holeDrill φ0.2 x L2.0 DrillingBall end mill R0.1 De-burringRadius end mill φ2.0 x R0.1 x L6 Pilot holeM threaded mill M3 Screw

To meet a wide range of machining needsAvailable rotational speeds: 20,000 ~ 120,000 min-1

A large range of tool types and sizes are available

Base surface

Base surface

Base surface Base surface

Material STAVAX (50HRC)Machining time 38 sec/hole, 100 holes total

Hole depth 2.0 mm (blind hole)Spindle rotation speed 30000 min-1

Feed speed 20 mm/minStep amount 0.016 mm

Material Fine particle cemented carbide

Machining shape

Convex width 10 μmConvex height 40 μm

Tools PCD toolφ0.1 mm

Material STAVAX (54HRC)Machining

shape49 concave R2 hemispheres

Material OPM-ULTRA1Molded object size φ175 x 80 mm

Material Fine particle cemented carbide

Machining shape

Concave width 30 μm Height 20 μm Slope 20°

Tools PCD toolφ0.03 mm

30mm

: Base surface

1 2Sodick Report 2019 WINTER

-5

-3

-10

1

35(µm)

1 2 3 4 5 6 7 8 9 10 11 12 13

Reference point

0.0

X-axis

Y-axis

Measuring instrument: 3D measuring machine

Machining position number

Linear motor driveHigh-speed and High Precision Large Wire-Cut EDM

Linear motor drive High-speed and High Precision Die-Sinker EDM

AL800PNEWNEW AP30L

Full cover (optional) / ATC specification(optional)

X-axis Stroke 800 mm

Wide and ultra-high precision full cover model

Ultra-Precision Machining

Adopted ceramic for machine structure

Thermal commit system (TH-COM)

Automation of High Precision Machining

High-speed automatic wire threading unit “FJ-AWT”

New core processing unit “S3CORE (Score)” (optional)

Pitch Machining Accuracy

±1.5 µm at the Long Plate

High Speed and High Responsiveness

High speed and dynamic responsiveness by linear motor and motion controller "K-SMC" developed and manufactured in-house

Lightweight and Highly Rigid Symmetry Head

Lightweight and high rigidity by adoption of our new CFRP and ceramics developed and manufactured in-house

AI technology

Equipped with the latest applications which uses AI (artificial intelligence) technology

Ark-less 4

Greatly improved machining speeds in all rough, medium and finished machining

New NC unit developed and manufactured in-house

LP4 Power Supply

Main Specifications

Each axis stroke (X x Y x Z) 800 x 600 x 250 mm

U x V axis stroke 150 x 150mm


Wire electrode diameter φ0.1 ~ φ0.3 mm

Main Specifications


Table dimensions (width x length) 500 x 350mm

Maximum electrode suspended mass 5kg


This is a high-precision large Wire-cut EDM equipped with a new structure and new system that minimizes thermal displacement,

which further realizes high-speed and high accuracy in large components related to energy and aircraft, and large molds

related to automobiles and electricity.

With the further evolved electric discharge stable machining system “Arc-less 4,” this is a 3-axis (XYZ) linear motor drive high-

precision Die-Sinker EDM which realizes various surface finishing at high-speed and highly efficient machining in the fine and

precision areas.

Pitch Machining Accuracy ±1.5 µmGreatly improved in all areas of Pitch, Shape, Position and Speed

250m

m 125m

m

75m

m

50mm 50mm

75m

m50

0mm

250m

m

650m

m

350mm350mm

175mm

700mm

800mm

5

7

4

1

8

2

9

6

3

10

12

11

13

Head casting

Arm casting

Linear motor

In machining tankTable

Work piece

Electrode

Table liquid leveling

CR axis(optional)

Bed casting

Head structure

Overall temperature control

Developed to allow circulation of

to control the overall temperature.


Machining precisionShape precision +0.0030 ~ +0.0040 (Range 1.0 μm)Position accuracy −0.0010 ~ +0.0008 (Range 1.8 μm)Pitch accuracy −0.0011 ~ −0.0005 (Range 0.6 μm)Depth accuracy −0.0046 ~ −0.0036 (Range 1.0 μm)

Material SLDWorkpiece size 800 x 650 x 20 mm

Wire φ0.25 mm Tsubame Wire PlusMaximum pitch distance X direction 700 mm Y direction 500 mm

Material STAVAXElectrode material CuSurface roughness Ra 0.14 μm Rz 1.07 μm

Machining depth 1.5mmWorkpiece dimensions 100 x 100mmMaximum pitch distance 80mm

Material S-STARElectrode material CuW

Electrode reduction dimension

0.03 mm/side

Surface roughness Rz 0.34μmMachining depth 0.05 mm

Workpiece dimensions 0.3×0.1 mmMachining liquid OIL Vitol-2

Corner R 3 μm (machined bottom)BSN4 circuit use 30% higher machining speed

Ultra-fine connector machining


Linear motor drive High-Speed and High Performance Wire-Cut EDM

Linear motor driveUltra High Speed Milling Center

ALN600G + Erowa Robot Compact 80 UH430L

Developed and manufactured in-house

XYZ 3 Linear Motor Drive

High accuracy and high quality at high speeds

SEPTune

SEPT (high-speed, high-precision contour control function) configuration support mode

Sped up control cycles for each axis

High-quality finish machining in fine precision areas

Lightweight head using CFRP

Lightweight, highly rigid, high vibrational dampening (HSK-E25 type)

New software usingAI (artificial intelligence)

Main Specifications


U x V axis stroke 150 x 150mm


Wire electrode diameter φ0.05 ~ φ0.3 mm*

Main Specifications

Table dimensions (width x length) 600 x 400mm



Main spindle rotation speed 1500 ~ 60000 min-1(HSK-E25IK)

All of the underlying technology is developed and manufactured in-house, including linear motors mounted on the XYUV4 axes.

Demonstrates excellent affinity for automated system construction and with Advanced Smart Pulse and Advanced Smart Linear,

it is a high-speed, high-performance wire-cut EDM with a top class linear motor drive.

This is a an ultra-high speed milling center with linear motor drives developed and manufactured in-house mounted on the XYZ3 axes,

supports increased speed of direct engraving by using diamond tools and high quality mirror surface machining of optical lenses, etc.

Large wire-cut EDM control technology

Drum-less control II

TMP control II

Digital-PIKA-W Plus


XYUV4 Linear Motor Drive

Maintains semi-permanent precise axis movements without backlash

Automation of High Precision Machining

High-speed automatic wire threading unit “FJ-AWT”

New core processing unit “S3CORE (Score)” (optional)


Uses ceramics

Insulation structure of the wire running system and workpiece securing part

Increased operating rate by robots for automatic work pallet exchange New core processing unit “S3CORE” Machinable Ceramic Drilling Stair-shaped optical forms


Material 20 x 20 x 5mmMachining conditions

Spindle rotation speed 14,000 min-1 Feed speed 40 mm/min

Tools Used Center drill φ0.08 mm (for positioning/drilling)Features Can machine large numbers of holes in high-hardness workpieces such as

ceramics and super engineering plastics, with high precision and accurate pitch.

Material STAVAX (52HRC)Machining conditions

Spindle rotation speed 22,000 ~ 40,000 min-1 Feed speed 350 ~ 3,000 mm/min

Tools Used Ball end mill R1.5-R0.05 Finished CBN ball end mill R0.05Features High precision, high definition surface finishing (Ra0.1μm or less)

We designed a mold shape for creating small diameter (R0.05)automobile headlights.

(Optional)

*Less than φ0.1 mm is optional.


eV-LINE Electric Injection Molding Machine

Connect, Master, Sodick-IoT

MS50

Ultra-narrow pitch

Enlarged view

Enlarged view

Enlarged view

Lead frame100µm narrow pitchSaves 50µm

Ultra-fine engraving

Precision bending

15 µm depth for plume machiningMicro forming engraving

Bending machining on the plume part

MODEL Kagoshima Prefecture, Sakurajima Mt. SAKURAJIMA*The mold shape uses the “Sakurajima” motif.

Kagoshima Satellite

Launched as a small satellite, joined to the HIIA rocket No. 17 which is carried by the Venus probe “Akatsuki”. (Image source: JAXA)

Small on-board satellite photographs

Size: 10 cm x 10 cm x 10 cm approx.Weight: 1.4 kg approx.

This project has succeeded in using high processing technology to become lightweight and highly rigid.

[Satellite Objective]Intended to study and predict severe storms and tornadoesVideo recording from space


Ultra-narrow pitch

Enlarged view

Enlarged view

Enlarged view



Precision bending




Kagoshima Satellite







Ultra-narrow pitch

Enlarged view

Enlarged view

Enlarged view



Precision bending




Kagoshima Satellite







株式会社新潟プレシジョン

“Uesugi's clan 35 chosen swords”

Takasenagamitsu

Sword Inscription Nagafune Nagamitsu

Users who offer the latest machining examples

Client PC Client PC Client PCClient PC Client PC

Browsing client PCunlimited connections

ETDL4 �le server

Collect!Collects molding data for quality control

Up to

20machines

Clearly displayed!Molding Site Quality & Production Control System

MS Series GL Series EH3 SeriesVRE Series EHV Series

ETDL4 Option

Application Dedicated for Sodick's Injection Molding Machines

The ETDL4 is installed in the file server, and is connected to the molding machines online. Various data of the molding machines is displayed on the PC terminals. What's happening on site can be clearly understood, which contributes to improvement in the production efficiency and quality.

Netw

ork configuration

IoT supported Displays molding data in tabular or graph formatDisplays the history of errors, operation and condition changes of the molding machine

Access from anywhere with a smartphone or PC

Operating stateCollective management

Detailed informationCan be viewed

Maintainabilityimprovements

Insulator

Developed and manufactured in-houseLinear motor

Based on “V-LINE®” which has excellent performance, high precision and repetition stability,

we developed this energy saving eV-LINE all-electric injection mounding machine

with motorized responsiveness, a new mold clamping mechanism and improved productivity through high cycle.

Main Specifications

Maximum mold clamping force 490 kN

Tie bar interval (W x L) 360 x 360mm

Minimum/maximum mold thickness 150/350 mm

Machine body dimensions (L x W x H) 3725 x 1155 x 1970mm

Built-in 3D cooling pipingHigh-cycle insulator molding with ametal 3D printer mold

Corresponds to telecommunications standards MTConnect, OPC-UA

Production controlSupport

Simplescreen layout

S-ViewerNEW S-HARMNY

Togo Engineering Corporation Niigata Precision Co., Ltd.

Striving for the best QCDS (quality, cost, delivery time and service),

we are the first and only one to achieve high customer satisfaction.

We introduce each measuring instrument used to evaluate the

precision. We work hard every day as experts of ultra-precision

machining to deliver more accurate and safe parts.

Mirror ball(Sphere diameter 30 mm)

We use cutting, grinding, wire EDM, and die-engraving EDM to

produce small quantities of various kinds of products. We offer the

best materials and machining methods to suit customer needs.

This is a sample of the results of serious, imaginative work.

We aim for “manufacturing without limits”.

Meticulous precision machining without compromise

Precision automatic machine components

Precision metal components

Cemented carbide components

Ceramic components

�Expressing technical

and engineering skill

Component production

Imaginative component production


Electrode machining sample Machining time Model HS150L

Machining time 0.25 Hrs.3Machining time 0.54 Hrs.1

Machining time 0.83 Hrs.5


Machining time 0.25 Hrs.Round hole electrode Model AQ35L


Electrode production

without deburring

Electrode production up to the minimum Ø0.09

The electrode shape is concentrated as much as possible, leading to reduced discharge setup time.

Improved insert nut suction nozzlesFor insert molding robots

Metal 3D PrinterPlastic models made with the “OPM250L”

Mold and printed withan inkjet printer

The nut is inserted into the hole during insert molding, but is too small

to be effectively inserted by hand. For a robotic insert molding, a section

nozzle to grab the insert nut is required. Suction nozzles created by

normal machining have weak suction and frequently cause problems.

�For normal machining, performance cannot be maximized due to

machining limitations!

Consider what can be improved by creatingwith a metal 3D printer.

* “Puripura” is a registered trademark of M.I.C. Co., Ltd. Comparison method [mold] We used two molds for mass

production. One incorporates a 3D cooling die. [Molding material]

PA+GF50 (CM3531G-50 B3), PA6 (CM3001N) PC (SD Polica 301-15

030030), POM (NW-02), PP (Novatec MH4) [Conditions] Uses PA

+ GF50 mass production conditions. Fixed conditions, except for

cooling time. [Evaluation] Measurement of each molded item in

the illustrated position. Compare the values and verify the effect.

Warp deformation improvements3D cooling effect verification

Results

3D cooling results

Improved process problems

Able to produce finer details than expected

Create new ideas by overcoming normal machining constraints

Fully integrated unitCombines normally machined partsIntegrated air hose and fittings

Study contents Differences in the amount of molded object deformation for each cooling system and cooling time

Air flow path optimizationMaximized suction hole areaFlow path homogenization

Ideal value...the value with no warm deformation at allSection force homogenizationVolume maximized sub tank

Can shorten freezing time by 1/3Warp

deformation is

Improved

ManufacturingManufacturing

Design and production of plastic precision dies (insert dies and mold dies)

Can manufacture molds of up to 50t specifications and machining

can handle a minimum 0.13 gate diameter

We earnestly strive for precision.

First, we try to challenge ourselves.

Because we don’t want to say “that’s impossible”.

“Is this right?”

we ask ourselves.

Designdesign

Inspectioninspection

Suction hole area

10X21 parts

Reduced to 3 parts

Unit weight

40%Down

eV-LINE Only for OPM molds Manufacturing cell system

MR30

Sanko Kasei Co., Ltd.M.I.C. Co., Ltd.Mutoh Seimitsu Co., Ltd. Shibata-Gosei Co., Ltd.

The closer to the ideal value,the smaller the warp deformation

Ideal value

3D cooling

Normal cooling

For normal cooling, even if the cooling

time is extended, there is hardly any

improvement in warp deformation.

For 3D cooling, even if the cooling

time is shortened, warp deformation

improves.

Resin name POM

Cooling time (seconds) 35 12

Mold temperature (°C) 30 30

Measurement results (mm) Normal cooling product 51.99 51.80

Measurement results (mm) 3D cooling product 52.81 52.56

Improved value (mm) 0.82 0.76

3D cooling position and product Normal cooling position and product Points to compare warp deformation

Digital modeling

CAD design

Mold

Molding

Printing

Building

Linear motor drive Precision metal 3D printer

OPM250L

Work flow


wakayama city, wakayama report - sodick€¦ · machining center, 5-axis processing machine, etc....

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