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Case Study
Solution to user issues
Improved production efficiency by eliminating the stripping process for the enameled wire coating
Issues and requests of customers
In order to bundle multiple enameled wires and crimp them to the terminals, the coating of the enameled wires had to be stripped off one by one. Therefore, a lot of manpower was required to strip the coating
Suggestions from DENGENSHA TOA
The stripping process has been eliminated in their mass production by crimping the bundled enameled wires with the terminals on, without stripping the coating, while resistively heating.
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Solution to user issues
Improved voltage fluctuation and greatly reduced weld expulsions!
Issues and requests of customers
The customer was performing a high-current projection welding on a single-phase AC power supply. Because of the large voltage-fluctuation, the electric power company issued the order to improve the situation.Installation of devices such as flicker compensators was considered, but they were very expensive, and they would have had imposed severe burden on the company.
Suggestions from DENGENSHA TOA
Dengensha suggested replacing the control device of the welding machine to an AC inverter, and the customer implemented this change.As a result, voltage fluctuation was cut down to 1/3 of the original amount, and welding expulsion was also drastically reduced.
Solution to user issues
Drastic production cost down with resistance heating equipment change
Issues and requests of customers
The customer was using a single-phase AC (thyristor-type) resistive heating device to quench and anneal steel pipes, but the electricity charge was very high, and the production cost was under pressure.
Suggestions from DENGENSHA TOA
Resistance heating is a method that generates heat more efficiently than heating furnaces or high-frequency heating because electricity is directly passed through the metal, which is then heated by its inherent resistance.Dengensha proposed changing the control method of the resistor heater to an MFDC type.The MFDC type resistive heater is very efficient because 40% of the power consumption is converted to a heating temperature. Compared to the single-phase AC system, it is more efficient in generating heat. The customer was able to achieve a 23% reduction in electric charges and reduce the heating time, enhancing the productivity as a result.
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Proposal for new material application
Stable high-quality welding achieved with a newly purchased welding machine
Issues and requests of customers
The customer was welding M5 nuts to hot stamp materials and was unable to stabilize the quality.
Suggestions from DENGENSHA TOA
It was found that the NDZ’s single-phase AC method would not be able to stabilize the quality. The welding test was performed using an MFDC welder and a capacitor welder.The welding tests showed that the capacitor type had the highest strength and stable quality.The capacitor type enables superior quality welding by its feature of high current, short weld time, and high pressure.It is also an energy-saving equipment.The customer purchased a new welding machine and was able to achieve stable welding.
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Global service
Prompt response to permanent countermeasures through overseas base services
Issues and requests of customers
A trouble occurred at a customer's overseas base.
Suggestions from DENGENSHA TOA
Our overseas base service staff visited the customer and checked the details of the trouble.The overseas staff informed the details of the problem to our head office, which then instructed a temporary measure. The overseas staff implemented the given measure at the customer site and recovered to its normal operation.A replacement component for the failed part was immediately prepared to promptly put a permanent countermeasure in place.
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