When we hear from our customers about the problems they are having when introducing or updating equipment, we are often asked about ways to improve losses and yields.
Since the equipment we provide can be customized from a single unit, we make proposals for adding or changing parts to be incorporated or modifying the design according to what we hear from them.
Our proposals vary depending on the conditions of the workplace and the nature of the workpiece, but this column focuses on the two processes of “feeding” and “discharging,” and introduces customizations that lead to improvements in losses and yields, focusing on those actually adopted by our customers.
Introduction by cause of loss
- Workpieces dance and scatter.
- Work spills during feeding.
- Workpiece cannot be completely discharged from the container (residual liquid remains)
1] Workpiece dances and splashes.
Keep the distance between the workpiece outlet and the receiving container as close as possible.
*For powder workpieces Install a dust collecting hood.
Keep the distance between the workpiece outlet and the receiving container as close as possible.
Extend piping to match the position and size of the receiving vessel to reduce scattering at the time of discharge.
In some cases, only piping components need to be purchased additionally. This is a simple but low-cost solution that can be easily adopted.
*Example adopted by a materials manufacturer
The outlet extending directly below the container is extended to the side. The extended piping is sloped to prevent residual liquid.
*Example adopted from a chemical manufacturer
The tip of the discharge port is sized to fit into the mouth of a single-lot can in order to collect workpieces that have completed the process into a single-lot can.
The receiving container can be connected with piping to prevent splashing during discharge.
*An air vent is provided to prevent the risk of powder leakage due to pressure buildup in the receiving container when the material is placed in a sealed container.
We also offer a series of powder collection containers that can be used with various types of piping.
For processes where the height of the receiving container is not constant, or where the height needs to be adjusted, we recommend placing the container on a low floor lifter and adjusting the position of the container.
In some cases, a lifter with a weighing function is used to check the weight of the powder in the receiving container and adjust the feeding amount.
*For powder workpieces : Installing a dust collecting hood
Install a cover over the container at the feeding destination and connect it to a dust collector to collect any powder that may be blown up.
Raw materials collected by the dust collector may be reused at the discretion of the customer.
2] Spillage during feeding
- Provide a hopper for feeding.
- Use a container with a spout
- Support the throwing-in operation
- Install a step
Install a hopper
Generally, the lid of a container is designed so that it can be opened and closed halfway, but there are cases where other equipment is attached to the lid and sufficient space cannot be secured.
Depending on the nature of the work to be handled and the factory environment, some customers may be concerned about foreign matter entering through the wide-open mouth.
In such cases, a hopper is installed on the lid.
The limited area of the lid provides ample space for feeding rather than a small feeding port.
The photo on the right shows an example of a labor-saving device added to the feeding hopper installed on the lid. Raw materials in one-liter cans are fed through this hopper, which is shaped so that a one-liter can can be placed upside down in the hopper.
Supporting the feeding operation
When handling a certain amount of workpieces, there are many materials to be handled, and it may be difficult to handle them as expected because they are too heavy.
If the process involves tilting a container containing raw materials to transfer them to the next process, we recommend a container that supports the tilting motion. This supports stable handling and reliable feeding.
Alternatively, a balancer is also effective. The operator will feel almost no weight. The operator only needs to pay attention to the position of the container and the angle at which the container is tilted, so the container can be fed stably.
Installing a step
If the distance from the inlet is too far, it is a good idea to set up a step (step) so that the operator can throw in the container close to it. This will allow you to throw in the material more reliably than if you were in an unreasonable posture, resulting in less loss and, above all, safer operation.
3] Liquid cannot be completely drained out of the container (residual liquid).
- Use a container with a sloped bottom.
- Ensure that the container can be inverted.
- (For liquid workpieces) Coat the inner surface of the container.
- (For powder workpieces) Widen the outlet port.
- (For powder workpieces) Install a knocker or vibrator.
Use containers with sloped bottoms
When a flat-bottomed container is used with a discharge port, stagnation at the bottom inevitably occurs. If a container with a sloped bottom is used, the bottom will naturally discharge under its own weight.
Ensure that the container can be inverted.
If scraping out the contents is necessary, it is recommended that the container be designed so that it can be inverted.
This eliminates the need for manual inversion and saves labor.
(For liquid workpieces) Coating the inner surface of the container
In the case of highly adhesive liquids, the liquid may remain on the inner wall of the container and cannot be discharged easily. Coating improves surface water repellency and promotes smooth discharge. The photo shows an example of a ladle used to scoop cosmetic ingredients.
(For powder workpieces) Eliminating powder clogging in the hopper
Powders can become “bridged” when the pressure applied during discharge causes the outlet to become blocked. If this occurs, the entire amount cannot be discharged, and the remaining powder may be treated as loss or mixed with the next lot.
Widening the outlet or installing a knocker or vibrator at the bottom of the hopper may eliminate the powder blockage.
Alternatively, a knocker can be installed at the bottom of the hopper.
Translated by DeepL
https://www.nitto-kinzoku.jp/blog/blog/b-column-loss-custom/