Examples of Problem Solving

Problem

We use an AC solenoid to open and close the duct, but when the linkage gets dirty and its movement becomes sluggish, the solenoid can burn out, making it difficult to find a solution.
A DC solenoid cannot achieve the required stroke, and there are no suitable replacements. Replacing it with a motor would complicate the mechanism and slow down the operation.

Solution

We resolved the stroke issue and enabled operation by redesigning the linkage and using a DC rotary solenoid instead of an AC solenoid.

Effect

Even if a lock occurs, the DC solenoid will not burn out, and it can be restored to normal operation simply by cleaning.

Problem

We have installed a vibration device to remove adhered powder from the outdoor hopper.
This device is an air-driven actuator.
During cold winter periods, moisture in the drive air can freeze within the piping, causing the actuator to malfunction.
During severe cold periods, it can take several days for the ice to thaw and for the system to recover, making it difficult to find a solution.

Solution

We replaced the vibration device with a solenoid type, eliminated the air piping, and switched to electrical wiring.

Effect

It can now operate regardless of the outside temperature.

Problem

A mechanism that reciprocates within a certain angle range is needed, but they were having trouble securing space to accommodate the drive unit.
If we reduce the size of the motor and change the gear ratio, the operation becomes too slow, which affects the functionality.

Solution

Replace the motor, gearbox, position sensor, and driver with a rotary solenoid.

Effect

The mechanism was simplified, and the main component is now only the rotary solenoid.
This results in space savings, improved reliability, and cost reduction.

Problem

In airtight buildings, dedicated ducts are required to introduce outside air for ventilation.
In the event of a fire or other emergencies, these ducts automatically close to prevent air inflow.
During such emergencies, power may be lost.
If the drive unit consists of a motor combined with a reducer, it is not possible to reverse the motor to close the ducts.
Alternatively, a complex mechanism such as disengaging the drive unit with a clutch and returning it with a return spring is required.
There are even systems equipped with emergency batteries for reversing.
These systems are complex and costly.
There are concerns about their reliability in ensuring operation during emergencies.
Regular maintenance of the batteries is essential.

Solution

The valve drive unit was configured with a rotary solenoid.
It opens when energized and closes when the power is cut off.

Effect

The mechanism is very simple, which has kept costs down.
The simplicity of the mechanism also enhances its reliability.