Manufacturing & Distribution
Contec Co., Ltd.
The R-series S/R machine is a stacker crane that stores and retrieves pallets into and from racks. The technologies implemented on the R-L10 model S/R machine, which was certified as an eco-product last year, has now been spread to all R-series models. Its refined frame structure and use of premium efficiency motors contribute to a 6 % reduction in electricity consumption, and a 5 % reduction in CO2 emissions and energy consumption compared to conventional models.
The seismic damping rack is one of our anti-seismic products. In the event of an earthquake, the seismic damper units installed at the top of the racking structure absorb the seismic vibrations, which prevents the stored items from falling off the racking. Changed from the conventional arrangement, the dampers are now at the center of the S/R machine aisle. This modification has led to a decrease in the required number of dampers, and an increase in rigidity that has also brought a about decrease in size of the beams of the damper unit. These factors add up to a 20 % decrease in weight, and a 19 % decrease in CO2 emission and energy consumption.
The S/R Machine (R-L10) is a stacker crane that stores and retrieves pallets, up to 1 ton, into racks up to 15 meters. By making the frame lightweight and standardizing use of motors with premium efficiency, energy consumption was reduced 8% compared to standard models. The frame structure was also redesigned and the amount of wiring was reduced, leading to a 10% decrease in the number of parts.
The Bolt-up Rack, which uses rivets and bolts to hold parts together, is used mainly as storage racks for automated warehouses. By remodeling the columns, the rack can now be applied in high-rise automated warehouses, which were traditionally welded structures, decreasing weight by 10%. In addition, by not welding, energy used during fabrication was reduced by 30%. In addition, shipping can now be done with the brackets removed, decreasing the number of trucks used and emission of CO2 by about 60%.
The Shuttle Rack is a mini load AS/RS that operates with a vehicle on each rack level. The system stores and retrieves containers and cardboard boxes at high speeds and is used for picking or sorting for shipping. The weight of the shuttles were redesigned and are now 36% lighter than the conventional weight, contributing to a decrease in energy consumption.
An AS/RS for storing long objects such as steel beams and timber. Using a customized lightweight pallet, the materials are transferred and stored lengthwise to realize a more lightweight system. The crane incorporates a push-pull method for transferring materials to minimize the moments created during transfers and reducing crane weight by 15%. In addition, by using resin that is installed onto the rack's beams to support the pallets at points, the system weight was reduced by 60% compared to traditional systems. Through these efforts, not only was energy consumption reduced, the environmental impact from manufacturing the system was also decreased.
The Motor Roller Conveyor is ideal for conveying containers and cardboard boxes. Energy consumption is reduced by about 20% by placing rollers that contain highly efficient brushless motor in intervals and activating motors at the necessary locations when needed. The system is also lightweight, as the number of parts has been decreased. In addition, the system does not use air supply and essentially produces no noise, improving the work environment.
Daifuku's mini load AS/RS is appropriate for the storage and retrieval of items in containers and cardboard boxes and is widely used in distribution centers and factories of various industries, as a system designed to promptly and accurately supply "necessary items in the right quantities where and when required." Daifuku upgraded the mini load AS/RS, reducing the weight by 15%. The motor size was also decreased, helping reduce electricity consumption.
This mechanical centering system serves to correct the position of the transfer cassette that has been lowered by a crane before the glass processing equipment. It is designed for use in liquid crystal panel plants with automated warehousing. The positioning unit is driven mechanically by a compressed spring system that eliminates the need for motors or compressors. As a result, power consumption is reduced by 93%, parts count by 22% and weight by 41%.
The Clean Space Carrier is an overhead monorail system used in cleanrooms for the production of flat-panel displays. Compared to standard systems, the carrier speed was increased from 120 m/min to 180 m/min, a 50% increase. Acceleration was also increased 30% from 0.06G to 0.08G and deceleration was increased 150% from 0.06G to 0.15G. These improvements led to a decrease in the number of carriers needed in a system. In addition, the carrier increased energy efficiency by using energy produced during deceleration. These efforts led to a 16% decrease in energy consumption and 43% decrease in waste.
The Cleanway is a cleanroom transport system for semiconductor factories. In addition to decreasing weight compared to conventional models, the motor control was upgraded, increasing travel speeds from 200m/min to 300m/min. By increasing the capabilities of the system, the number of carriers is reduced, decreasing energy consumption and waste by 5%.
The MMHS effectively uses the ceiling space and combines transporting and storing functions, which decreases power consumption compared to conventional systems that separate the transport and storage functions. Transfer points are also flexible to move, which cuts the number of parts replaced during layout changes, making the system highly reusable.
The Clean Space Carrier, which transports flat panel displays, moves 50% faster than conventional systems by optimizing the rotational speed of motors with improved speed drive controls, increasing the transport capacity. This enables a reduction in the number of carriers, which in turn decreases the amount of energy used. In addition, the efficiency of the HID non-contact power supply system was improved, leading to a total of 16% reduced power consumption.
A large number of the Clean Stocker storage systems have been used for clean rooms, a dust-free environment where flat-panel displays are manufactured. We enhanced energy conservation by upgrading the HID non-contact power supply system, with the aim of significantly reducing overall power consumption, while adding a regenerative charging capability. As stacker cranes require a tiny but constant trickle of power in standby mode, the upgraded Clean Stockers use the regenerated power to additionally save energy.
With the previous lineup of floor type Flexible Drive Systems, the smallest model was rated for 500 kg. We have now added a 150 kg transport model suitable for lightweight objects such as bumpers and doors. By reducing the capacity of the friction drive motor, power consumption when transporting objects with 150 kg or less has been reduced by about 40% compared to conventional systems. In addition, the structure of rails and trolleys has been drastically redesigned for a weight reduction by 45%, which also helps to conserve resources.
The SPDR (pronounced “spider”) stores and sorts a variety of cases used in parts logistics. As it does not use racks like conventional AS/RS, it can effectively be applied in limited spaces, contributing to resource saving. In addition to freely handling stacked cases, the system efficiently picks stacked cases and was made lightweight, making it an energy efficient system. By using a transmission belt to move, the system operates quietly, improving the work environment, and is easy to maintain.
A load bar turn was incorporated into the Flexible Drive System (FDS), allowing the carriers to switch directions efficiently. The FDS is used to convey vehicle bodies on assembly lines and can be ridden by workers as they work on the vehicle. The carrier was split into three sections and are joined with a load bar that has an articulating mechanism. The carrier is able to separate and turn, looking like an open fan, eliminating the need for a turn table. This greatly reduced the required energy, weight and the number of parts. In addition, the carriers can be completely separated to be shipped, increasing transportation efficiency.
The ECO POWER ASSIST system reuses the energy generated from the deceleration of motors and then temporarily stored in condensers, which are storage-effective and befitted for rapid charge/discharges. By incorporating this system into lifts and shuttle-type vehicles, the system cuts energy consumption by up to 28%.
Unlike conventional chain conveyor systems, the E-DIP carrier flexibly adjusts the vehicle body angle while immersing and removing it from the dipping tank. In doing so, the E-DIP improves the coating quality, reduces liquid lost from the tank, and helps prevent liquid waste due to inadvertent mixing with other liquids. The E-DIP also enables smaller tanks, which shortens conveyor lines, and actively uses reusable materials.
The Twinfect Feat is the industry's only car wash system that completely separates the washing and drying functions to achieve impressive throughput. Besides improving washing and drying performance, the newly developed glass-type coating process that is included as part of the standard configuration shortens the time required for coating by 20%. In terms of environment friendliness, we ensure significantly better corrosion and weather resistance by using highly corrosion-resistant galvanized steel sheets for the frame. Lower power and water consumption as well as the use of environmentally safe liquids also demonstrate our concern for the environment.
The Twinthru Luke uses newly developed brushes for more intensive cleaning, and drying performance has been improved as well. The range of options available has also been expanded. In terms of environment friendliness, we ensure significantly better corrosion and weather resistance by using highly corrosion-resistant galvanized steel sheets for the frame. The system consumes less power and water, and environmentally safe liquids are used as standard.
The Fabrica is able to wash underneath rear spoilers using the industry-first “inclined and separable side brush.” The model also incorporates new features, including high-pressure hoses and a brush to clean wheels and an under-body wash that functions according to the length of the vehicle. The machine is built with a highly corrosion resistant steel frames, contains water-saving measures, and uses environmentally-friendly detergent as its standard.
The Avante uses a newly developed brush that thoroughly washes vehicles, along with other accessories that also have increased washing capabilities, as well as a side nozzle for drying smaller vehicles. The machine incorporates the newest features and options to meet every driver’s needs. It is built with a highly corrosion resistant steel frames, contains water-saving measures, and uses environmentally-friendly detergent as its standard.
By using the industry-first "inclined and separable side-brush," the Flare is able to wash beneath rear spoilers, which was not possible with previous machines. In addition, the sensors were enhanced to increase the washing performance of vehicle accessories and vehicle throughput. The Flare is also eco-friendly, using 41% less water during high-speed washing speeds and using LED lightings in its front mask, which reduce nighttime standby electricity consumption by 14%. It also uses biodegradable detergent that has a reduced volume of normal-hexane extract.
The Grossa greatly decreased the washing time to 85 seconds per vehicle. The diameters of the brushes were also enlarged to further enhance washing performance. The Grossa is also eco-friendly, using 41% less water during high-speed washing speeds. It also uses biodegradable detergent that has a reduced volume of normal-hexane extract.
The Twinfect Force boasts a 20% improvement in its washing throughput while increasing cleaning capabilities. Also, washers are completely separated from dryers, which enables higher efficiency in drying the washed cars. In addition, the machine is eco-friendly, using only 36 liters of water per vehicle at normal washing speeds and LED lightings in its front mask, which reduce nighttime standby electricity consumption by 18%. It also uses biodegradable detergent that has a reduced volume of normal-hexane extract.
The Twinthru Arento boasts a 20% improvement in its washing throughput while increasing cleaning capabilities. The machine is eco-friendly, using only 36 liters of water per vehicle at normal washing speeds and LED lightings in its front mask, which reduce nighttime standby electricity consumption by 18%. It also uses biodegradable detergent that has a reduced volume of normal-hexane extract.
The Euros is an environmentally friendly gate-type car wash machine with improved cleaning and drying capabilities. It features a washing throughput of 85 seconds per vehicle, the fastest gate-type car wash machine, and a reduced machine size by shortening the rail length by 0.5 meter. The machine uses a large keypad with an LCD screen to make it easier to operate. The machine uses only 40 liters of water per vehicle at normal washing speeds while using 31% less power than conventional machines. It also uses biodegradable detergent that has a reduced volume of normal-hexane extract.
The Granada, an environmentally friendly drive-through car wash machine, boasts a 30% improvement in its washing throughput and uses more sponge brushes, which increases cleaning capabilities while producing less noise. From an environmental standpoint, the Granada uses only 34 liters of water per vehicle, the industry's lowest amount at regular operating speeds. In addition, the Granada uses LED lighting in its front mask, which reduces nighttime standby electricity consumption by 14%, and is equipped with an eco-friendly mode that reduces electricity usage by about 25%. It also uses biodegradable detergent that has a reduced volume of normal-hexane extract.
The GSPECT, an environmentally friendly gate-type car wash machine, uses only 41 liters of water per vehicle at regular operating speeds while maintaining the same cleaning capabilities. Also, by redesigning the entire machine, the size of the machine was reduced as well as the rail length, which was shortened by 0.5 meters compared to normal machines to 7.8 meters.
This highly compact switching hub supports operation over a wide temperature range from -20℃ to +60℃ and is mountable in a 35 mm DIN rail. Thanks to circuit optimization, the unit consumes 45% less power than the predecessor product, and the improved heat dissipation design enables more compact dimensions (32% reduction). Redesigned packaging results in a reduction of 52% by volume and 24% by weight and thereby contributes to the conservation of resources.
This compact power-saving device is designed for measurement and information display in systems that combine solar cells and lithium ion batteries. Unlike conventional systems that are configured with a general-purpose computer, the new product utilizes a dedicated all-in-one measurement controller, realizing a 91% reduction in power usage, 81% weight reduction, and 96% reduction in packaging material.
This Slave Module realizes high-speed real-time operation in accordance with EtherCAT, a global standard for real-time communications. It provides a dedicated high-speed expansion bus that supports real-time control of a wide range of I/O combinations, including digital and analog I/O. The circuitry has been optimized for EtherCAT functionality, resulting in 41% lower power consumption than with conventional systems, along with a 30% weight reduction.
The BX-320 is a small, high-performance industrial PC, which can fit on the palm of a hand, with an Intel Quad Core Atom processor that can be installed on a 35mm DIN rail. For cooling efficiency, the heat sink and other features were structured with the optimal design, decreasing weight by 14%. In addition, energy consumption was decreased by 2%, despite having a high-speed CPU, with total decrease of 11% if increased power consumption by the CPU is not included. Packaging was also redesigned, cutting packaging volume by 69% and weight by 33%.
The M2M Controller is a compact device for remote monitoring and controls that combines a variety of I/O functions, including digital and analog input/output. By combining the I/O functions, which conventionally required multiple I/O devices for one system, electric consumption was decreased by 34% and weight was reduced by 37%.
The SolarView Compact measures solar power generation and displays and saves data on a small console. By switching from a Windows-based computer to a specialized measuring device based on a microcomputer, energy consumption was cut by 99% and weight was reduced by 91%.