Minowa-cho, Kamiinagun , Nagano prefecture
Nisshin Welding is a sheet-metal processing company established in 1953 (Showa 28)
We provide high quality metal work with an integrated production system including design, modeling by 3D CAD/CAM, laser processing, bending, plating, welding, painting, surface treatment, inspection, packaging and shipping.
Our experienced staff is responsible for assisting customers from large-frame to detailed-precision welding.
Nisshin Welding Co., Ltd.
Minowa-cho, Kamiinagun , Nagano prefecture
There is a common challenge in the sheet-metal business: deburring work itself does not pay. Even if a project is labor intensive, it needs to be done at very little cost by experienced and efficient workers who can quickly make the necessary provisions for each project.
An immediate response in determining the best processing plan depending on the materials is important for a smooth operation.
Starting with deburring the external form, the process through to completion involves alternating tools such as a nipper, sander, grindstone drill, file, and other tools according to the diameter of the interior holes and the punched die cut.
Even more, larger materials require two workers as a synchronized pair.
Such a diverse array of materials and processing methods necessitates detailed work that requires manual labor by only experienced workers.
However, such intensive manual labor work caused inconsistencies in efficiency and quality even when done by experienced workers. The greatest challenge was overcoming this inconsistency.
In the past five years, as the demand for high-quality deburring increased, the more cost became the contributing factor.
Materials like stainless steel plate 2B, and SUS430 become worthless if they are scratched so they must be handled very carefully. Buffing may conceal scratches but any treated area may be visible and the material may end up defective.
For the past five years, the surface of stainless steel has been protected from scratches by a film coating.
This protective casing on the material body caused an extra step in the deburring process - or perhaps two steps if taking care of the sheet is included.
As a result, work in some materials began to not be cost effective unless the operation time was decreased in order to maintain the value of the merchandise and a stable quality.
We discovered the AuDeBu at an exhibition of the sheet metal industry, MF-Tokyo 2013 (Press / Sheet Metal / Forming Exhibit).
We witness a demonstration of the deburring machine at the Authentec booth and thought it could be useful.
Then, we referred to the functions mentioned in the video on the Authentec homepage when we evaluated it for use at our company.
Hoping for a solution to some of our ongoing problems, Authentec was invited to visit our company. The Authentec staff sincerely listened to our problems, suggested solutions, and helped us to immediately choose a specific model of deburring machine.
I may be repeating myself, but our reason for installing the AuDeBu was being able to solve the problem of “time taken by manual labor and processing are difficult to visualize.” We can look forward to stable manufacturing, improvements in our working environment, and a source of deburring know-how.
Simply put, we expect a deburring machine to excel in deburring, to be easy to maintain, and to be low in daily strain on our workers.
It is only the first day so is hard to say, but deburring small materials has given us a better-than-expected result if set up for the right materials. And, I like the fact it is easy to clean - only pump in air using the air blower (the optional dust collector was installed as well as the main unit).
It was also appealing that the main shaft of AuDeBu does not use any gears. If gears were used to operate the brush, lubrication would be necessary.
We were aware of how difficult cleaning can be when oil leaks, mixes with dust and hardens into a cake. AuDeBu has no gear in the main shaft so no oil is needed. In that respect, the operation needs no unnecessary time for maintenance.
"It really gives us a good feeling!"
Most of all, deburring is easier on smaller materials, which took more work in the past. Happily, we made a fortunate mistake.
Although we also process smaller pieces, we mostly work with material of 500-900mm, but we chose the AuDeBu1000 which handles up to 1000mm-wide materials.
MiniAuDeBu is recommended for work on small materials, so we were planning to continue working manually on our projects with smaller materials.
However, we actually tried deburring small materials by adjusting the adsorption pressure of the belt conveyer and the rotation number of the brushes and the result was better than we expected.
In the future, we plan to test a variety of settings in order to discover which settings are best suited to different materials and workmanship.
We receive various requests for deburring projects from our customers, such as Light-chamfering, C-chamfering, R-chamfering, and deburring small to large materials.
Quality control and keeping a balance of cost and efficiency were difficult in our deburring operation because of differences in the level of experience in our personnel and differences in how the materials were assessed.
Our future goal is to gain a better understanding of the features of AuDeBu1000 through the advice of the Authentec staff and experienced users, to accumulate know-how in quickly responding to each of our customers’ needs, to share this knowledge within our company, and to further our systems development.