1. ELE Expo
Introduction to the Electric Cylinder Actuators

2. Major Clients 2

3. Japan’s Air Cylinder Market3

4. Specific Focus: Applications not currently using IAI Products.4

5. ELE Cylinder Benefits 5

6. Benefits of Going Electric
A toner cartridge manufacturer produces 12,000 toner cartridges per day per assembly line
The main reason why they switched to electric actuators was keep a constant high speed production line
Electric Actuator
Air Cylinder
Life Span
10,000,000 cycles
1,000,000 cycles
Line Stoppage/Disruptions
Very Few
A Few
Quality
Example: Clamping work leaves no damage to work due to smooth acceleration/deceleration
Clamping work damages work
Adjustment
Once (Stored as data points)
Constantly needs adjustment (summer, winter, when temp varies, etc.) 6

7. Ele Cylinder Features
Environmental
Health
(Saving Energy)
Easily Change Program
Settings for Improved
Efficiency
More Stable Operation Lowers the Defect Rate
Highly Functional System Reduces the Overall Production Costs
Eliminating Startup Adjustments Reduce Labor Costs
Reduced Running Costs 7
─　　　　─

8. Ele Cylinder Features 8 Air Cylinder Control PLC Air Cylinder
Retreat signal
Retreat to end completion signal
Output
Input
Advancement signal
Advance to end completion signal
Retreat to end signal
Advance to end sensor
24v DC Power
Air Cylinder
Air for advancement
Air
Compressor
Regulator
Valve
Flow Control
Air for retreat
Lubricator 8

9. Ele Cylinder Features 9 PLC ELECylinder Control Retreat signal
Retreat to end completion signal
(to position 0)
(position 0 complete signal)
Output
Input
Advancement signal
Advance to end completion signal
(to position 1)
(position 1 complete signal)
ELE Cylinder
Attached cable
24v DC Power
Acceleration, Velocity, and Deceleration values 9

10. EleCylinder Functions
EleCylinder has the following 7 functions
Expanded Product Lineup
Easy operation/Easy entry
Stable operation
Programming not required
Predictive maintenance features
Quickly fixable
Cost savings 10

11. 1 ELECylinder Function 1 1. Expanded Product Lineup IAI America, Inc.
 The EC series now has the EC mini, high rigidity, and dustproof/splash-proof types available.
The EC series has product lines previously only found with the RCA2 mini Cylinders.
The EC radial rod types also have many mounting method found with only a few other actuator series, such as the knuckle joint and clevis mounting. It also has the unique NJPB and QRPB mounting options, which are the clevis and knuckle joint, including the oscillating brackets.
Dustproof/Splash-proof ECs have an IP67 rating, higher than the RCP6W, which has IP65. Matches RCP4W-RA and RCP5W-RA6/RA7 rating.
IAI America, Inc.

12. 2
ELECylinder Function 2
2. Desired start/end points can be easily set.
 Changing those settings for air cylinder require a lot of work
With ELE CYLINDER®...
 All you need is to enter values in two fields.
 How to enter the start/end points
Input range
Position setting
Rear end
(Home side)
Front end
Position acquisition
You can enter them instantly.
IAI America, Inc.

13. 2 ELECylinder Function 2 [1] Adjustment of mechanical end position
With air cylinder...
[1] Adjustment of mechanical end position
[2] Adjustment of auto switch position
[3] Adjustment of shock absorber position
[4] Checking (fine-adjustment) of position of each part
* Some do not require [2] and/or [3]　
Adjust bolts
Adjustment requires several minutes.
[1]
[2]
Shock absorber
[3]
IAI America, Inc.

14. AVD 2 ELECylinder Function 2
Each A.V.D. can be individually set to a desired value.
 Individual values can be entered for acceleration, speed and deceleration! 　
Operating conditions (Outbound: Rear end  Front end)
Press fitting
Cycle time
S: Speed
S: Speed (%)
A: Acceleration
A: Acceleration (％)
D: Deceleration (%)
D: Deceleration
Speed
Time
Input range
Position acquisition
* S (speed) on the screen will be changed to V (velocity).
Fine-adjustment Settings can be done!
A: Acceleration
V: Velocity
D: Deceleration
AVD
IAI America, Inc.

15. 2
ELECylinder Function 2
It is very easy to set a push move with the EC actuators.
 Select the Push box, set the desired force, and location to begin the push.
Both pushing and pulling are available, though only one can be used at a time.
Push force can also be set in terms of Newtons (as a reference value), something that, otherwise, is only seen with our RCS3 servo press actuators with the load cell.
IAI America, Inc.

16. 3
ELECylinder Function 3
IAI America, Inc.

17. 3
ELECylinder Function 3
IAI America, Inc.

18. 3
ELECylinder Function 3
IAI America, Inc.

19. 4
ELECylinder Function 4
IAI America, Inc.

20. 4
ELECylinder Function 4
IAI America, Inc.

21. 5 ELECylinder Function 5 5. Predictive maintenance features
 Not available with air cylinders
IAI America, Inc.

22. 5 ELECylinder Function 5 IAI America, Inc. Built-in controller
Doing all these with air cylinders is difficult.
These features are available only with ELE CYLINDER.
Preventive Maintenance
Predictive Maintenance
Regular maintenance performed at specific intervals regardless of whether or not the facility is malfunctioning
Prevent sudden failures
Extend the service life
Maintenance performed when symptoms of abnormality are detected through constant monitoring of the facility
Predict sudden failures
Prevent sudden stopping of the line
Built-in controller
Controller board
IAI America, Inc.

23. 6
ELECylinder Function 6
IAI America, Inc.

24. 6
ELECylinder Function 6
IAI America, Inc.

25. 6 ELECylinder Function 6 IAI America, Inc.
List of maintenance parts No
Product name 1
　Controller board (Motor cover Assy) 2
　Motor unit
Maintenance part 1
Controller board
(Motor cover Assy)
The board is on the back side of the motor cover.
Maintenance part 2
Motor unit
The controller board can be replaced with the motor cover assy.
The product can be recovered only by replacing the parts above because the ball screws or guides do not break.
IAI America, Inc.

26. 6
ELECylinder Function 6
IAI America, Inc.

27. 7 ELECylinder Function 7 7. Cost Savings
 Lower cycle times, reduced Choco Tei, longer service life and lower electric costs lead to an overall less expensive system
IAI America, Inc.

28. 7 ELECylinder Function 7 Shorter cycle time
 Opening/closing of processing machine door
Move at low speed
Move at high speed
Required quantity can be produced quickly
Move at high speed
Move at low speed
Door opens
Door closes
Explanation of Line （3 operators per line)
Shorter work time of the operator
Cutting [1]
Cutting [2]
Heat treatment
Grinding
Cleaning
Inspection
Improved system
Operator
Operator
Operator
Note: As the cycle time for “Cutting [1]” became shorter, the total cycle time of the line became shorter.
Shorter cycle time equals less labor cost
Production cost is reduced!
IAI America, Inc.

29. 7 ELECylinder Function 7 Longer service life
 The service life of an air cylinder is primarily determined by the service life of its gaskets & seal.
 Service Life of Air Cylinder (Distance and number of motions)
Standard rod type
Slim compact rod type
Cylinder tube
Piston
Rod cover
O-ring
Seal holder
Piston gasket
Rod cover
Magnet
Head cover
Piston rod
Oil-impregnated bushing
Rod gasket
Bumper
Piston gasket 
2000 km Service life assumed by the manufacturer
Rod gasket
Piston
Cylinder body 
Expected service life by manufacturer : 5 million times
Moving element
Top cover
Rod-less type
The service life of an air cylinder varies depending on the cylinder shape and cylinder manufacturer.
Rodless actuators are said to be vulnerable to air leakage from dust seals, although the specific situation varies depending on the structure of the actuator.
End cover
Hexagonal socket head button bolt
Dust seal band
Setscrew
Belt clamp
Clearance: 1 mm
Head cover 
2000 km Service life assumed by the manufacturer
Cap bolt
IAI America, Inc.

30. 7 ELECylinder Function 7 Gasket & Seal deterioration 2 years
Horizontal installation
 Service Life Comparison of ELE CYLINDER® and Air Cylinder
Load weight: 6.5 kg
Overhang: 200 mm
Annual operating days
Operating hours
Moving stroke
Operation cycle
Annual distance traveled
Operating conditions
365 days
16 hours/day
3 sec/cycle
1500 km/year
Service life
Traveling life
Factor that determines service life
Gasket & Seal deterioration
Air cylinder
(rod-less type)
2 years
* Source: Life characteristics data from the cylinder manufacturer
Lasting 15 times longer
Service life of guide
ELE CYLINDER® (slider type)
20 years
Calculation of moment: Mc moment: 6.5 kg x 0.2 m x 9.8 m/s2 = 12.8 N•m 　
23.3 N-m
12.8 N-m 3
x 5,000 km
= 30,148 km
Calculation of traveling life:L＝
IAI America, Inc.

31. Running Cost Comparison of Air Cylinder and Electric Actuator7
ELECylinder Function 7
Lower electricity cost (CO2 reduction)
 The higher the operation frequency, the higher the energy-saving.
Running Cost Comparison of Air Cylinder and Electric Actuator
* Same effects for reducing CO2
* Based on tests conducted by IAI
5-sec cycle 1
 Examples: Electronic/electrical parts industry
20 kg is transferred horizontally
Comparison with 25-mm rod-type air cylinder
5-sec cycle operation
Speed
Cycle time 5 sec
Reduced by up to 1/17
Time
Air
Operating time
Stationary time
Electric
Moving 200 mm
Operating time: 1.54 sec x 2 = 3.08 sec
Stationary time: 1.92 sec
IAI America, Inc.

32. 7 ELECylinder Function 7 2 IAI America, Inc.
 Example: Automotive industry
20 kg is transferred horizontally
Comparison with 25-mm rod-type air cylinder
Speed
60-sec cycle operation
Reduced by up to 1/3
Cycle time 60 sec
Time
Air
Operating time
Stationary time
Moving 200 mm
Operating time: 1.54 sec x 2 = 3.08 sec
Stationary time: sec
Electric
[Air cylinder - Air consumption calculation conditions]
[Electric cylinder - Power measurement conditions]
Service air pressure
0.5 Mpa
Air piping conditions
2.5 mm, 2 m
Unit price of air
2.4 yen/㎥ (ANR)
Unit price of electricity
15 yen/kWh
Actuator used for measurement
RCP6-RRA4C (Lead 5)
Operation condition
350 mm/s　0.3 G High-output setting enabled
* Losses due to compressor efficiency, air leakage, etc., are not included.
* The unit price information of air is from company D.
* Air consumption x Unit price of air = Electricity cost
* The measured values do not include losses due to the power supply.
* Measurement was performed according to the conditions (unit price of electricity, payload) specified by company R
* Measured electricity x Unit price of electricity = Electricity cost
IAI America, Inc.

33. Application Example 1

34. Application Example 1