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- Vol.4: "KOIWAI" Method Achieves Short-Term Delivery&Precise Manufacturing of Casting Prototypes!
3D Digitizer User Reports
Measuring Instruments
3D Digitizer User Reports
Front lines of the casting technology
Vol.4: "KOIWAI" Method Achieves Short-Term Delivery &
Precise Manufacturing of Casting Prototypes!
KOIWAI Co., Ltd.
(Odawara City, Kanagawa Pref.Japan)
Traditional expertise is blended with the latest digital technology to
achieve short-term delivery and precise manufacturing of casting prototypes.
Shuji Koiwai, Managing Director
KOIWAI is a company with top-class technologies in thin-walled precision casting and lightweight precision casting based on more than 30 years experience in casting prototyping. Its employees are casting specialists for automobile parts who have experienced casting of every cast part installed in vehicles.
With its motto of "short-term delivery & precise manufacturing", KOIWAI pursues its new goals to achieve large volume production using gravity aluminum die casting and to establish a cast prototyping system using aluminum/magnesium/FC sand molds. To accomplish these goals, the company established the Seisho Techno R&D laboratory in Seisho Techno Park (Haneo Industrial Park, Odawara City, Kanagawa Pref.). It features cutting-edge equipment for the design, manufacturing, and quality checking of casting. These equipment are used in part for: high-end 3D CAD/CAM, laser-sintering RP system (EOSINT/S), high-speed universal aluminum CNC drill, and CT scanner, as well as the Non-Contact 3D Digitizer VIVID 9i and the RAPIDFORM XOR/XOV reverse engineering/inspection software. These state-of-the-art digital technologies play the central role both to offer products according to the company's motto "short-term delivery & precise manufacturing" and to achieve the unique "KOIWAI" method.
"It's necessary for small-and-medium-size companies like us to survive not only by offering products of high accuracy and high quality, but also by doing it in a shorter time at lower cost," said Mr. Shuji Koiwai, managing director of KOIWAI. "And to achieve such a high goal, we must establish unparalleled technologies by blending cutting-edge digital technologies into our unique experiences and know-how." According to Koiwai, introducing the 3D digital technology in particular was extremely effective in reducing costs for the product inspection process, helping to achieve rapid delivery.
Introduction of 3D digital technology into inspection
process using conventional "marking"
The key factor of the "KOIWAI" method is to achieve both high quality and short-term delivery. Even if the company succeeds in establishing high-quality prototyping and a large volume production system, which improves the manufacturing speed only, spending much time for product inspection with the conventional method prevents improvement in the throughput, disabling short-term delivery. To prevent this problem, KOIWAI introduced 3D digital technology into the inspection process, which significantry reduced the working time. The Non-Contact 3D Digitizer VIVID 9i replaced the conventional inspection process using manual marking.
The following shows a comparison between the conventional manual inspection and the latest inspection process, as well as the effects of
introducing 3D digital technology. The example used is a supercharger casing with a complicated shape, which is manufactured with KOIWAI's
sophisticated technology to prevent core displacement.
Conventional method:
The work margins on the formed metal are measured with a contact-type measuring instrument based on the marking lines drawn manually.
Problem:
It isto secure the workpiece (leveling) due to its complicated solid structure. Manual marking requires longtime experience and expertise. Even a subtle mistake in the securing method or measurement will cause defective results in secondary working processes. Consequently, the inspection staff bears a heavy workload and is subject to mental stress.
Improved work ef f iciency achieved by the VIVID 9i system
Conventional manual marking required a whole day to obtain results. The VIVID 9i system, however, achieves a significant reduction in man-hours (to one-fifth) by improving operability.
Advantages of the VIVID 9i
- No need for bothersome leveling work. The workpiece can be measured fiexibly and easily by using the AF/AE function.
- The shape information of the workpiece (measurement points) can be obtained quickly and accurately.
- Several pieces of measurement data can be integrated easily, accurately, and immediately, without the need for markers or stickers.
- The inspection software XOV offiers the GD& T function based on CAD data, allowing real-time inspection.
- Inspection reports can be prepared automatically, preventing mistakes while copying dimensions.
Unexpected effects and new challenges in reverse engineering
KOIWAI's young staff: Messrs. Terazono, Ishino, Koiwai, and Kobayashi
(from left to right)
At first, KOIWAI considered introducing an expensive 3D digitizer from another company. On hearing of the VIVID 9i, the sta immediately requested a demonstration of the actual instrument. The benchmark test showed that the VIVID 9i compared favorably with the other company's expensive instruments by achieving the accuracy required by KOIWAI. The sta said that the VIVID 9i showed the best operability and highest cost performance. Since it is manufactured by Konica Minolta, there was also a feeling of security about the after-sales support and service. "Honestly, I didn't expect to obtain such effects immediately after the introduction,"said Koiwai (Managing Director), and he also mentioned the unexpected effects."It was our young sta who appreciated the introduction most. They had a difficult time with the marking inspection and were under pressure every day. Now they can do the work easily, accurately, and quickly, which is almost unbelievable. They regained their inherent cheerfulness, which is the thing I'm especially glad about."
At KOIWAI, a combination of the Non-Contact 3D Digitizer VIVID 9i and inspection software XOV was a breakthrough in the inspection process.
The company will attempt to further develop the "KOIWAI" method by using the VIVID 9i together with the reverse engineering software XOR.
