Offering human oriented production process
SINTOKOGIO, LTD

Who is KOYAMA ?
• Company Name: KOYAMA Co., Ltd.
• Business Place: Headquarter & Kawanakajima Plant
Nagano City, Nagano Pref., JAPAN
• Establishment: October, 1945
• Capital: 98 million JPY
• Number of employee: 455 (as of December 2012)
• Major customers: FUJI Heavy Industries , KOMATSU
MITSUBISHI Heavy Industries, YANMAR,
HITACHI Construction, etc.
• Establishment : January, 2011
(KBT – KOYAMA BARINDER THAILAND)

Who is KOYAMA ?
• KOYAMA has been a developing foundry producing iron casting with established foundry technology under stable management since foundation in 1945.
• KOYAMA ’s 4 major business categories

Who is KOYAMA ?
BARINDER was developed in 1972 for the purpose of labor-saving in the foundry.
BARINDER has been loved and used by many foundry customers as a system specialized for qualified finishing of castings, in over 28 different countries in the world.

Problem of conventional manual work
• Problem of conventional manual work for removing burrs and fins of casting
– Human error (Uneven quality by workers)
– Taking time for preparation
– Numerous hazards

What is BARINDER?
• BARINDER is a solution to the conventional manual finishing and deburring work, realizing automation!!
•
•
•

Problem of conventional manual work
• Hand grinders
■ Grinder for small and
■ Grinder for large size
■ Double-end grinder medium size work work
Holding a heavy-weight grinder or work with the same posture is a heavy work, that obstructs high dimensional accuracy finishing.

Problem of conventional manual work
• Safety issues
Vibration
Hazards
・ Vibration (White finger disease)
・ Noise
・ Dust flying
・ Injury by accident
・ Heavy work, back pain, etc.
Noise, Dust
Back pain

Solution by BARINDER
• Introducing BARINDER will solve the aforementioned problems and contribute to the following advantages!!
– Improved productivity
– Improved grinding accuracy
– Space saving, Energy saving
– Improved working environment

Advantages by introducing BARINDER
• Sophisticated and easy operation
• Easy programming
• Long-life tools
• Reduced running cost and dust generation by diamond tool
• Easy fixture change and shortened preparation time
• Quick correspondence to frequent work change
• Can handle complicated profile
• Small installation space
• Excellent durability and maintainability
• Plural-unit operation by a single operator
• Improved productivity and quality by high-efficient and high-speed process

Advantages by introducing BARINDER
• Sustained quality and dimensional accuracy of finish
■ Manual finishing work
Non-uniform finish
■ Automatic finishing by BARINDER
Uniform finish

Composition of BARINDER
• Main Unit
Front shutter Operation panel
Hood
Chip and dust collection box

Work clamp bar
Composition of BARINDER
Small wheel
Work
Main wheel
Work set fixture

Break bracket VTR

Composition of BARINDER
• Unique horizontal & vertical work moving mechanism
• NACR Control System has achieved fast moving of work, by horizontal rotation table, horizontal joint arm and vertical lift mechanism.

【 NACR Control System 】
• NACR control is a system that converts the motion of the mechanism by polar coordinate to the rectangular coordinate.
• NACR is KOYAMA ’ s original control software achieving easy operation similar to NC control, utilizing robot arm mechanism.
X-axis A-axis
Y-axis
Z-axis

【 Automatic Load control system 】
Grinding speed (work feed speed) is controlled to vary so that the load to the work is sustained same.
• Advantages:
– 1. Improved efficiency of tool drive motor (Reduced electricity consumption)
– 2. Shortened grinding time
– 3. Improved life of tool and machine (Reduced heat generation from tool)
– 4. Reduced tool motor size (due to equalized grinding load)
– 5. Improved grinding accuracy

• Main unit
Change rotation door
Composition of BARINDER
Pallet changer type
Hood
Operation panel
Safety door

Work clamp bar
Composition of BARINDER
Pallet changer type
Small wheel
Main wheel
Work
Pallet Work set fixture

【
】
Pallet changer type
• 2-position Pallet changer or work load/unload system is available as an option, for more efficient work feed.
• Pallet change is generally used for two same fixture, however, it can also be used for two different fixtures to process different works alternately or randomly.

【
】
Pallet changer type
1. Work set or change is possible while the work is processed in the machine. (This system is particularly effective for medium and large size work.)
2. Automated line can be built by adding work transfer system after processing.

• Grinding tool: Diamond
Wheel
– Main wheel
– Small-wheel
Complex shape can be processed by utilizing two different tools.
【 Tool: Wheel 】

【 Tool: Wheel 】
• Features
Diamond grains are bonded to various shape of iron wheel. Tool diameter does not change in large volume.
Tool itself has high durability, achieving high-accurate and high-speed finishing.
Φ 355xT12x Φ 80 Φ 405xT10x Φ 80 Φ 405xT4x Φ 80

【 Tool: Wheel 】
• Small wheel
High-speed (Max. 15,000 rpm) small tool is effectively used to clean narrow and small area where main wheel cannot reach.
Various size of tool is available according to the shape of work.

Programming
• Direct teaching using the work is the base of the programming.
• There are 3 different methods in Direct teaching . Each method has unique features. Combination of each method is also available.
1. Hand Teaching (available in F300 & F400 Series
Clamp unit
Operator hold the work, which is held by the clamp unit and sits on the fixture mounted on A-axis table.
Then the operator let the teaching point touch the grinding tool.
Coordinate value is input on the touch panel.
Main wheel
Fixture

Programming
2. Manual pulse generator teaching
Manual pulse generator attached to the operation panel has selector switch of axis and job-dial. Work table (fixture) moves by the number of pulse by jog-dial on each axis. Operator moves the work by this dial operation and let the teaching point touch the tool so that coordinate value can be input by 1-push operation. This method is effective for more accurate position teaching.

3. JOG Teaching
• Operator moves the work by operating by the switches on the touch panel. Coordinate value where work touches the tool will be written to the program.
(Equipped as standard in all models)
• In this mode, only minimum drive force for teaching is required.
Teaching can be performed under safe circumstance. (Safe operation control system) ;
(Available in F300 and F400 series)
Programming

Programming
• Part of the grinding program can be modified by block.
・ Modification or correction of grinding program is easy by only input of moving direction (front/back, left/right, up/down, rotation) and value of movement.
・ Correction of data in the specified block can be done by pointing the range. ( NACR control system)

Networking of BARINDER
• 98 (99 for changer type) grinding programs can be stored in BARINDER .
• If number of programs exceed above,
BARINDER can communicate with outer devices such as NACR device, CNC equipment or PC, using NACR Network System via. Hub by Ethernet.
• Function
(1) Upload and download of NACR and CNC programs
(2) Input/output of CNC parameters
(3) Directory display in PC
(4) Printout of grinding program

Basic BARINDER Models
•300 Series
MODEL
Max. work size
Max. work weight
Tool
X6-FDS12R-331 X6-FDS12R-331GR
Φ300 x H200 mm
8kg
Main x 1 Main x 1, Sub x 1

•300 Series
Basic BARINDER Models

Basic BARINDER Models
•400 series
Model
Max. work size
Max. work weight
Tool
Changer
X6-FDH22R-443GR X7-FDH22R-455GR-C
Φ400 x H200mm Φ500 x H200mm
20kg 30kg
None
Main x 1, Sub x 1
Equipped

Basic BARINDER Models
•500 Series
Model
Max. work size
Max. work weight
Tool
Changer
X6-FDH22R-
577GR
Φ700 x
H250mm
50kg
None
X7-FDH22R-
56FGR-C
Φ600 x
H400mm
100kg
Main x 1, Sub x 1
Equipped
X7-FDH22R-
59FGR-C
L750 x W430 x
H450mm
100kg
Equipped

•500 Series
Basic BARINDER Models

Major Applicable Work Sample
Caliper body
18 sec/pc
Differential case
40 sec/pc
Manifold
43 sec/pc
Water pump
37 sec/pc
Crankshaft
60 sec/pc
Cylinder block
120 sec/pc
Bracket
43 sec/pc
Pipe joint holder
60 sec/pc
Gear box
24 sec/pc
Differential carrier
70 sec/pc
Differential carrier
80 sec/pc
Cylinder head
120 sec/pc

Worldwide users and countries
• 2,600 units of BARINDER sold to worldwide users (as of the end of year 2012)
■ North-South
America
CANADA
U.S.A.
MEXICO
BRAZIL
■ Europe
UK
SWEDEN
FINLAND
DENMARK
HOLLAND
BELGIUM
GERMANY
FRANCE
ITALY
HUNGARY
SPAIN
PORTUGAL
TURKEY
■ Asia
JAPAN
CHINA
KOREA
TAIWAN
THAILAND
MALAYSIA
SINGAPORE
INDONESIA
INDIA

Major Worldwide Users

Awards
7 th “Development
Award of Machine for automobile for small and medium size business” in 1976
Technical Award of
Japan High Grade Cast
Iron Association in
1992
Technical Award of
Japan High Grade Cast
Iron Association in
2001
GENERAL MOTORS “Worldwide Supplier of the year” in 2002

SINTOKOGIO, LTD