Automobile manufacturing
Pressing process
This is the process of making the main parts that form the framework of the body, such as the ceiling and hood.
In the pressing process, a single steel plate is cut and formed into a three-dimensional body shape using a press machine.
Servo Press Synchronous Belts Ultra PX Belt HY Type
Servo presses operate continuously and are subjected to frequent impact loads, so belts required must be highly rigid and strong.
Ultra PX Belt HY Type is a belt that has achieved significantly higher strength and rigidity through the use of a hybrid core wire made of glass and carbon. It has achieved a transmission capacity improvement of approximately 1.3 to 2.0 times that of the conventional HC Type. This also allows for downsizing of equipment and makes it more compact.
Tsubaki PX Belt transmission capacity comparison graph

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Tsubaki PX Belt stiffness comparison graph

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Scrap Material Conveyor Large size conveyor chain /Scrap Conveyor-
Multiple scrap conveyors operate under the floor of the press shop to remove excess materials from underneath the shop floor. The scrap conveyors are Tsubaki Large size conveyor chain with slats attached, and transport excess materials after pressing out of the shop.
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Tsubaki Hypoid Motor are used as small gear motors to drive scrap conveyors that send out scrap materials. Both solid and hollow shafts are available as output shafts, and a wide range of reduction ratios are available.
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Scrap conveyor shuffle conveyor
Press scraps and offcuts generated during press processing are handled by the repeated reciprocating movement of the tray itself. Because it is not a belt type, there is no need to worry about scraps getting caught or belts breaking.
Also, unlike vibrating conveyors, it produces less vibration and noise, and has fewer components, making maintenance easier.
Low maintenance
[structure]
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For lifting and lowering components -Zip Chain Lifter -
Zip Chain Lifters are used to raise and lower stacked steel materials for pressing, and pressed components. Zip Chain Lifters are capable of higher speeds of raising and lowering than hydraulic lifters, and their positioning accuracy is also high, contributing to improved productivity.
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Zip Chain Actuator for spray nozzle traversal
Zip Chain Actuator are used to move the nozzle opening that sprays processing oil onto the press die. They can be installed in a small space, and are compact and achieve high-speed traversal.
Space Saving
High-speed driving
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Linipower Jack and Linispeed Jack for press peripheral equipment
Multiple linked jacks are used to hold and raise/lower the supply materials in front of and behind the press. By adopting not only the conventional Linipower Jack but also Linispeed Jack, high speed and high frequency operation is possible.
Jack Linkage System
We will select and propose not only jacks but also complete drive mechanisms such as gear motors and couplings.
Please access the selection request form here.
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automobile manufacturing
Body welding process
This is the process where parts made in the press process are assembled into the car body by many multi-axis robots. Most of the welding work is automated by machines.
Assembly and welding robots -Cable Carrier (CABLEVEYOR) / Synchronous Belts
Cable Carrier (CABLEVEYOR) is a device that organizes, protects, and guides the cables of moving parts in industrial machinery, including machine tools.
The TKRB type Cable Carrier (CABLEVEYOR) uses a special plastic material for excellent protection and durability, and its built-in steel wire allows it to withstand large tension.The open structure allows the cable to be inserted by pushing it in, making maintenance easy.
The TKRB type, which moves in three dimensions, is used for the robot arm that welds the body.
More details about the TKRB type Cable Carrier (CABLEVEYOR)
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Cable Carrier (CABLEVEYOR) Plastic Series is used to protect the cables of welding robots that move across the area.
Robots often move horizontally over Long travel length, so long Gliding arrangement specifications and sliding shoe series such as the TKC and TKMT models are used to reduce wear Cable Carrier (CABLEVEYOR) and extend its lifespan.
Comparison of wear conditions of Gliding arrangement specification and sliding shoe series
(*After 130,000 round trips)

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Tsubaki Synchronous Belts Ultra PX Belt HC Type, used as a transmission device for welding machines
A clean transmission mechanism is required for the gun that moves the welding electrode, so Tsubaki Synchronous Belts Ultra PX Belt HC Type is used, which is a high-strength, compact transmission device that does not scatter grease or oil.
Benefits
- Operating elongation is extremely small compared to conventional PX Belt
- Transmission capacity is more than twice that of conventional PX Belt

Comparison graph of belt elongation by operating time
Transmission capacity comparison graph
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For body and parts assembly equipment -Lift Master-
Lift Master is an electric lifter that can tolerate overhang and lateral loads.
Lift Master are used in the lifting equipment for workpieces entering and leaving the lines where parts such as body frames and doors are welded and assembled. They can be used immediately by simply placing them on the line, and their low-floor, compact design allows for space savings.
Conventional product
Lift Master
Lift Master working on work lifting equipment
Lift Master which are strong against lateral loads and have a long lifespan, are also used in the transfer equipment that loads assembled bodies onto the carts for the next process.
The four linked units can be used as a simple lifting device for workpieces with large overhangs.
Transfer equipment for loading the assembled body onto the next process cart
Lift Master for body assembly equipment
After picking up parts such as back doors loaded on pallets, Lift Master is used in equipment that raises and lowers the empty pallets to the recovery conveyor below.It can be raised and lowered on one side and can be installed in a small space, allowing for effective use of space.
Cantilever lift
Plug and play

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Pin gear drive unit for body welding equipment
Pin gear drive unit are used as an alternative to the friction method for transporting welding jigs. Meshing drive by pin gears ensures reliable transport even when machining oil is present, which contributes to shortening transport cycle time.
High rigidity

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Pallet Transport -Double Plus Free Flow Chains Steel Roller Series / Lift Master-
Accumulable Double Plus Free Flow Chains /steel roller series is used for transporting body transport pallets. Also, by utilizing a thin frame, a compact transport conveyor can be manufactured.
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For supplying welding materials -Zip Master / Zip Chain Lifter
Two linked Lift Master which can lift and lower on one side, are used to raise and lower the pallets that carry the bodies to the welding process.
Two Lift Master, which are electric lifters with a simple structure, can be synchronized either by mechanical interlocking or by assembling a motor on each unit, creating a neat and clean work environment.
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In the process of supplying materials to the welding process, a skid/pallet circulation system can be configured that combines a lifting mechanism using Lift Master before and after a transfer conveyor using Double Plus Free Flow Chains.
Space-saving installation
Lift Master requires the same installation space regardless of the lifting stroke, allowing for space savings.
Cut specifications too!

Frame for Double Plus Free Flow Chains
Special frames are also available as accessories for Double Plus Free Flow Chains.
This makes conveyor installation, including parts selection, easier.
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Zip Master for supplying welding materials
Zip Master is used as equipment to transfer body parts to be welded to the next process at different heights. It can handle high lifts and can be operated at high speeds and frequently, contributing to improved productivity.
High-speed driving
Cantilever lift

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Zip Chain lifter for supplying welding materials
Between the body welding processes, there are parts transport equipment using gantry loaders and robots, and Zip Chain Lifters are used to shorten the takt time for parts delivery there.With its high speed lifting and high positioning accuracy, it can also be combined with other transport equipment.
High-speed driving

High speed operation and high positioning accuracy make it ideal for robotic transfers!
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Zip Chain Actuator for Parts Pickup Equipment
The compact Zip Chain Actuator is used in the lifting section of simple loader equipment. It allows the production of equipment with a simple structure, and allows parts to be picked up at high speed.
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Zip Chain Actuator for Parts Gantry Loaders
Zip Chain Actuator, which can be installed in a space-saving manner, are used in the lifting mechanism of gantry loaders used in aerial transport.Compared to when air cylinders are used for lifting, the cylinder body does not protrude toward the ceiling, so the ceiling can be lowered.
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Ultra PX Belt HY Type (Open-ended belt) for trolley travel
Open-ended belt are used as the drive system for running carts between stations (processes that are not exposed to spatter). The toothed belt allows for reliable meshing drive, making it possible to run the carts smoothly. In addition, by using the ultra-high strength HY Type belt, it is possible to make the belt narrower, allowing for compact equipment designs.
High rigidity
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automobile manufacturing
Painting process
Cars are dipped into a pool of paint, and then painted by a painting robot. To achieve a glossy finish, multiple painting processes are required.
For lifting and lowering vehicles -Zip Chain Lifter/ Zip Master
Zip Chain Lifters and Zip Master, which are capable of high-speed lifting, are used to transfer painted car bodies onto overhead conveyors and to raise and lower car bodies during the assembly process.
It can also handle high loads and high lifts, contributing to improved productivity in lifting applications.
Zip Chain Lifter
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Zip Master
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Car body transport system -Simtrack-
Between painting processes, the car body is loaded onto a cart and transported.
There is a demand for a simple and compact transport system, and Shimtrack, a friction transport system with a unit structure that can be placed and wired inside the rail, is used.
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Plastic modular chain for man conveyors
Plastic modular chain for door removal process man conveyor
Man conveyors are used in the process of removing doors from painted car bodies to reduce the burden on workers. Man conveyors use Plastic modular chain and feature a slide plug system that makes them easy cut and connect and connect, making maintenance easy.
Low maintenance
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Painting process - Primer - Small gear motor
The undercoat of the vehicle body is an anti-rust electro-deposition paint, so the vehicle body is hung from the ceiling and transported by being submerged in a pool of "paint."
After the intermediate coat is applied, each car body is placed on a carriage and driven by friction rollers. Tsubaki's reducers and small gear motors are used to drive the rollers.
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Painting process - Intermediate coating -Cable Carrier (CABLEVEYOR) TKRB type -
For the undercoat, a gray paint is sprayed evenly over the entire surface by a painting robot to smooth the surface and prevent discoloration.
Tsubaki Cable Carrier (CABLEVEYOR) are used to support the electric wires of multi-axis robots. Their open structure allows cables to be inserted by pushing them in, making maintenance easy. They can be bent in three dimensions, making them ideal for multi-axis robots.
More details about the TKRB type Cable Carrier (CABLEVEYOR)
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Painting process -Lube-free Drive chain Lambda Chain-
The top coat is sprayed on using a painting robot or reciprocating sprayer in the actual car color, resulting in a clean, even finish.
Tsubaki's Lube-free Drive chain, Lambda Chain, and reducer are used in reciprocating sprayers. Lambda Chain uses special oil-impregnated bush, so the chain does not need to be oiled. This significantly reduces the frequency of chain replacement.
Lambda Chain basic structure
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automobile manufacturing
Assembly process
In the assembly process, doors, interior parts, seats, and tires are attached to the painted car body. The car body is transported on a slat conveyor, or it is transported from the ceiling on a special hanging jig, or it is transported on a cart driven by friction rollers with the assembly worker on board.
Plastic modular chain for man conveyors
When attaching parts to a vehicle, the mancon that workers ride in together uses Tsubaki's Plastic modular chain, which is quiet, requires no oiling, and is clean.
The BTH16 modular chain has a non-slip surface and the highest Maximum allowable load of any Tsubaki Plastic modular chain also uses a slide plug system that makes it easy cut and connect and connect, reducing maintenance time.
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WT3109-W Type Plastic modular chain for Low-Floor Man Conveyors
This Plastic modular chain is suitable for low-floor man conveyors that transport workers and tool carts.It allows the conveyor to be installed on a low floor (220mm or less) without digging a pit.

Recommended conditions
- Chain width: 1200mm or less
- conveyor length...30mm or less
- Transport mass: 100 kg/m or less
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For interior and exterior part assembly equipment -Small size conveyor chain-
On the seat assembly line, pallets carrying each part are transported to the work area, and after assembly, they are quickly removed using friction conveyance.
Examples include Lift Master, which can be used as a cantilever for equipment that raises and lowers pallets, the Free Flow Chain, which can accumulate for assembly line transport, and the hypoid reducer, which is used as a reducer for friction transport for discharge.
Small size conveyor chain
Hypoid reducer
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For lifting parts -Zip Chain Lifter/ Zip Master
To make effective use of the site, doors and seats are sometimes supplied from above the process, separate from the vehicle body transport conveyor. Zip Chain Lifter is used in the process of lowering them from above onto the vehicle body, allowing for smooth, high-speed lifting.
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Interior parts such as seats are loaded onto pallets and transported to the assembly plant. Zip Master which can be raised and lowered at high speed, high frequency, and high precision, is used in multi-stage positioning equipment to distribute these parts to the roller conveyors that supply them to the assembly line. As it is a drop-and-pop type equipment, it can be installed in a short construction period, allowing for speedy on-site improvements.
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Lift Master low-floor model is a low-height model that can be used when space is limited and it is difficult to install Lift Master.
The low-floor, compactly designed Lift Master is used on lines where parts such as body frames and doors are welded and assembled, and in lifting devices for workpieces being loaded and unloaded. Please contact us for details on low-floor specifications.
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Lift Master for car body assembly equipment
Lift Master is an electric lifter that can tolerate overhang and lateral loads.
Lifting the vehicle body with two Lift Master on the left and right ensures workability. It also minimizes the need for equipment changes when changing the production vehicle body.
Lift Master high rigidity specification
If shaking during lifting or deflection when stopping is an issue, we can address this by strengthening the support column itself. Please contact us for details.
Before transporting tires stacked in groups of four to the assembly line, there is equipment that separates and de-stacks them one by one. This equipment uses Lift Master, which uses two lifting devices on both sides.
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There is a facility where the engine and rear suspension are installed on a vehicle body suspended by an overhead conveyor. This process requires high positioning accuracy, Zip Chain Lifters are used, which have superior stopping accuracy compared to hydraulic lifters and can be raised and lowered at high speeds.
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For transferring in-vehicle parts -Lift Master / Pin gear drive unit-
A module combining Lift Master and Pin gear drive unit is used in equipment that rotates heavy parts such as rear suspensions and transfers them between conveyors.By installing Lift Master, which can be placed and dropped, on a rotating plate that utilizes Pin gear drive unit, smooth rotation and transfer can be achieved in a small space.
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For fixing dollies -Power Cylinder-
Electric Power Cylinder are used on the carts to secure the loaded vehicle to the work process. They reduce power consumption and can be installed in the limited space on the cart.
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Pallet transport -Double Plus Free Flow Chains / outboard roller /top roller chain, lambda roller specification -
For pallet transport -Double Plus Free Flow Chains steel roller specification -
In equipment where sheets and other materials are loaded onto pallets and supplied to assembly lines, there is a lot of accumulation, so Double Plus Free Flow Chains and steel roller series are used. Pallets loaded with heavy items can also be transported, and damage to the pallet is reduced. For pallet transport where there is a lot of accumulation of lightweight items Plastic Roller series is recommended.
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For pallet transport -outboard roller /top roller chain, lambda roller specifications -
Lambda Chain are widely used to reduce the amount of maintenance work required for conveyor chains. Changing the bearings in the side and top rollers of outboard roller outboard roller chains and top roller chains to Lambda specifications also contributes to reducing the noise made by the rollers rotating.
Low maintenance
This roller has a special oil-impregnated bearing inserted into the steel roller, allowing it to be used Lube-free. This prevents the abnormal noise that occurs when a steel roller is used without oiling. Under in-house testing conditions, it has been reduced by approximately 10 dB compared to steel.
Check out the difference in sound in the video
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automobile manufacturing
Inspection process
After the automobile is fully assembled, it is inspected for engine output, brake tester, headlamp optical axis and appearance, and subjected to a high-pressure water spray test to check for rain leaks.
Engine and brake tester - One-way clutch (cam clutch) / Electric cylinder Power Cylinder-
A reducer with a built-in one-way clutch is used to drive the rollers of an engine brake tester.
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The engine brake tester uses high-precision Tsubaki Power Cylinder for roller pressure and front and rear axle positioning.
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For vehicle transport conveyors -Bearing Roller Conveyor Chain / Short Pitch Large size conveyor chain with outboard roller-
After inspections of the engine, brakes, and light axis, the finished vehicle passes through a booth where high-pressure water is sprayed to conduct a water leak test (shower tester). During this process, the finished vehicle is loaded and transported on a long, slow-conveyor length conveyor chain.
Long, slow-conveyor length conveyors that are constantly exposed to water can experience stick-slip phenomenon, which is where our oil-Water Resistant Lube Free Series Bearing Roller Conveyor Chain comes into play.
This chain's unique structure, which uses cylindrical bearing inside the rollers, not only suppresses stick-slip phenomenon, but also achieves high efficiency, reduced costs, and a long life for the rollers and rails.
Bearing Roller Conveyor Chain Structure

Compared to our experimental results (without additional refueling)

More information on bearing roller conveyor chains Water Resistant Lube Free Series
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With conventional conveyor chains, it was necessary to dig a pit to install the conveyor, but by shortening the chain pitch, it is possible to install a low-floor conveyor, and by installing the conveyor on the floor without digging a pit, the installation time has been shortened.
Bearings are built into outboard roller to increase the roller's allowable load, reduce the coefficient of friction, and suppress stick-slip phenomenon of the conveyor.
↑
outboard roller with bearings
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Plastic modular chain for vehicle transport conveyors
Plastic modular chain are used on conveyors that transport inspectors and vehicles together during the final inspection process.Plastic Plastic modular chain are easy to maintain because parts can be repaired.
Low maintenance
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Cable Carrier (CABLEVEYOR) for inspection robots
ROBOTRAX (TKRB type) Cable Carrier (CABLEVEYOR) carrier for inspection robots
Robots are also being introduced into vehicle inspection processes, and the three-dimensionally moving Cable Carrier (CABLEVEYOR) ROBOTRAX is used on these robot arms. ROBOTRAX is Cable Carrier (CABLEVEYOR) with an open structure that allows cables to be inserted by pushing them into the slits on the side of the links, making maintenance work easy.
A wide range of accessories are available, including Coil spring that prevents interference with the robot arm.
Low maintenance
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automobile manufacturing
Automotive parts manufacturing process
A wide variety of parts are used in automobiles, and this process involves processing and assembling these parts. We will introduce examples of application in the manufacturing of parts such as engines and doors.
Drive chain for lifting and transporting devices
The ever-evolving RS roller chain and Super chain, which has Maximum allowable load and allows for a smaller chain size, are used in hanging drop lifters that raise and lower parts such as bodies and engines.
In addition, for this application where double rows are used, we can also support "matched and tagged" that suppress variations in the initial chain overall length and minimize relative differences in overall length.
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For transporting parts
A unique structure combining small and large diameter rollers achieves 2.5 times faster transport speed. The chain speed can be set to a low speed, allowing for quiet accumulation.
A snap cover can be attached to prevent parts from falling into the frame. The lambda specification also significantly improves wear elongation and life in environments where lubrication is difficult.
More information about Double Plus Free Flow Chains / Plastic Roller series
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Lambda Chain, which uses special oil-impregnated bush, is compatible with most Small size conveyor chain. Since its launch in 1988, its performance has been highly praised.
Features of Lambda Small size conveyor chain
- Long life Lube-free...Long life is achieved thanks to the effect of special oil-impregnated bush.
- Compatibility: Compatible with general-purpose Small size conveyor chain.
- Operating temperature range: -10°C to +150°C (KF Series: +230°C)
- Compared to general-purpose Small size conveyor chain wear elongation and lifespan are significantly improved.
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Free flow chain Conveyor chain with top rollers
Top roller chains are free-flow chains that have the plate of Double pitch or RS-type roller chain extended upwards, with freely rotating top rollers attached to it. Specifications include hard chrome plated and buffed top rollers, allowing you to select the chain that best suits your work and environment.
Free Flow Chain Conveyor Chain with outboard roller
Chains with outboard roller are free-flow chains that have extended pins on Double pitch or RS chains, with freely rotating outboard roller attached to them.
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Stainless steel Top chain TS type
This is a conveyor chain with plates attached to double pitch chain. There are various specifications, such as hardened plates that improve wear resistance, and plates with hard chrome plating and buffing on the top surface, so you can select the chain that best suits your work and environment.
Stainless steel Top chain TO type
This is a chain for horizontal transport, and the return section can also be used effectively.
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On parts processing and inspection lines, plastic chains and accumulation chains with rollers built into the conveying surface are used to prevent scratches on parts.
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Conveyors using Plastic modular chain are used in the equipment that transports cart-loaded auto parts into and out of the factory at the receiving yard.The low-floor, drop-and-pump conveyor can be installed without digging a pit, allowing for equipment upgrades in a short period of time.
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WinCS mini (standard modular chain conveyor) for transporting metal parts
WinCS mini is used to transport small metal parts in processing machines. It uses a short-pitch modular chain and has little dead space, allowing smooth transfer of transported items without the need for transfer plates.
In addition, since it is provided as a standardized conveyor, it can be installed and used simply by placing it on the conveyor.
Plug and play
Can be cut and connect with just one flathead screwdriver
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Man Conveyor Plastic modular chain
On parts processing and assembly lines, work efficiency is improved by synchronizing the operation of conveyors that transport suspended parts and engines loaded on carts with conveyors that transport workers and tool carts.
A man conveyor using Plastic modular chain is used for this synchronized operation. The chain width can be selected, and a man conveyor that can be installed on a low floor can also shorten the installation period.
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For lifting parts
In parts processing and assembly lines, Lift Master, which can lift and lower on one side and is compact, is used for lifting equipment at discharge and loading entrances.It can be installed in a small space, and by installing the reducer on top, maintenance is improved.
Parts to be assembled to the vehicle body are managed on a pallet for each vehicle. Lift Master is used as a lifter to store pallets in a simple stocker that holds pallets waiting for assembly.
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Parts are raised and lowered from the supply conveyor to the assembly workbench where workers assemble them. Tsubaki's Zip Chain Actuator is used, which can be installed in narrow spaces up to waist height of the worker.
Zip Chain is a chain developed exclusively by our company, in which two chains interlock like a zipper to form a single, strong column that can "push and pull." Zip Chain Actuator is a commercialized linear actuator that uses this chain.
Zip Chain Actuator, which can be installed in a space-saving manner, are used in equipment such as gantry loaders that suspend parts. They are also capable of high-speed lifting and lowering, contributing to shorter cycle times.
Zip Chain Actuator for Stacking Device
Zip Chain Actuator are used in the lifting mechanism for stacking transported items. In response to demand for extremely low-floor lifters, Long travel length lifting can be achieved without digging a pit.
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Tire mounter - Mounting tires onto wheels - Electric cylinder Power Cylinder-
Tsubaki's electric Power Cylinder are used to secure the side of the tire where the tire and wheel are assembled.
Power Cylinder have high positioning accuracy and do not require adjustment. Power Cylinder are also used in lifting devices.
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For parts assembly equipment -Pin gear drive unit-
Parts are assembled and attached using a turntable.Tsubaki's Pin gear drive unit is used on the turntable, which requires space saving.
Pin gear drive unit is a new drive unit that replaces gear racks, etc. The combination of a pin-mechanical wheel rack and a special tooth gear greatly expands the design freedom of rotary and linear drive units.
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