NAGANO MONOZUKURI EXCELLENCE 2014

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1 NAGANO s High Quality Technologies and Products Monozukuri is a distinctive Japanese word, meaning the spirit of producing excellent products and the ability to constantly improve a production system and process. NAGANO PREFECTURE NAGANO MONOZUKURI EXCELLENCE is an award for high quality technologies and original and innovative products. 10 technologies and products received Award. Nagano Prefecture publicizes these technologies and products to both inside and outside Japan, to promote further development of businesses by supporting them with prefecture-sponsored projects. For inquiries, contact: Industrial InnovationSection,IndustrialPolicyDivision, Industry and Labor Department, Nagano Prefecture TEL: (Direct),FAX: sansei@pref.nagano.lg.jp

2 contents Vacuum Chamber Manufacturing Technology (Akada Industry Co., Ltd.) 1 Gsyori, Heat Treatment Technology with Minimum Distortion (Okaya Heat Treating Co., Ltd.) 2 Metal Separator for Fuel Cell (SUN Industry Co.,Ltd.) 3 MPS (Material Processing Service) (CERATECH JAPAN Co., Ltd.) 4 Scanning Peripheral Anterior Chamber Depth Analyzer SPAC (Takagi Seiko Co., Ltd.) 5 Flat Panel Display Tester FREEDOM mkⅡ (Chikuma Seiki Co., Ltd.) 6 High Efficiency Electric Melting Furnace (NAVIO CORPORATION ) 7 DANDELION Autoclave for Research (Hanyuda Co., Ltd.) 8 Ultra-High-Precision, Fine Sheet Metal Processing Technology (Hiraide Precision Co., Ltd.) 9 Biaxial Stretch Blow Molding Technology (Frontier, Inc.) 10

3 Akada Industry Co., Ltd Aisome, Ikeda Town, Nagano Pref. CEO: Yasufumi Akada What is a Vacuum Chamber Manufacturing Technology? A chamber is an airtight container. In order to make a vacuum chamber, it is important to create rigidity against atmospheric pressure and high precision of the installation surface of the cover. It is widely used in a variety of fields, including electron microscopes, medical equipment, semiconductors, space industries, etc. Akada Industry produces various chambers from low-vacuum to ultra-high-vacuum, with high skills and experiences in welding and machining. The chamber sizes also vary, from small to large ( m). They are able to identify cracks in the welded joints and penetration of helium gas inside when testing airtightness. They have succeeded in creating higher precision and more complex products by introducing the latest fiveaxis processor, while achieving mechanization of hand-finishing using a new hale machining method. A semi-custom vacuum chamber produced in-house is wellreceived by the customers, without the needs of designing, and because of its open price tag and short delivery time. Vacuum Chamber Manufacturing Technology Custom-built: Machined product Custom-built: Welding structure product In-house product: Semi-custom vacuum chamber 1 Okaya Heat Treating Co., Ltd Nangu, Okaya City, Nagano Pref. CEO: Kuniji Nishizawa What is Gsyori? It is a heat treatment method to control distortion of a metal heat treatment within 0.03mm. It can be used for all kinds of metals. The treatment method has been named Gsyori and been commercialized (International Patent Pending). Gshori drastically reduces the workload of finishing heat-treated metal molds (plane polishing and fine-tune processing). It reduces deterioration, and maintains precision of aged metal molds. Metal Mold Producer 金型製作者 エユーンドザー End User Gsyori, Heat Treatment Technology with Minimum Distortion Conventional treatment large distortion (A3 size metal molds) Conventional Treatment 従来技術 Gsyori Wear on cutting tools 切削工具 機械損 and machines 消耗 large大 消耗 small 小 Electricity and 電気 切削油 cutting fluids large 使用量 consumption 多 small 使用量 consumption 少 Effect 仕上げ加工が金型に及ぼす影響 of Finishing on Metal Molds Residual 残留応力 stress large 大 small 小 経年変形 large 大 small 小 Gsyori minimized distortion Gsyori Benefits によるメリット of Gsyori 金型プレートの研磨しろ Comparison of Polishing ( 余裕肉しろ Margins ) の比較 resource 省資源化 conserving Grinding 研磨しろ margin 0.3mm~ ~0.05mm省力化 Comparison 仕上げ加工 of Finishing ( 平面出し研磨 微調整加工 (plane polishing & fine-tune ) の比較 processing) ( 短納期化 ) Operation 作業時間 time half 半日 day ~2 ~ 日間 2 days a few minutes ~ 2 hours 数分 ~2 時間 energy 省エネ化 Secular distortion labor saving (faster delivery) conserving 低コスト化 low costs 環境配慮化 eco-friendly 高精度化 high precision 低コスト化 low costs 2

4 SUN INDUSTRY Co.,Ltd Nishiminowa, Ina City, Nagano Pref. CEO: Takeo Kawakami Metal Separator for Fuel Cell What is a Metal Separator for a Fuel Cell? Fuel cell is widely used for households, as well as for industry and automobiles. Separator is a main part of a fuel cell and separates air and gas flow at the time of power generation. Ordinary separator is made of plastic. Metal Separator has many advantages that are less expensive, lightweight and power generation performance. However, it is easy to corrosion. SUN INDUSTRY Co.,Ltd has developed a method of plating for metal separator with excellent corrosion resistance and electroconductivity for stainless steel, titanium and aluminum. In 2011, the titamium separator with conductive palting was used most compact and lightweight fuel cell system in the world made by the Supporting Industry Project Team. That system was successfully tested with excellent generation performance. Supporting Industry Project: The government s Strategic Core Technology Advancement Program to support joint R&D by businesses, universities and public research and development institutes. Participating organizations: SYVEC Corporation, IHI Shibaura Machinery Corporation, Nagano Prefecture General Industrial Technology Center, Nagano Techno Foundation, Alps Highland Regional Center, SUN INDUSTRY Co.,Ltd An example of plating producing a press formed product A fuel cell stack with 100 cells of metal separators 3 MPS (Material Processing Service) CERATECH JAPAN Co., Ltd. 500 Shinonoi Okada, Nagano City, Nagano Pref. CEO and President: Akira Hirabayashi What is an MPS (Material Processing Service)? It is a proposal-based processing service specializing mainly in providing precision machining of ceramics in a wider sense for electronic and optical parts. This unique model provides one-stop commissioned machining services of variety of materials with different forms. Ceramics in a wider sense and machining samples CERATECH JAPAN is a specialist in machining from cutting to high precision surface finishing. They further provide the market with a unique system of consistent in-house machining with profiling, grinding and optical film processing technologies. As an independent manufacturer specializing in machining, CERATECH JAPAN has become a connector hub company, taking advantage of the partnership with many businesses. This has enabled them to singlehandedly provide a proposal-based machining service of the entire process of parts manufacturing, meeting the needs of their customers. MPS s core, free and fixed abrasive machining technology 4

5 What is SPAC? Takagi Seiko Co., Ltd Iwafune, Nakano City, Nagano Pref. President: Kazutoshi Takagi The No. 1 cause of vision loss is glaucoma in Japan. Angle closure glaucoma is a kind of glaucoma, seriously affected by an anterior chamber depth. The shallower the anterior chamber depth, the higher the risk of developing angle closure glaucoma. Takagi Seiko s SPAC is able to precisely identify the people with a shallow anterior chamber depth, to prevent vision loss by treating it in the early stage. SPAC is a noncontact, noninvasive scanner which analyzes the anterior chamber depth by scanning images every 0.2mm as a slitshaped infrared ray moves in front of the anterior segment. The examination results include the anterior chamber volume, corneal thickness, corneal radius of curvature, etc. which enable threedimensional display of images. The results are easy for patients to understand, and effective in obtaining informed consent. Chikuma Seiki Co., Ltd Akashina Nanaki, Azumino City, Nagano Pref. CEO: Kaoru Hanamura Scanning Peripheral Anterior Chamber Depth Analyzer SPAC SPAC Medical device Certification No.: 226AFBZX ) (Examination ( 測定結果表示 result 1) 1) Anterior evaluation chamber depth threshold: suspect evaluation threshold: potential (Examination ( 測定結果表示 result 2) 2) Glaucoma is an eye disease which damages visual functions. Once they are damaged, the improvement cannot be expected by treatment. Early detection and treatment are the key. Examination result 1 is shown as a cross section in the two dimensions. Here the anterior chamber depth is above the potential and suspect lines, which means it is very shallow and dangerous. In the Examination result 2, the same result is shown in three dimensions on the left, and the result of a healthy person on the right. The shallowness of the anterior chamber depth is visually easy to understand. Flat Panel Display Tester FREEDOM mkii 5 What is FREEDOM mkii? FREEDOM mkii is a dynamic operating inspection device for an FPD (Flat Panel Display), a display used for smartphones, etc.. It is equipped with a pattern generator 1 compatible with 4K resolution 2, responding to the market demands of high resolution FPDs. It also has a unique feature of 32 built-in power supplies (8 x 4 modules), which enables us to test maximum four FPDs at the same time. 1 pattern generator: sends out a digital signal necessary for FPD operation 2 4K resolution: FPD resolution of 4,096 4,096. 4K=about 4,000 Tester (main device + operation box) FREEDOM mkii enables us to operate maximum four FPDs and to measure current at the same time, which makes inspection time shorter. Its 4K-resolution compatibility makes it competitive for a long time in the FPD industry with higher resolution. It easily responds to the user demands and market change with its excellent hardware and software expandability. Image of configuration of testing devices FREEDOM mkii is a base unit. Optimal testing environment is provided by customizing the expansion base. 6

6 High Efficiency Electric Melting Furnace NAVIO CORPORATION Tomono, Saku City, Nagano Pref. CEO: Akio Ogihara What is a High Efficiency Electric Melting Furnace? This highly efficient aluminum melting and holding furnace reduces over 20% of electricity, compared to existing electric furnaces. Perfect for small-scale manufacturers who do not own a base furnace. With this newly developed structure, the electrical heating element is directly processed to the crucible, and a high efficiency control technology uses a high-frequency inverter and a highfrequency isolation transformer. This structure has enabled dramatically high-efficiency heat conduction, improved safety, longer life and higher energy conservation rate. Also, high-frequency electric power has enabled a miniature power supply unit. Main device of a furnace and a power supply Showing a furnace with melted aluminum. The furnace can hold melted aluminum at a certain temperature. 7 Hanyuda Co.,Ltd Yanagihara, Nagano City, Nagano Pref. CEO: Gota Hanyuda What is DANDELION? DANDELION is a compact and portable autoclave for heat-curing molding of composite materials to produce a prototype or a test piece. DANDELION Autoclave for Research Record of Business Achievements with Public Organizations: Shinshu University (Faculty of Textile Science and Technology) Tokyo University Tsukuba University Hiroshima Prefecture Industrial Research Institute Chiba Prefecture Industrial Support Research Institute Ehime Institute of Industrial Technology National Institute of Advanced Industrial Science and Technology, etc. Autoclave: a device to heat and compress a pre-impregnated carbon fiber sheet with cured resign to mold carbon fiber reinforced plastics (CFRP). CFRP is stronger than iron, but lighter than aluminum. Hanyuda Company has succeeded in developing 5-level temperature-rising steps including cured molding of composite materials and metal bonding, fit for a wide range of test piece manufacturing, and heating/compressing technology up to 200 /0.98MPa. They are able to respond to manufacturing in the higher temperature zone of 300 or 350, and adding cooling functions upon request. DANDELION is made compact with a vacuum pump installed in the cabinet. It is also made portable with pivoting casters so that it can be used anywhere with power and pressure supplies. DANDELION DL-2010 Specifications Usable dimensions: φ435 (H)350 (D)600mm Cabinet dimensions: (W)995 (H)1660 (D)1180mm Designed temperature: 200 Designed pressure: 0.98MPa Rate of temperature rise: 4 /min Vacuum circuits: 2 Record of product thermograph:2 8

7 Hiraide Precision Co., Ltd Imai, Okaya City, Nagano Pref. Ultra-High-Precision, Fine Sheet Metal Processing Technology Masahiko Hiraide, Director What is an Ultra-High-Precision, Fine Sheet Metal Processing Technology? It is a technology of manufacturing precision machinery parts by bending fine sheet metals like paper folding. It enables processing without metal molds, as precisely as progressive press or machining. Hiraide Precision has developed as a leading-edge digital factory which can flexibly respond to now current demand, various kinds and various volume. The company has Ultra-High-Precision, Fine sheet metal processing, the features are more precise than existing, for example, high accuracy of punching (±0.01mm) and of bending of 1 mm size products (±0.03mm). Based on their high precision sheet metal processing technology, Hiraide Precision has expanded to the fields of medical equipment, environmental energy and aerospace industry. They support customers throughout the process of sheet metal work designing by using a 3D-CAD, Trial sample, mass production and assembling. Solar-driven ultra thin S-Y stage using ultra precision sheet metal working technology Ultra high precision fine sheet metal bending ±0.03mm Ultra high precision sheet metal work using one sheet metal 9 Frontier, Inc. Biaxial Stretch Blow Molding Technology 333 Kojima, Ueda City, Nagano Pref. CEO and President: Yoshinori Nakamura What is a Biaxial Stretch Blow Molding Technology? Biaxial Stretch Blow Molding Machine A blow molding technology conducted by sending air into resin materials has developed into wide variety of fields from PET bottles to industrial machinery. It can be also used to mold medical and food containers. Above all, Plastic Fire Extinguisher molded by this technology is remarkably outstanding because it is Safe, Light and Transparent. It was officially approved as Japan s first plastic fire extinguisher. A Biaxial Stretch Blow Molding technology for plastic materials has enabled creating a new molding method of containers/parts and equipment, contributing to energy conservation and ecology. Is it safe to use plastic fire extinguishers at a fire scene? is a needless concern. Plastic extinguishers are safer, because when exposed to high temperature, holes are formed in the container, resulting in a lower internal pressure and no explosion. In addition, these fire extinguishers weigh about a half of the ones made of iron. This means that they are lighter, and that people of all ages can handle them easily. They are also transparent, and makes it easier to know how much agent still remains in the container. Fire extinguishers made of plastic 10

8 MADE IN NAGANO