Ricoh: toner cartridge manufacture

The most efficient solution: A measurement chain from HBM

Initially, Ricoh UK Products Ltd worked with Mechatronic Production Systems, the automation partner who designed and built the assembly machines, to investigate possible solutions. After extensive research, it was decided that HBM’s equipment could provide the most cost-effective solution to achieve the desired results.

HBM’s solution is based on a PW15 single point load cell combined with an MP85A FASTpress amplifier. It also utilizes modules from the FASTpress software suite to monitor and control the fitting processes.

PW15

The PW15 is a robust stainless-steel load cell, ideal for use in the food, packaging and chemical industries. It can be easily integrated into different applications and performs reliably in demanding environments for extended periods of time. The PW15 is also available in explosion-proof variants as well as with IP68/IP69K degrees of protection.

MP85A FASTpress

HBM’s MP85A FASTpress can process data at up to 300 fitting cycles per minute, ensuring maximum reliability even in very fast production lines. The industrial amplifier acquires up to two measured quantities, such as force, displacement or time, while monitoring fitting processes. It features industrial fieldbus technology and Ethernet protocols that facilitate optimal integration into automation systems.

Data is either stored on the device’s memory card or downloaded onto a PC, while reports containing all the process information can be produced for each process if required. Dave Roberts explains, “It is important for us to record and store all the data from the assembly process, so that we have traceability of our product. The HBM system has this functionality and that had a direct bearing on the decision to select this equipment.”

FASTpress suite

HBM’s FASTpress suite comprises a series of powerful software modules for data evaluation and analysis. Ricoh UK Products Ltd decided to purchase the EASYteach module to complement the hardware. It was used to modify the original process curves and determine the most suitable tolerance windows as well as checking the OK/NOK process. Roberts comments, “We would recommend purchasing the extra EASYteach software as this really helped speed up the development of the systems”.

Fully automated

The system, built with the help of HBM, allowed Ricoh to push all the functions that are critical to quality to the automated assembly lines rather than relying on manual operations. This ensures that only the very highest quality product is distributed to the company’s customers. The solution also makes it possible to identify production rejects earlier and thus reduce wastage.

Roberts adds, “The support from HBM in developing the system has been very good with a number of site visits during development. These proved invaluable in the successful implementation of the systems while the ongoing support, both from the UK and Germany, has also been excellent.”

Yet, like any good engineer, Roberts is already looking to develop the system further. He says, “We would like to work with Mechatronic and HBM to capture the unique serial number created in our assembly machines and save these against each curve. This will complete the integration of our production facility to give us total product traceability.”

Roberts concludes, “Overall, we are happy with the solution. It’s straightforward to use and develop with EASYteach and satisfies our quality assurance needs.”

Ricoh UK Products Ltd

Ricoh UK is a subsidiary of the Japanese multinational imaging and electronics company Ricoh Company, Ltd. The company provides end-to-end office solutions focusing on the core areas of commercial and industrial printing, IT and communication services, as well as cameras and photo equipment.

Mechatronic Production Systems Ltd

Mechatronic Production Systems is one of the UK’s leading providers of innovative automation solutions and systems integration services with the goal to create processes and systems that can deliver economy, speed and quality to any manufacturing environment.