Competition in the printer market is intensifying both at home and abroad. In order to meet the strict market needs of not only "print quality" but also "low cost" and "high speed printing," manufacturers are developing a variety of new functions and working day and night to improve the basic specifications of the printer itself.
Given this background, the selection of components essential to improving printer performance, particularly stepping motors, has become more important than ever before, as they directly affect printing speed and manufacturing costs.
Company G is an information and communications equipment manufacturer that has earned a high reputation in the field of commercial printers. In response to its sluggish market share in recent years, the company decided to completely redesign its flagship printer product and has begun development for the launch of the next model.
The development team carried out an examination of the current model in order to drastically review the basic performance. As a result, they determined that the characteristics of the stepping motor used in the paper feed section were not enough to achieve the printing speed required for the next model.
In fact, Company G had been using the same motors in multiple printer models for a long time. With the need to reduce manufacturing costs, there were significant cost benefits to purchasing in bulk, and continuing to use the same motors was advantageous for development and design within a limited time frame.
However, the stepping motor is a component that greatly affects the basic performance of the printer. The development team continued their testing to select a new motor, but they ran into a major problem. Mr. W from the Planning and Development Department at Company G had this to say about the problem:
"The current motor came with a rubber damper called a mounting surface damper, but we didn't know why this part was necessary. Adding an option naturally increases costs. The original developer had already left the company, so we didn't know why it was selected."
The development team organized the requirements for the stepping motor to be installed in the next model. In order to improve the printing speed of the printer, it was necessary to increase the torque of the motor, but they did not have any criteria for determining the "optimum torque." Increasing the size of the motor to increase torque could lead to increased costs, so a decision could not be made without a criterion. There was also a discussion about the necessity of a rubber damper. Unable to make a decision, Mr. W consulted the manufacturer of the motor he currently uses, but
"All they sent us was a frequency-torque characteristic diagram, but no answers on how to solve the problem. This was not helpful. We had a development deadline and needed to find a solution quickly."
While continuing to gather information to solve the problem, Mr. W stopped by SANYO DENKI CO., LTD. 's booth at an exhibition. Knowing that SANYO DENKI CO., LTD. cooling fans were used in other products, Mr. W asked the development team for advice on the problem they were facing. The answer he received was, "To determine the optimal motor characteristics, it is necessary to verify not only the motor itself, but also the conditions under which the device is used."
"They approached us and said they wanted to propose the optimal motor for the next model, taking into account the characteristics of the current motor. We were very grateful for this proposal." (Mr. W)
A sales representative from SANYO DENKI CO., LTD. immediately visited G company accompanied by the design staff and held a meeting to discuss the information and required specifications for selecting the optimal motor for the next model. In addition, they cooperated in the analysis test of the current motor and damper. A simulated actual machine test was carried out by attaching a load inertia equivalent to that of the actual machine.
The "torque characteristics," "speed fluctuation (vibration) characteristics," and "temperature characteristics" were measured to clarify the current problems and issues. As a result, it was discovered that the rubber damper, which the development team was unsure of the necessity for, was installed to improve the torque (vibration) characteristics in the operating range. The analysis results by SANYO DENKI CO., LTD. are as follows:
Based on the results of these analyses, Company G will be able to clarify the motor characteristics required for the next model.
SANYO DENKI CO., LTD. first began designing a motor that satisfied the required torque and also considered heat generation. To avoid risks during mass production, they took into consideration the variations that occur within the tolerances of the machining and assembly processes, and the variations in load caused by aging and the condition of the oil, and prototyped and delivered motors with maximum, target, and minimum torque accordingly. This was done so that when G Company evaluates the prototype motors, they could analyze the effects of slight individual differences in the motors from the measurement results, and feed this back into the design of mass-produced products for both companies.
After testing a prototype, we came to the conclusion that we could achieve the following performance improvements while keeping the size the same as it is now.
The significant reduction in speed fluctuations (vibrations) was achieved not only through improved performance of the motor itself, but also through a proposal from SANYO DENKI CO., LTD. (*) to use the motor outside of its vibration range, which eliminated the need for rubber dampers.
"It was a proposal that truly showed deep knowledge of stepping motors. Rather than simply applying an existing product, they carried out detailed testing to meet our requirements, which was a constant source of surprise." (Mr. W)
(*) Stepping motors have large vibrations at certain speeds due to their characteristics. If you avoid using them at those speeds, you can operate them with low vibrations.
Company G decided to adopt a new stepping motor manufactured by SANYO DENKI CO., LTD.. They were able to increase the torque without changing the motor size, and succeeded in significantly improving the printing speed. In addition, the motor cost was reduced because the optional rubber damper was no longer necessary.
Mr. W. says:
"SANYO DENKI CO., LTD. was a great help to us with their extensive knowledge of stepping motors, their measurement know-how, and their precise support based on our company's perspective."
Later, Company G successfully released the next-generation model. In addition to its diverse functions, the significantly faster printing speed earned it favorable reviews from users, and the company was able to demonstrate a strong presence in the commercial printer market.
For more information about stepping motors, please see "What is a stepping motor? An explanation of its structure, types, usage (drive system and control method), advantages and features."
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