Spring Machine
Forming Machine

RX series
MX-20B
MX series
RM-20
MS-20
MCS-10
MCS-20
RS-8
AX series
MCS series
SX series
MF-10B
FX series

Coiling Machine
PCX-30
PCX series
PC-8A
PC-4
CX series
CX-2A
CS-8
CK-8

discontinued
SCD-7
MCS-G series
MCX series
PC/PC-H Series
SCD-5


MCS-4G, 8G, 15G, 30G

Computer Controlled Spring Making Machine

They are capable of producing various types of springs, fast but still being accurate; even to suit industrial trend of "multifarious but small lot quantity".

It has integrated many features of the models MCS, MCT, PC and SCD, and even been equipped with two sets of new servo driven slides (patented) as standard.
The "Rotary Wire Guide System", which greatly expands the forming capacity of the machine, is standard.
Spring making on the MCS now is: with greater capability !, even more accurate !, faster than ever ! and, operator friendly with new "teaching" feature !

MCS-15G Computer Controlled Spring Making Machine
MCS-15G



Basic Specification is greatly up-graded.

  • Maximum speed each and all of available Servo Axes have been improved, and now the machine had become even faster and more precise.
  • The production speed has increased 30% as average comparing with MCS-E type.
  • The mechanism of each part become more precise and easier to use.
  • Besides 4 of those standard Feed, Cam, 2 Servo Slide axes (X & Y Axes), and R (rotary wire guide) axes, MCS-G series machine is capable of controlling extra Z (servo slides), all totals up to 6 axes.

Servo Slides:
  • Two sets of Servo Slides are provided as standard accessories, each of them to be used as the spindle or the independently driven tool slide.
  • Each Servo Slide may be used as the Spinner type or as the Linear type by re-assembling their parts.
  • Spinner type Servo Slide is used to actuate the spindle arbor or the bending tool.
  • Linear type Servo Slide is used to actuate the coiling tool or the pitch tool.
  • 4 axes of servo motor are equipped as standard. With the maximum setup, 6 axes can be controlled.

Rotary Wire Guide System:
  • This device enables various forming process which have been impossible using the Quill. Also, this device affords higher modules of rigidity than the Quill system.
  • Because the Rotary Wire Guide Tool can rotates around the wire during its forming process, it has greatly expanded the forming capability, and has even eliminated the necessity of grinding process required to the Quill.
  • Being in 2 separate pieces, wire will not be clogged and their maintenance is very easy.
  • This system may be found very economical, since various springs such as Single/Double Torsion Springs and Battery Springs can be produced, and some wire forming may be possible, only with one set of the R.W.G. Tools.

Remote Handle:
  • Each of those Feed, Cam, X, Y, Z and R axis can be operated with the Remote Handle, as desired.
  • The Remote Handle is used for Teaching Function also.

Teaching Function:
  • The Program Teaching Function allows the machine operator to generate the program automatically.
  • In the Program Teaching mode, while making the trial spring using the remote handle, the computer generates the program for trial spring simultaneously. Then machine will repeat the same sequence by the program.
  • Besides, the Step Teaching Function can carried out the program according to the rotation of Remote Handle.

High Speed Production without stopping cam shaft:
  • If the spring to be produced is simple in shape, machine can produce it without stopping cam shaft at speed rate.
  • The new Cam Axis Continuous Rotation Command make the high speed production possible.

Compatibility with MCS-E type:
  • All tools, cams, and slides used with the MCS-E type machines can be used for MCS-G type.
  • Basic commands used for the MCS-E type machine also can be used for MCS-G type; and furthermore, commands are enhanced for easier and more advanced operation.

Simple but accurate mechanism:
  • Mechanisms of the MCS are adopted to suit the control of the computer.
  • Feed Roller can feed the wire forward or backward by the increment of 0.02mm.
  • The axial position adjusting mechanism allows you to fine adjust the Feed Roll against groove of the wire guides.
  • Even the feed roll pressure can be set through the gauge.
  • Wire Wheel keeps the wire cast direction constant; thus it stabilizes the coiling process.
  • 8 Cam Shafts are placed in the radial pattern centering the quill section, and the Cam Axis to drive those shafts can be rotated in forward or reverse direction by the increment of 0.05 degrees.
  • There are various types of slides available to suit different wire forming purposes, and they can be easily mounted onto each cam shafts. Each and all of those slides are equipped with a set of linear motion bearings, designed to achieve high accuracy with durability.

Benefits of Computerized Control:
  • Total of 6, namely, those standard Feed, Cam, and 2 of the Servo Slide (X & Y) axes, with the extra Rotary Wire Guide and another Servo Slide (Z) axes may be controlled synchronously.
  • Spindle of the Servo Slides and the Cam & Feed Axes may be rotated forward or backward as many turns as necessary, allowing the MCS-G machine with greatly enhanced forming capability. For example, a tapered spring may be produced easily with the Cam and Feed Axes synchronized together, and a magazine spring may be produced with the Cam Axis programmed to move back and forth.
  • Machine operators can concentrate only on the tooling layout, since those tool positions and timing of their movements are controlled through the computer, eliminating cumbersome cam grinding and lever adjustments process, etc.
  • Each measurement on the spring may be very simply adjusted, only by changing numerical figures on the program. Therefore, re-calling of the set-up once done on the machine can be re-gained in a short period of time, simply by re-loading the program from the floppy disk and fine adjusting the tool positions, etc.
  • Position of the Cam Axis and wire feed amount can be fine adjusted even while the machine is running, for the fine modification of the producing spring.
  • Those Servo Slides and Rotary Wire Guide became available over and beyond the traditional Slides and Tools, the machine is now capable of producing more variety of springs, as follows: German, English, Long, Side, Outside and Dual loop hook extension springs, Single and Double Torsion springs, Other springs, i.e.: Battery, Magazine, Long body, Compression, Tapered, Combined, etc.
  • We trust that those features listed on the above make our MCS-G machines versatile between the mass production of a single spring and the small quantity production of numbers of springs.

Sensor Input:
  • There are 4 Sensor Input Terminals provided as a standard feature of the machine. Those terminals will send signals when they make contact with the wire material, etc.
  • Using those Sensor Inputs, MCS-G can self-adjust to correct the variation occurred on the spring shape, caused by various reasons such as the casting of the wire, etc.
  • These sensors are ordinarily used for regulating the relative angle between two hooks.

Slide Check Sensor:
  • Each Slide is equipped with a sensor to detect its movement.
  • Either by keying-in in the parameter on the One Cycle Mode display, or by writing-in in the spring production program, the MCS-G can avoid tool breakage caused by abnormality occurred on the Slides.

Alarm Input:
  • There are 4 Alarm Input Terminals provided as a standard feature of the machine. MCS-G can stop itself and/or notify operator of the "wire-run out" and the other abnormal states detected on the machine or on its controlling peripheral devices.
  • Sequence of "Abnormality Processing Program" may be prepared to stop the machine on detection of the abnormal state or on count-up of the production. For example, MCS-G can be programmed to shut down an Electric Furnace, 30 minutes after the count-up of the production.

Peripheral Device Control:
  • There are 4 Pneumatic Valves provided as standard and 4 more can be easily added onto the machine. Pneumatic Valves operate the Hook Angle Sensors, Air Cylinders, Parts Ejector, etc.
  • There are 8 other Peripheral Device Control Terminals available on the MCS-G for the control of the Feedback Devices, Sorting Chute, Payoff Reel, etc.

Parts Ejector:
  • There is a robot arm for ejecting the produced spring provided as a standard feature of the machine. It graves the produced spring just before its cutting process, and brings it to the designated position for constant ejection.
  • This feature can eliminate following accidents from happening: Cut product jump into the tooling set to cause deformation on the producing spring, and Rejects get mixed into the bulk of good products to go to the customer.

Other Features:
  • Status of the machine can be monitored from a distance through the standard "Tri-color Signal Tower with Buzzer". Its green lamp is lit during the normal operation, yellow lamp is lit at the count-up, and the red lamp is lit upon the detection of abnormality. Buzzer is also available to be programmed for the use.
  • There are other standard accessories to assist the production, such as : Parts Chute, Working Light with Magnifying Glass, etc.
  • The machine's computer has build in calendar/clock up to the year 2090.
  • MCS-G conforms with the European CE safety standard. Openings on the machine, such as doors of the high-voltaged areas and the side covers, are guarded with reliable inter-locking system.
  • Being build by the hands of our mechanical & electrical engineer stuffs with all of their components being designed internally, all of our mechatronics machines are the genuine ITAYA machines.

Layout Record Display:
  • Layout Record Display is available to record parameter setting for each slides and the name of producing parts.
  • Tooling layout details (such as the setting for each of those 8 slides, positions of each cams and tools, feed roll pressure reading, set angle of wire wheel, etc.) may also be record on the same display page.
  • All of these information may be saved onto the floppy disk along with each production program, thus providing a convenient measures to the re-setting of same spring.

Menu Display:
  • Computer may display the histogram made from the auxiliary feed measurement, or the free length measurement, at real time; therefore, the present production state and the detailed manufacturing capability may be monitored at once.
  • Also, the mean value (X bar), standard deviation (3s), and co-efficient of process capability are derived from and shown with such histogram. These statistical information provide the most current production status in the most precise manner.

Display during the machine's operation:
  • Computer may display the histogram made from the auxiliary feed measurement, or the free length measurement, at real time; therefore, the present production state and the detailed manufacturing capability may be monitored at once.
  • Also, the mean value (X bar), standard deviation (3s), and co-efficient of process capability are derived from and shown with such histogram. These statistical information provide the most current production status in the most precise manner.

Slides:
  • Following types of slides are available to suit various purposes of production:
T Slide The standard tool slide, for forming spring's hook, body, etc.
S Slide For forming the 2nd hook of the extension spring
C Slide For cutting the wire material
U Attachment For square bending process, being mounted onto the T Slide
L Slide For bending process
H2 Slide For forming the double loop hook
Front Slide For forming the body from the front side of the machine, being mounted onto the T Slide
M Slide The rotary cut slide, for special forming process
V Slide For forming the hook

  • Servo Slides may be used, either as the Spinner type or the Linear type.
Spinner type For rotating the spindle tool by an independent servo motor
Linear type For advancing/retracting the standard tools by an independent servo motor


Feedback Device (optional):
  • Feedback Device is available to be mounted on a "spring-body coiling" T slide, for auto-correcting the outside diameter of the producing spring, to compensate the tool wear-out occurred during long-run production.
  • The same Feedback Device is available to be mounted on a "coil-pitch forming" T slide, for auto-correcting the free length of the producing spring, to compensate each time the variation is measured on the free length of producing spring. This optional device is not necessary when a standard Linear type Servo Slide is used for such "coil-pitch forming" process.

Detecting the Free Length (Optional):
  • Measurement of Free Length on the PC-15 has adopted the Static Capacity Detection Method which established high reputation on the SCD series.
  • PC-15 digitally displays the Free Lengths of springs detected in a sequence and generates a line graph out of such data; thus it permits a real-time grasp of the machines' producing condition.
  • The Rotary Solenoid Chute of the PC-15 is an item of standard equipment which rejects the bad springs into the plus or minus side at high speed.
  • Because the measurement of the free length deviations are directly fed back onto the computer's pitch control program by the increment of 1/100mm, its effect is observable from the next produced spring. Highly accurate mechanism of the PC-15 improves the percentage of the good springs.
  • Monitor Screen displays the numbers of good springs, the numbers of bad springs and the percentage of the good springs produced in the real-time.
  • Production speed is displayed as: secs./pc.(at increment of 1/100 sec.), pcs./min., and pcs./hr.
  • Pre-set Counter for each of the good springs and the bad springs are provided as standard.
  • PC-15 also contains a function to shut down the machine, when the numbers of bad springs and / or +/- abnormal springs exceed the amounts you set prior to the operation, and when the percentage of good springs is dropped down below the desired pre-set level.
  • You can pre-set the number of springs to be sampled, how often to be sampled, how many times to be sampled; then the PC-15, as standard functions, will samples the springs, and displays the statistics and the histogram of such springs during the production.
  • It also has a function to automatically increase Feed Back Ratio in every sampling to find out the optimal Feed Back Ratio, while sampling.
  • PC-15 does not only detect the Free Length, but it also detects and controls the Outside Diameter of the springs.
  • The same Probe used in detecting Free Length is also applied for the Outside Diameter Control function.
  • Initially, this function makes one Close Wound Coil in the beginning of the normal production, and set the measurement of its Developed Length as the reference value. Next, it makes a Close Wound Coil at every given interval (you pre-set such interval value between 1,000-5,000 pcs. prior to the operation). Then, it calculate the deviation of the Outside Diameter out of the difference between sampled Close Wound Coil and the Initial reference to make collection of the Out- side Diameter. (patent pending)
  • Those Close Wound Coil made during the production will be sorted out to direction of the bad springs.

It is very easy to operate MCS-G's Computer:
  • You can build the program just as easily as using a calculator through the keyboard.
  • MCS-15G uses the program with simple commands designed originally by ITAYA for the use of our spring making machines.
  • Ordinary operation of the machine may be obtained though several days of training program without difficulties.
There are 9 of the basic commands, which are:
Feed Command F feeds the wire.
Cam Axis Command O controls the Cam Axis.
Angle Detection Command d detects the Cam Axis Angle
Slide Axes Commands X,Y,Zcontrol the Servo Slide Axes.
Rotary Axis Command R controls the Rotary Wire Guide Axis
Check Command C detects the condition of the sensor.
Output Command A controls on/off of the peripheral devices.
Timer Command L controls the waiting time.
End Command E commands to end the program.

Program consists of these basic commands and the following marks:
Synchronization ( )synchronizes the movements of different axes.
Overlapping [ ]overlaps the movements of different axes.
Velocity Control ; controls the rotating speed of each axis.
Detecting Position @ detects the position of each axis.
Working Datum / sets the working datum value of each axis.
Limiting # sets the limit to each axis' movement.
Absolute Movement ! rotates each axis to the position expressed in the absolute value.
Multiplier Setting * sets the multipliers of each axis' movement value.


Color Monitor Screen (CRT) will assist your visual comprehension:
  • Color display panel shows 100 steps at once to help you picture the program as a whole.
  • You can get real-time grasp of the production condition through the histogram, the line graph, and the other various statistical information displayed during the production.
  • 24 of the Status Indicator Lamps let you know the Probe and the other systems' on/off status at once.

High-tech forming process can be programmed:
  • Product such as the magazine (oval coil) spring, which requires repetition of the same mechanical action, may be programmed with the "Loop Command".
  • Various high-tech processing programs may be created using Counter, Slide Check, Speed Control, Jump, Sub-routine, various Conditional, and other special commands.
  • By implementing your ideas, the "high-tech spring making" will become possible.

Large memory capacity and built-in Floppy Disk Drive unit:
  • Large capacity of the Internal Memory Bank is a characteristic of the MCS-G, and such memory bank is capable of storing 300 Steps and the other various parameters and counters of a program, thus it allows you to write a program for complicated spring with ease.
  • A 3.5 inch Floppy Disk Drive is built into the MCS-G as another standard equipment allowing each disk to store up to 70 programs.
  • Contents on the floppy disk are various parameters and counters, the layout record, and the total record of measured free length (optional), along with each program.
  • Directory menu of the floppy disk keeps the records of "name (of the spring you want to store)" and the " time & date (of when you stored the program)".

Convenient features of Computer Print Out and Video Print Out functions:
  • Computer print out is a standard function of the MCS-G. You can connect an optional printer to print out the programs, the total records of measured free length (optional), and the sampling records on a 10 x11 inch computer print out sheet.
  • Video print out is also a standard function of the MCS-G. Just by connecting the optional Video Printer, you can get the print-outs of what you see on the monitor screen instantly.

Communication feature:
  • Computer of the MCS-G is equipped with the communication function as a standard feature. Operating condition of the machine may be referred from, and the internally stored data such as the spring making program may be monitored from the outside computer linked to the MCS-G machine.

Specifications:

Machine

MCS-4G MCS-8G MCS-15G MCS-30G
Forming Capability Wire Dia. 0.05mm-0.4mm 0.2mm-0.8mm 0.4mm-1.5mm 1.5mm-3.0mm
Outside Dia. max.4.0mm max.10mm max.15mm max.24mm
Coil Length max.32mm max.60mm max.100mm max.180mm
Feed Axis Min. Increment 0.01mm 0.02mm 0.02mm 0.02mm
Max. Increment 9999.99mm 9999.98mm 9999.98mm 9999.98mm
Max. Speed 72m/min. 90m/min. 90m/min. 90m/min.
Motor 200W 750W 1500W 5200W
Cam Axis Min. Increment 0.05 degree 0.05 degree 0.05 degree 0.05 degree
Max. Increment 359.95 degree359.95 degree359.95 degree359.95 degree
Max. Speed 272rpm 400rpm 300rpm 200rpm
Motor 200W 750W 1500W 5200W
Slide Axis Min. Increment 0.001 0.001 0.001 0.001
Max. Increment 99.999 99.999 99.999 99.999
Max. Speed 600rpm 800rpm 800rpm 250rpm
Motor 30W 50W 200W 400W
Pneumatic Solenoid Valves
4 4 sets 4 sets 4 sets
Peripheral Device Control
16 ports 16 ports 16 ports 16 ports
Power Supply
10A 10A 15A 25A
Dimension Height 1662mm 1658mm 1667mm 1900mm
Width 1096.5mm 1260mm 1500mm 1969mm
Depth 718.5mm 716mm 816mm 1166mm
Net Weight
500kg 600kg 800kg 1600kg

Computer
CPU 32 bit Micro Processor
Internal Memory 600 Programmable Steps
External Memory 3.5 Inch Micro Floppy Discket
Display 10 Inch Color CRT
Operable
Temperature
0-45 degree Celsius
(32-113 degree Fahrenheit)
Patent:
In Japan 1624092
1077286
1635176
1673640
1792188
In United States 4227392
4669289
In Germany 3539730
In United Kingdom2008998

Please note the contents of this web page is subject to change without notice.