Tokyo, Japan - January 20, 2015
Yokogawa Manufacturing Corporation's Kofu Factory has won the Judging Committee Special Prize for its development of an energy efficient drilling system that reduces power consumption and waste liquid amounts in control equipment production operations. This is one of the Energy Conservation Grand Prizes* that was offered by the Energy Conservation Center this year in the energy-saving activities category. Yokogawa Manufacturing Corporation is a subsidiary of Yokogawa Electric Corporation.
The Kofu Factory produces differential pressure/pressure transmitters, which are an important Yokogawa product. The production line that produces hermetically sealed body components is a key part of the overall transmitter production process, and it is important to optimize its efficiency. To increase output and conserve energy, the factory decided to discontinue electric discharge machining and rely instead on a newly developed drilling system to produce small-bore deep holes. In addition to developing fundamental new drilling technology, the factory automated the production line by introducing the use of industrial robots. This new drilling system increases output, reduces labor costs, reduces waste liquid amounts, uses less space, and significantly reduces power consumption.
Following this revamp, the production line takes up half the space, uses 25% less electricity (56 MWh/year reduction), and produces 95% less waste fluid. The same changes were made to the line that produces the transmitter capsule bodies. The upgrade of both lines reduced power consumption by 128 MWh/year (equivalent to 33,000 liters of crude oil) and CO2 emissions by 58 tons.
The factory will continue improving its processing technology to shorten the drilling time, extend the usable life of drills, and reduce hole diameter.
* A commendation system sponsored by the Energy Conservation Center, Japan with the support of the Ministry of Economy, Trade and Industry. The awards commend energy-saving activities and advanced energy-saving products to enhance energy conservation awareness and expand the use of energy-efficient products.