en.Wedoany.com Reported - Cosel Co., Ltd. has adopted IMAO Corporation's Thumb-Type Clamps to replace its self-made fixtures, reducing fixture manufacturing costs by 70% while achieving nearly two years of maintenance-free operation.
Cosel Co., Ltd., located in Toyama City, Toyama Prefecture, was founded in 1969 and employs 514 people. It is a manufacturer specializing in switching power supplies. The company produces switching power supplies, DC-DC converters, noise filters, and other DC stabilized power supply devices, supplying both domestic and international markets. In the power module production process, circuit boards with electronic components need to be covered with resin cases and injected with silicone gel for curing. However, gaps between the board and the resin case often cause silicone leakage, and the silicone expands and contracts during heat curing. To address this, the company previously used self-made fixture base plates and pressure plates, with one fixture base plate per product. With a daily output of 200 products, approximately 400 installation and removal operations were required each day, resulting in a heavy workload.
The previous clamping components were designed and manufactured in-house by Cosel Co., Ltd. They had complex structures and needed to be customized according to product dimensions, consuming significant time from design and processing to assembly. Including material costs, each clamping component cost over 10,000 yen. During heat curing, thermal expansion often caused bolt loosening, leading to failures approximately once a week, requiring repairs or part replacements. In severe cases, production came to a halt. Additionally, wear on friction surfaces reduced clamping force, making regular clamping status checks a necessary step and increasing the risk of defective products.
Cosel Co., Ltd. learned about the Thumb-Type Clamp from IMAO Corporation's "Quick Clamp" series on the company's website. After physically handling the product at the "Mechanical Elements Technology Expo," they determined it could meet their needs. The Thumb-Type Clamp requires only a 90° rotation of the knob to clamp or release, with a clamping force of 90N, durability exceeding 10,000 cycles, and an outer diameter of 34mm, making it suitable for small workpieces. However, in the standard version, the "ON/OFF" markings would disappear in the 150°C heat curing environment, potentially causing operators to forget to clamp. After consulting with IMAO, Cosel adopted a custom version: the markings were changed to laser engraving, and the body color was changed to black to ensure the markings remained clearly visible under high-temperature conditions.
After switching to the Thumb-Type Clamps, fixture costs dropped significantly: the cost per clamping component fell from over 10,000 yen to just a few thousand yen, reducing overall fixture manufacturing costs by approximately 70%. Cosel had designed eight types of fixtures for various sizes, making the cost savings substantial. Furthermore, the fixtures achieved maintenance-free operation, requiring no repairs for nearly two years, eliminating downtime caused by bolt loosening and friction surface wear. Operators can confirm the clamping status through the knob position, markings, and the audible "click" sound and tactile feedback during operation, preventing operational errors. With standardized clamping components, designing new fixtures no longer requires separate consideration of the clamping mechanism, improving design efficiency.
Currently, Cosel Co., Ltd. has expanded the use of Thumb-Type Clamps to other processes requiring quick fixation beyond heat curing fixtures. For future product development, the company suggests that IMAO consider developing a left-rotating version to enable a natural operation mode where "turning the knob outward clamps, and turning it inward releases" when simultaneously operating clamps on both left and right sides, reducing operator burden.
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