What are the types and characteristics of balancers? How to choose and what are checkpoints? You can also find examples of installation.

We hear people say, “We are interested in balancers, but we are not sure what are the differences between balancers and other hoisting machines.”

In this article, we will introduce,
　・Basic structure and roles of balancers
　・Types of balancers
　・Differences from other lifting devices

We also introduce some examples of the actual installation of our Intelligent Air Balancers
We hope this will give you some ideas for installation.

It might be easier to understand the principle of a balancers by comparing it to a balance scale. In a balance scale, a weight of known weight and an object to be measured are placed on the left and right plates, and the weight and number of weights are adjusted until the balance is level.
The balancers equalizes the force in the winding direction generated by springs (spiral springs), air cylinders, electric motors, etc., and the suspended workpiece (load), which makes the weight of the workpiece close to zero.

A balancers allows the operator to easily adjust the height of hanging tools or heavy items with little or no vertical force. Therefore, it makes aligning operation of tools and assembled parts easier, reduces the physical burden on the operator, and improves operability.

By installing balancers

• Workload saving for workers
• Labor saving from 2 to 1 worker

In this way, work can be done efficiently.
By reviewing the layout when installing balancers, you can expect to improve work efficiency even further.

Not only that, but also

• Prevention of accidents and injuries caused by falling heavy objects
• Prevention of back pain from working long hours

It helps to ensure the safety of employees.

Regardless of the worker's gender, age, or strength, they can work

• Same burden
• Same operation

There are various types of balancers power sources.

1.Spring type that requires no external power
2.Electric or air type using external power
3.Hybrid type(Electro-pnuematic) that uses air as the power source to achieve the balancing function through electronic control.

Product Name:Tool balancers
Power : Coil spring (spring)
Feature : Work can be performed with a small load by suspending and balancing tools, etc.
※*Cannot be used for transporting workpiece.

Product Name:Electric Balancers
Power : Electric (servo motor)
Feature : Rated load is 300kg. Balancing operation is possible. Fine aligning by servo control. Enable to follow the load fluctuation of the suspended load.

Product Name:Air Balancers
Power : Compressed air
Feature : The power source is air. Balanced operation is possible with a control module.It is used for conveying. It is suitable at sites where the use of electricity is restricted.

Product Name: Intelligent Air Balancers
Power : Compressed air (power) + electronic control
Feature : Power source is air. Rated load up to 130 kg. Smoother operation than air balancers by electric control. Balancing operation is possible. We can make proposals to meet your needs and environment of use.

We can make proposals to meet your needs and environment of use.

We sometimes hear a question, ”Can we use a tool balancers to convey items?”
Because of the following two reasons,it is impossible to use tool balancers to convey items.

① Workpiece suspended by tool balancers cannot land on the ground.

Tool balancers always has a pulling force in the winding direction. Therefore, the suspended workpiece cannot land on the ground. It is always balanced (floating).

② It is very dangerous and difficult to attach and detach workpieces suspended by tool balancers.

When a workpiece is removed from the tool balancers forcibly, the tension of the spring causes the bottom hook to rise rapidly, and the wire rope is rapidly wound up into the case.
This is very dangerous because the wire rope and hook may hit the operator during the winding process.

Please use the drum lock when attaching and detaching workpieces. For models without a drum lock, store all wire ropes inside the case before attaching and detaching workpieces. When attaching and detaching workpieces, please do safely while reading the instruction manual.

Tool balancers are used with tools and workpieces left suspended.
On the other hand, the electric type or air-electric hybrid type balancers detects the load of the workpiece through control. And it automatically adjusts the force generated in the lifting direction to equalize with the load of the workpiece.
Thus, the workpiece can be removed. And so this type of balancers can be used for conveying items at plants or distribution sites, chucking into machine tools, and conveying molds.

Tool balancers is used to keep suspending loads.

• Various tools
• Various equipment

Balancing these items in the air allows to perform accurate work with light force.

Unhooking a load while the spring is under tension may cause the wire to jump It is dangerous. This product cannot be used for work that requires the removal of a suspended load, such as conveyance work. This product cannot be used for work that requires the removal of a suspended load, such as conveyance work.。

No external power such as electricity or air is required.
Because the structure is so simple, it is easy equipment to install.

Purpose	For suspension of various tools in assembly and production lines
Advantages	Reduces fatigue and improves work efficiency

Electric Balancers is load handling equipment with balancing function for lifting heavy loads with electric power.

It makes it possible to manipulate heavy loads with less force at the balancing operation.

Purpose	Conveys heavy loads, such as from pallets to workbenches Aligning work Assembles parts that require careful handling Works requiring precise handling
Advantages	Reduces back pain of employees Saves manpower Increases work efficiency

Air Balancers is load handling equipment that is mainly powered by compressed air. It can be used without electricity. The piston structure of the Air Balancers gives a light and airy feel. Continuous operation is possible because it is powered by air.

Purpose

Conveys workpieces to be carried by more than one person or frequently conveys heavy items by person. Aligning work in the assembly process. Handles workpieces that require careful handling, such as glass and various types of panels. Changes metal molds that require precise handling.

Advantages

Significantly reduces the burden of conveying heavy loads. Suitable for conveying items that require carefulness and precision. Therefore, it reduces work time and improves work efficiency. Because the suspended load can be moved by direct touch, no inching work for aligning and grounding is required. Easy to operate. Allows use in frequently used processes. Unlike electric hoists, continuous use is possible. Therefore, it can be used in processes that are used frequently.

Intelligent Air Balancers is a new generation air balancers combining compressed air and electronic control.
Smooth changeover from gripping to balancing operation without any switch operation.

Purpose

Removes and attaches workpieces from/to the processing machine. Conveys using a jig. Aligns workpieces in the assembly process. Changes molds.

Advantages

Smooth and natural feeling of operation by air drive. Assists workers with burdened tasks. Suspended loads do not fall rapidly even if electricity or air supply is stopped. Flexible handling for conveying multiple workpieces of different weights with a single unit. No inching work for aligning and grounding is required because the suspended load can be moved by direct contact. Easy to operate so that anyone can use it. Can be used in frequently used processes. Reduces takt time.

“We understand that balancers reduce the burden on the operator, but what kind of assistive device exist in the first place?”

You may be interested in other types of assistive device.
The most important thing is to choose assistive device that suits your work environment.
Let’s consider installing a balancers while understanding how it is different from other assistive device.

The air hoist is powered by compressed air and operated by a push-button system. The speed can be adjusted by pushing the button, and it can be operated flexibly from high to low speed. Less chance of ignition compared to electric systems because of air power, therefore, the hoist can be used in the locations as follows:

• Chemical plants.
• Locations where hazardous materials are handled.

＜Advantages＞

• Compact and lightweight design.
• Suitable for work requiring speed.
• High safety because the power source is air.

＜Disadvantages＞

• No balance function because of no load detection.

Assistive suits are supporting devices that people directly wear and use.
It reduces the burden of heavy loads on the body and protects the back.

＜Advantages＞

• Makes it easier for women or the elderly with limited strength to work.
• Can be used in limited spaces where only one person can enter.
• Can be moved easily.
• Using assistive suits makes workers feel easy to work.

＜Disadvantages＞

• Relatively small weight capacity.
• Not a full body aid.

Here are some installation examples of our Intelligent Air Balancers.

The challenge was how to convey workpieces quickly and accurately without damaging them.

＜Tasks＞

１、Lift workpieces

２、Land workpieces

The installation of balancers reduces the risk of impact to workpieces.
Inching is not required, therefore, even unfamiliar operators can work with the same quality.

＜Tasks＞

１、Attach jig

２、Align the position

Fine- tuning has become easier with the support of Intelligent Air Balancers for aligning. Work efficiency has been greatly improved because work can be done smoothly as if it were done by hand.

Assistive devices were being considered to enable anyone to work alone.

＜Tasks＞

１、Disassemble the agitator

２、Clean the agitator

３、Assemble the agitator

Even difficult tasks such as supporting heavy items can be performed safely. The operator's workload is greatly reduced and operation is simple, so that any operator can work alone.

In order to improve conveying operations and shorten takt time, a company was considering installing a balancers.

＜Tasks＞

１、Convey workpieces

２、Assemble

３、Convey workpieces

Time-consuming processes due to difficult-to-handle equipment have been improved. Tact time has been successfully reduced, and the stress of operators, whose sense of operation changes each time, has been eliminated.

「Let's install a balancers.」
Even if you decide to install a balancers, it may not be possible to do so depending on the environment of the site.
We recommend that you first confirm in advance whether the environment is suitable for a balancers.

Please check the area for the equipment in advance.

• What floor is the equipment installed on?
• How high is the ceiling of the location?
• What is the floor load capacity at the location where installation is considered?

Please confirm that there is enough space to install a balancers.

If a balancers is installed on a jib crane and used by turning, please make sure that no objects will hit it within the turning radius.

You will need to consider the workspace along with the installation.
Workspace requirements vary, so it is important to know how much space you will need.

There are two kinds of balancers.
　・Fixed type (Floor or Ceiling)
　・Mobile type
In the case of fixed balancers, as many balancers as the number of operations to be covered are required.

• Shape
• Physical properties
• Weight

Depending on these factors, attachments will be different.
If there are multiple types of workpieces to convey, the workpiece information must be confirmed in advance.

Depending on the workpiece conditions, load capacity is different.

• Consider the appropriate attachment for the target workpiece.
• What is the load capacity?

These are important points to check when installing equipment.

For those who are still wondering whether to choose assistive device or an industrial robot.
Industrial robots perform assembly and other work in factories instead of humans.
Although they are very convenient, there are five challenges to install industrial robots.

Initial cost	Large initial cost to install.
Losses due to defects	If a defect occurs in the installed robot, the following may happen. The production line stops . Production will be delayed from the plan .
Requires certification for operation and inspection	Industrial robots, with the exception of some robots, require the following qualifications. Teaching, which is the process of programming the robot's operation. Inspection to perform maintenance and repair.
Risk of injury due to misoperation	A worker accidentally entered the operating range. Operation accidentally started during maintenance. If these occur, there is a possibility of contact with the robot, which can lead to serious injury.
Secure installation space	Some products are large in size and require additional work space.

You need to understand these challenges.

Types of balancers include:

• Tool balancers
• Electric balancers
• Air balancers

Tool balancers are used with the suspended load left hanging.

• Various tools
• Various equipment

Balancing these things in the air allows you to work with light force and precision.

Electric balancers and air balancers are used for heavyweight items　

• Lifting
• Conveying

They support weight and provide mobility assistance when working.
It is also called an aid or weight-assist equipment because it reduces the workload.

By installing a balancers, you can

• Prevent injuries caused by falling heavy objects
• Prevent back pain due to work
• Save labor of operators
• Reduce the number of workers from two to one

We hope that these actual examples and points to check for installation will help you consider installing a balancers.