池田金属工業 List of Products and Services

The "Recoil Kit" is a thread repair kit for recoil widely used around the world for the maintenance and repair of industrial machinery, automobiles, and motorcycles. In the case of the trade series, remove the damaged screw section with a drill, then tap to the required depth, and attach the recoil tang downward to the insertion tool. Insert the recoil while lightly pressing vertically, and after insertion, break off the tang with a dedicated tool. The contents of the set vary by size, so please feel free to contact us when placing an order. [Usage Instructions] 1. Drill 2. Tap 3. Insert insertion 4. Break off the tang *For more details, please refer to the related links or feel free to contact us.

• Work tools

The "Recoil Tangless Insert" is a product that allows for insertion and removal without a tang, using a dedicated tool. When removing, it does not damage the male threads or the tangless insert. Since there is no tang on the wire insert, the insertion time can be reduced to one-third of the conventional time. 【Features】 ■ SUS304: Standard product ■ SUS316: Corrosion resistance and chemical resistance ■ Inconel X-750: Corrosion resistance, heat resistance, and chemical resistance ■ Phosphor bronze: Non-magnetic ■ Nitronic 60: Non-magnetic and galling resistant *For more details, please refer to the related links or feel free to contact us.

• Subsidiary materials

"Karatan (Color Tangless Insert)" is a product that makes it easier to confirm after insertion work by adding color to the tangless insert. It is possible to eliminate insertion omissions with just a visual check. Additionally, there are no concerns about coating peeling or outgassing during insertion, making it suitable for semiconductor-related components. 【Features】 ■ Prevention of insertion omissions through color coding ■ Ultra-thin film maintains workability ■ No peeling or outgassing ■ No need for cumbersome large taps ■ Material: A2 (SUS304) *For more details, please refer to the related links or feel free to contact us.

• Subsidiary materials

"Ensat" is an insert nut with a self-tapping feature. It eliminates the need for the tapping process required before inserting the wire insert. Additionally, compared to press-fit types, the external threaded part grips the base material tightly without gaps, making it less likely to come loose. 【Features】 ■ Eliminates the need for the pre-tapping process ■ Provides pull-out strength due to its one-piece molding ■ Reduces distortion of the base material caused by insert insertion *For more details, please refer to the related links or feel free to contact us.

• Steel

The "Keysert" is an insert nut used for repairing and reinforcing stripped screw threads. The insertion process does not require specialized tools and can utilize commercially available drills and taps. Additionally, after insertion is complete, the key that protrudes from the top can be driven into the groove with a specialized tool, creating a wedging effect. 【Features】 ■ Driving in the key prevents loosening of the insert and increases pull-out strength. ■ Since it is not a wire type, there is no concern about pitch skipping. ■ The drilling and tapping processes can use general tools instead of specialized ones. *For more details, please refer to the related links or feel free to contact us.

• Steel

The "Expander" can solve the wear-related play in the movable parts, which has been considered unavoidable due to the structure of the mechanical movable components, in a short time and for the long term. By expanding the gap in the pin hole area, which is the root cause of the problem, when the pin is fixed, the issue is resolved. Additionally, by reducing the distance between the fixed parts, the bending stress on the pin is halved and distributed, ensuring functionality for 10 years or 10,000 operating hours. 【Features】 ■ Long-term resolution of play in movable parts due to pin hole wear can be achieved through part replacement alone. ■ Compatible with a wide range of pin specifications, including size, single or double fastening, and lubrication presence and method. ■ Significantly reduces maintenance costs, maintenance time, and opportunity losses due to decreased operational accuracy. *For more details, please refer to the related links or feel free to contact us.

• Reinforcement and repair materials

The "TRF" is a tamper-proof screw used in terminal products that require safety measures such as the disassembly of public facilities and toys, accident prevention, theft prevention for equipment, and compliance with radio laws. By replacing existing screws, security is enhanced. Additionally, due to its aesthetic appeal, it is also appreciated for its design, and there are many situations where it is used as an accent for products. 【Features】 ■ Security is increased simply by replacing existing screws ■ Cannot be disassembled without a special tool ■ A variety of tamper-proof screws are in stock *For more details, please refer to the related links or feel free to contact us.

• Steel

This document introduces the reduction of breakage risk for Super Bolts. It explains the causes of breakage in large diameter bolts, and then provides a detailed explanation of the axial force generation process of Super Bolts and the absence of torsional stress. Our company has a dedicated support department. Please make use of it for product selection. [Contents] ■ What is a Super Bolt ■ Main causes of breakage in large diameter bolts ■ Reducing breakage risk with Super Bolts ■ Summary *For more details, please refer to the PDF document or feel free to contact us.

• others

The tightening failure test is an important test for determining the type of tapping screw, the diameter of the pilot hole, and the appropriate tightening torque when using tapping screws. Even if the types of tapping screws are the same, differences in other conditions (such as pilot hole diameter, the material being fastened, and the counterpart material) can lead to variations in test results. In this document, we conduct tightening failure tests under three different conditions using the same tapping screw and compare the differences in the results. [Contents] ■ Test Overview / Test Conditions / Comparison Conditions ■ Key Points to Observe in the Test ■ Test Result 1: Differences in Pilot Hole Diameter ■ Test Result 2: Differences in Engagement Length (Length of the screw section in contact with the counterpart material) ■ Test Result 3: Differences in the Material of the Fastened Component (Material of the contact surface of the tapping screw) *For more details, please refer to the PDF document or feel free to contact us.

• others

This document explains the unstable relationship between torque and axial force, and proposes the "DTI System" as a solution to this problem. An overview of the "DTI System" and its feature, the axial force display technology, will be introduced. We have prepared a questionnaire sheet to gather the necessary information for determining the feasibility of manufacturing and for estimates. Please make use of it when considering implementation. [Contents] ■ Figure 1. Torque Table ■ Figure 2. Relationship between Torque and Axial Force ■ Figure 3. DTI System ■ Key points indicated in the figures *For more details, please refer to the PDF document or feel free to contact us.

• others

This document explains the standard profiles, reference dimensions, pitch, tolerances, and allowable limit dimensions of screws. It includes information on "coarse and fine threads," "tolerances for general-purpose metric screws," and "Unified coarse and fine thread screws." This material is designed to be a helpful reference for product selection. We encourage you to read it. 【Contents】 1. Standard profiles and reference dimensions for general-purpose metric screws 2. Coarse and fine threads 3. Unified coarse and fine thread screws 4. Tolerances for general-purpose metric screws (principles and basic data) 5. Allowable limit dimensions for general-purpose metric screws *For more details, please refer to the PDF document or feel free to contact us.

• others

This document introduces design methods that you may want to consider regarding the safety of fastening components when using recoil. It includes dimensions of bosses and edges, as well as the strength of bolts and shear strength of the base material during assembly design. Please make use of this information when selecting products. [Contents] ■ Design Considerations ■ Assembly Design ■ Conversion Table *For more details, please refer to the PDF document or feel free to contact us.

• others

This document is a summary extracted from the standard JIS B 1021, which can be applied to special-shaped screw-type components, focusing on the tolerances for frequently used screw lengths. It also compiles tables of screw pitch, JS tolerances, and IT tolerances included in the standard, allowing you to check the tolerances for screw length with just this one document. Please make use of this when selecting products. 【Contents】 ■ Overview of the document ■ Scope of application of JIS B 1021 ■ Notes ■ Tolerances for screw lengths ■ Tolerances for lengths ■ Afterword *For more details, please refer to the PDF document or feel free to contact us.

• others

We would like to introduce a case where we proposed "Sea Horse Lock" to a machinery manufacturer. The components mounted on the rotating body of the product were fastened with hex socket flat head bolts M6x25, but there was an occurrence of "screw loosening." As a result of our proposal, the return torque of the adhesive type SL358 was found to be the most favorable, leading to its adoption after prototyping and subsequently for mass production. No loosening incidents have occurred since its adoption. 【Case Overview】 ■ Issues - Components mounted on the rotating body of the product were fastened with hex socket flat head bolts M6x25, but "screw loosening" occurred. - Variability in the anti-loosening effect due to missed application or uneven application of adhesive. *For more details, please refer to the related links or feel free to contact us.

• Other services and technologies

We would like to introduce a case where we proposed "Inconel Lock Recoil" to a semiconductor manufacturing equipment manufacturer. During the polishing process, the wafer that was being supported fell and broke. Furthermore, upon retrieving the parts, rust was found on the wire insert that was inserted into the female thread. After our proposal and subsequent measures, it has been adopted for mass production, and several years have passed without any occurrence of loosening or rust. 【Case Overview】 ■ Issues - The wafer supported during the polishing process fell and broke. - Rust had developed on the wire insert inserted into the female thread. ■ Requirements for Problem Resolution - It must be an effective countermeasure against rotational loosening. - It must be made of a material with excellent chemical resistance. *For more details, please refer to the related links or feel free to contact us.

• Other services and technologies

We would like to introduce a case where we proposed "Non-Sert" to a vehicle-mounted device manufacturer. There were frequent occurrences of thread stripping (commonly known as "screw stripping") at fastening points using tapping screws (with the counterpart material being thermoplastic resin). After the proposal, stable production became possible for anyone without relying on skilled craftsmanship. 【Case Overview】 ■ Issues - Frequent thread stripping at fastening points using tapping screws - Only certain experienced workers could ensure reliable assembly ■ Requirements for Solving the Issues - Selection of appropriate screws that match the fastening components - Selection of appropriate conditions and redesign of specifications through torque testing *For more details, please refer to the related links or feel free to contact us.

• Other services and technologies

Here is a case study of proposing "Super Bolt" to a manufacturer of injection molding machines. The customer had a request to eliminate both the physical burden and risks associated with the tightening methods used by workers. After implementation, it became possible to fasten safely without the use of hammers or special tools. 【Case Overview】 ■ Issues - The M150 tie rod (bar) was broken. - A tightening method that posed physical burdens and risks to workers was being used. ■ Requirements for Solving Issues - Anyone should be able to accurately achieve the design axial force for thick bolts. - Avoid excessive torsional stress on the bolts. *For more details, please refer to the related links or feel free to contact us.

• Other services and technologies

We would like to introduce a case where we proposed "reducing the manufacturing process and increasing production lots" to an industrial machinery manufacturer. The customer was purchasing low-head type special-shaped hexagon socket bolts M2 from an e-commerce site, but they had a request to reduce costs due to the high unit price and increasing usage. We proposed a change in the manufacturing method, which was adopted without any issues and met or exceeded the performance of the conventional products, resulting in significant cost reduction. [Case Overview] ■ Issues - Costs had become too high - The shape was not particularly difficult to manufacture, despite being outside JIS standards ■ Requirements for Solving the Issues - Reduction of costly machining processes - Establishing production lots that ensure stable lead times *For more details, please refer to the related links or feel free to contact us.

• Other services and technologies

Here is a case where we proposed the "Nord-Lock Washer" to a food processing manufacturer. In the final stage of packing the manufactured liquid, screws used in the equipment line fell off and were shipped without anyone noticing, resulting in contamination of the product. After our proposal, there have been no signs of screw detachment, and the emergency measure of inspection work has been eliminated, leading to a reduction in the burden on the workers. [Overview of the Issue] ■ Screws used in the equipment line fell off and were shipped while contaminating the product without anyone noticing. ■ The issue was discovered by chance during an inspection at a retail store, leading to a halt in production and a recall of all products. ■ Since then, all areas with potential for detachment have been addressed with emergency measures. ■ The inspection work before starting operations has become an excessive burden, so we want to implement a fundamental solution. *For more details, please refer to the related links or feel free to contact us.

• Other services and technologies

We would like to introduce a case where we proposed "switching manufacturers/automating the bagging process" to a battery manufacturer. There was a frequent issue with the small-diameter brass hex nuts used in battery production, where "the taps were cut at an angle." After our proposal, and following audits of two manufacturers, product defects have not occurred since the process changes were approved. 【Case Overview】 ■ Issue - There was a frequent issue with the small-diameter brass hex nuts used in battery production, where "the taps were cut at an angle." ■ Requirements for Solving the Issue - Select manufacturers that can ensure accurate quality control (to prevent occurrences). - Ensure that defective products can be detected during the bagging and inspection processes (to prevent outflow). *For more details, please refer to the related links or feel free to contact us.

• Other services and technologies

Here is an example of a proposal for "Color Tangless" to an aluminum processing manufacturer. At this manufacturer, after inserting Tangless inserts for thread reinforcement into the aluminum processing material, they deliver the products to the final assembly manufacturer. However, it was frequently occurring that the Tangless inserts were not inserted when the customers assembled the products. After the proposal, the work time was reduced to about half, as it only required visual confirmation, and since there were no longer any instances of missing inserts, it also prevented losses in time and trust due to after-sales support. [Case Overview] ■ Issues - Frequent occurrences of missing Tangless inserts - High inspection burden for preventive measures ■ Requirements for Issue Resolution - A fundamental method to eliminate missing inserts - A simpler method that eliminates the need for bolt checks after insertion *For more details, please refer to the related links or feel free to contact us.

• Other services and technologies

We would like to introduce a case where we proposed to manufacture adjustment screws from scratch for a machine tool and industrial machinery manufacturer, as per their request. During mass production, a request for the arrangement of adjustment screws was made to the purchasing department, and upon checking on an e-commerce site, it was found that the costs were high and did not fit the budget for purchasing the production lot (700 pieces). After our proposal, we were able to provide the screws at approximately 45% lower cost than the e-commerce site, taking into account the lead time (actual working days: 30). [Overview of the Issue] - During the prototype phase of a new machine tool, the design department intended to use "adjustment screws" available on an e-commerce site for the legs of the machine. - When a request for the arrangement of adjustment screws was made to the purchasing department during mass production, it was discovered that the unit price was high and did not fit the budget for purchasing the production lot. - Since they did not want to make significant specification changes, they were considering how to obtain the screws at a lower cost. *For more details, please refer to the related links or feel free to contact us.*

• Other services and technologies

Here is an example of a proposal for "rust prevention through Disgo treatment" made to a construction manufacturer. The customer was using stainless steel post-installed anchors to secure a marine pier, but rust was occurring during low tide, posing a risk of collapse. They requested a solution to this issue. We proposed Disgo treatment, which can extend the lifespan of the components, thereby enhancing rust prevention and reducing the likelihood of pier collapse. [Overview of the Issue] - Stainless steel post-installed anchors were being used to secure the marine pier, but rust was occurring during low tide. - If the post-installed anchors were to break, it could lead to the collapse of the pier, so a solution was needed. *For more details, please refer to the related links or feel free to contact us.

• Other services and technologies

We would like to introduce a case where we proposed replacing Truss screws with the ultra-low head screw '310 Slim' in the automotive industry. With Truss screws, the protruding head of the screw would get caught and could not be inserted, which was a challenge. After the proposal, assembly could be done without interference with other parts, and when inserting the housing into the vehicle, the head no longer got caught. [Overview of the Challenge] - The size of this compact vehicle has been reduced compared to conventional products, and each component is required to be smaller and lighter. - Although Truss screws are usually used for fastening, the design calculations indicated that the protruding head would interfere with other parts inside the housing. - The space on the vehicle side for inserting the housing is also narrow, and with Truss screws, the protruding head would get caught and could not be inserted. *For more details, please refer to the related links or feel free to contact us.

• Other services and technologies

We would like to introduce a case in the plant maintenance industry where we proposed the clarification of details for a special screw that became unclear due to the closure of a factory, utilizing knowledge of drawing production and inspection tools. During the maintenance of a rod mill, the screws used became unavailable, making maintenance impossible. After our proposal, we were able to manufacture screws identical to the samples by selecting a manufacturing method based on the size and shape of the screws. [Overview of the Issue] - The factory that was producing the specially shaped screws went out of business, and the screws needed for maintenance of the rod mill became unavailable. - The only remaining item was a sample screw, which provided information only about its shape and material, along with rough size. - Screws of three different sizes are needed in the quantities listed below by the maintenance scheduled to begin in four months; without these screws, maintenance of the rod mill cannot be performed. *For more details, please refer to the related links or feel free to contact us.*

• Other services and technologies

We would like to introduce a case where we proposed "Nord-Lock washers + Zorbest coating" to the manufacturing industry. While taking measures to prevent failures due to loosening of screws, there was a challenge of wanting to achieve high precision in axial force using lubricants, but most anti-loosening products could not be used in conjunction with lubricants. After the proposal, we successfully manufactured vehicle parts with high difficulty in design, contributing to the reduction of labor in the lubricant application process. [Overview of the Challenges] - To meet the demands of the end user (railway company), the design of vehicle parts had to be more stringent than what is usually produced. - While wanting to prevent failures due to screw loosening and achieve high precision in axial force, most anti-loosening products could not be used with lubricants. - Even if there were anti-loosening products that could be used with lubricants, the application process was labor-intensive. *For more details, please refer to the related links or feel free to contact us.

• Other services and technologies

We would like to introduce a case where we proposed an alternative for hexagon socket bolts with left-hand threads that have disappeared from the market due to the manufacturer's discontinuation to a textile machinery manufacturer. The M3×7 hexagon socket bolt (left-hand thread) used in textile machinery was discontinued, and without finding an alternative product, the production line would come to a halt, affecting sales. We proposed custom machining of the left-hand thread hexagon socket bolts and painting of the heads, allowing for the selection of right-hand and left-hand threads without changing the screw size, and we were able to deliver the product by the desired deadline. [Overview of the Issue] - The M3×7 hexagon socket bolt (left-hand thread) was used in textile machinery, but production by the manufacturer has ended and it has been discontinued. - If no alternative product is found, the production line will stop, impacting sales. *For more details, please refer to the related links or feel free to contact us.

• Other services and technologies

We would like to introduce a case where we proposed the identification of the cause of loosening and permanent countermeasures through hypothesis establishment and dimensional inspection using an image measurement device for an industrial vehicle manufacturer. There was an issue where the embedded bolts used to secure the forklift tire wheels would fall off after delivery to the customer. We shared knowledge regarding the embedded bolts and conducted dimensional measurements of the threaded parts using the image measurement device. We proposed clearly stating tolerances on the drawings to ensure accurate communication of information among design, quality control, procurement, and suppliers. [Overview of the Issue] ■ The embedded bolts used to secure the forklift tire wheels fall off after delivery to the customer. ■ If they fall off during operation, it could lead to a serious accident, so it must be resolved urgently. *For more details, please refer to the related links or feel free to contact us.

• Other services and technologies

Here is a case where we proposed "Nord-Lock washers" to an industrial machinery manufacturer. They were using hex socket bolts (CAP) in their binding equipment, but there was an issue with loosening occurring after delivery. After our proposal, the reports of loosening troubles, which had been occurring almost every month, dropped to zero. [Overview of the Issue] ■ Hex socket bolts (CAP) are used in the binding equipment, but loosening occurs after delivery. ■ There were 2 to 3 reports per month, and maintenance was performed at the customer site each time. *For more details, please refer to the related links or feel free to contact us.

• Other services and technologies