Three Companies Collaborate to Develop IoT Concentration Monitoring System for Early Detection of Abnormalities and Quality Stabilization

Ratoc Systems Co., Ltd. (Headquarters: Nishi-ku, Osaka City, Osaka Prefecture, Representative Director and President: Masakazu Kondo, hereinafter Ratoc Systems), Nichibei Co., Ltd. (Headquarters: Kashima City, Saitama Prefecture, Representative Director: Eisuke Yokoyama, hereinafter Nichibei), and Tokyo Koden Co., Ltd. (Headquarters: Adachi-ku, Tokyo, Representative Director and President: Tsukada Masaru, hereinafter Tokyo Koden) have jointly developed an IoT Concentration Monitoring System that monitors the dilution ratio of release agents in die-casting processes using IoT technology. The system will be provided starting in July 2026.

About the IoT Concentration Monitoring System

https://www.ratocsystems.com/sol/iotnoudo

This system combines Nichibei's expertise in die-casting sites, Tokyo Koden's concentration measurement technology, and Ratoc Systems' IoT technology. It continuously monitors the dilution ratio of release agents, supporting quality stabilization through early detection of concentration abnormalities and labor savings through reduced inspection workload.

The system will be sold by Ratoc Systems and Nichibei. The two companies have previously jointly proposed an IoT notification solution to prevent equipment shutdowns due to release agent shortages. Concentration monitoring is a new solution born from further developing this collaboration and integrating Tokyo Koden's concentration measurement technology.

Background

In die-casting manufacturing, managing the dilution ratio of release agents supplied to molds is a crucial process that affects product quality.

However, during the release agent dilution process, the dilution ratio can change due to fluctuations in supply water pressure or insufficient stirring. If the dilution ratio deviates from the appropriate range, it can cause product defects. If production continues without noticing the abnormality, it can result in lot defects on the scale of hundreds to thousands of units, potentially leading to large-scale disposal or re-production, causing time losses.

On the other hand, due to labor shortages, there are many cases where the dilution ratio is confirmed only once a day through manual measurement. This leads to delays in detecting abnormalities, resulting in increased costs due to defective products and re-production.

To solve these issues, the three companies have pooled their technologies and know-how to develop an IoT Concentration Monitoring System that continuously monitors the dilution ratio of release agents.

Comparison Before and After Introducing the IoT Concentration Monitoring System

Overview of the Three-Company Collaboration

This system is developed and provided by the three companies, each leveraging their strengths.

Nichibei

As a die-casting equipment manufacturer, Nichibei leverages its on-site expertise to extract user issues and make operational proposals.

[Compatible Equipment] Automatic Dilution and Pressure Feeding Device for Release Agents NC55-L-DP10 http://www.nichibei-ltd.com/product/06/

Tokyo Koden

Provides high-precision concentration measurement technology and supports the stable measurement of the dilution ratio of release agents.

[Compatible Equipment] Release Agent Dilution Ratio Meter CANA-3040 https://www.tokyokoden.com/products/colorimeter/%E9%9B%A2%E5%9E%8B%E5%89%A4%E5%B8%8C%E9%87%8F%E5%80%8D%E7%8E%87%E8%A8%88-cana-3040/

Ratoc Systems

Responsible for collecting data from various devices, cloud integration, and building a visualization and notification system via web apps.

[Target System] IoT Concentration Monitoring System

https://www.ratocsystems.com/sol/iotnoudo

Through the collaboration of the three companies, the efficiency of dilution ratio management, which was previously manual, and the strengthening of quality management are realized.

Solution Overview

The IoT Concentration Monitoring System is a solution that automatically measures the dilution ratio of release agents and manages it on the cloud.

System flow from measurement to notification

Main Features

[24-Hour Automation] Free from manual measurement, with periodic automatic measurement for constant monitoring. Concentration data is automatically measured and recorded on the cloud. Field operators can check the dilution state of release agents from a remote location, ensuring no abnormalities are missed even at night, on holidays, or in labor-short fields. *Note: Measurement intervals can be as short as 5 minutes and can be manually changed.

[Early Detection to Prevent Lot Defects] In case of abnormalities, the cloud sends notifications to smartphones or patrol lamps. This supports early response before it's too late, preventing lot defects that lead to disposal or re-production.

[Visualization of Quality] The web app displays the concentration trend in graphs, which can also be used for quality management and root cause analysis.

Future Developments

Based on the track record in the die-casting industry, we will promote the expansion to manufacturing industries with similar concentration management needs, such as:

Resin molding processes

Rubber molding processes

Plating processes

Cleaning processes

Cooling water and cleaning water management

Other manufacturing sites where liquid concentration management is required

Example Configuration of IoT Concentration Monitoring System

The connection to the communication unit, which performs A/D conversion and wireless transmission of the concentration sensor, adopts the analog (4-20mA) input used in many sensors. Up to 4 concentration meters can be connected. Communication with the gateway is done using the 920MHz band (Wi-SUN) wireless standard, which is stable even over long distances with obstacles.

Configuration Diagram of IoT Concentration Monitoring System

In the future, we also plan to support a configuration where data can be sent to the cloud directly from the concentration meter and communication unit without going through the gateway. We aim to expand the introduction to small-scale and standalone equipment with a simpler system configuration.

Company Profiles

About Nichibei

Company Name: Nichibei Co., Ltd. Location: 1596-1 Tsurugaoka, Kashima City, Saitama Prefecture Representative Director: Eisuke Yokoyama Established: March 15, 1950 Capital: 12 million yen URL: http://www.nichibei-ltd.com/ Business Content: We manufacture and sell release agents and lubricants for die-casting. With a well-equipped hardware aspect, such as spray equipment, and a software aspect with half a century of accumulated usage know-how, we are confident that our company is Japan's top manufacturer capable of accurately responding to user needs.

About Tokyo Koden

Company Name: Tokyo Koden Co., Ltd. Location: 3F, Suehiro Building, 5-24-5 Ayase, Adachi-ku, Tokyo Representative Director: Masaru Tsukada Established: April 1949 Capital: 24 million yen URL: https://www.tokyokoden.com/ Business Content: Established in 1949, we are a manufacturer of analytical and measuring instruments. We develop, manufacture, and sell instruments such as photometers, leveraging our long-cultivated optical analysis and measurement technologies to support a wide range of industries, including steel, semiconductors, and food.

About Ratoc Systems

Company Name: Ratoc Systems Co., Ltd. Headquarters Location: 8F, Minamihorie Building, 1-18-4 Minamihorie, Nishi-ku, Osaka City, Osaka Prefecture Representative Director and President: Masakazu Kondo Established: October 13, 1983 Capital: 100 million yen URL: https://www.ratocsystems.com/ Business Content: Founded in 1983, we develop and sell hardware, firmware, and apps related to PCs and smartphones in a one-stop manner. We have development experience with various interfaces such as RS-232C, Bluetooth, and Wi-SUN. We specialize in creating IoT systems with AWS cloud integration and respond to customer system environments with customization and embedded requirements.