Reducing Costs

with Static Eliminators

in the Automotive and Electric Appliances Industry

Jamming

ESD damage

Adhesion of foreign
particles

Sticking
 Case 1
Preventing adhesion of foreign particles
during transportation and assembly
BEFORE

❙❙PROBLEM
Static electricity generated during transportation or assembly of parts can
cause foreign particles to cling to them, which can result in defective
workpieces.

❙❙SOLUTION
Previously installed static eliminators lost their effectiveness over time.
Static elimination of
cell production booth

Solve this problem by introducing KEYENCE’s SJ-F Series

static eliminator and reduce costs!

Highest static elimination speed in its class

Covers twice the area of conventional models
Auto-sensing and feedback functions help maintain static elimination effect

AF T E R
Cost-effectiveness of installing the SJ Series
Sample:
Disposal cost per production line: Annual cost:
$909/month $10908/year
* As of July 2018

Static elimination effectiveness does not change over time!

Ion balancing function by auto-sensing
No need to install sensors

Featuring auto-sensing and feedback functions driven by KEYENCE’s original Ion Current Control (I.C.C.)
The I.C.C. method supplies the optimal balance of ions according to
the detected charge, so it does not require any additional set-up
during installation or maintenance and also enables effective static Figure: I.C.C.’s effect on static elimination duration
elimination. (typical example from the SJ-F Series)
14.0
Static elimination time (s)

No need for initial adjustment of ion balance 12.0

The ion balance does not need to be adjusted since the 10.0
quantity of the generated ions is controlled automatically. 8.0
With I.C.C. OFF
6.0
Optimal amount of ions supplied for high-speed 4.0 With I.C.C. ON
static elimination 2.0
Rapid static elimination is possible because ions are supplied 0.0
according to the amount of charge to be eliminated. 250 500 750 1000 1250 1500
Start measurement Elapsed time (h)
Constant monitoring of ion balance for long- * Measurement conditions for KEYENCE comparison test
term stability Static voltage: +1 kV ’100 V
Plate monitor: 150 mm × 150 mm (20 pF)
Automatic adjustment compensates for deterioration in ion Installation distance: 300 mm
balance due to build-up on the electrode probe.

2
 Case 2
Prevent jamming in a hopper bowl

BEFORE

❙❙PROBLEM
Hopper and feeder bowls have conventionally clogged due to static cling,
causing production lines to stop.

❙❙SOLUTION
This problem is often resolved by operators.
The human operating costs and ad-hoc response are problematic and affect
operating rates and yields.

Solve this problem by introducing KEYENCE’s SJ-F Series

static eliminator and reduce costs! Electrostatic charge (kV)
1
0.8
Highest static elimination speed in its class SJ-F2500
0.6 Conventional static eliminators
The SJ-F Series achieves the best ion production per electrode in
0.4
its class by combining the pulse AC method and our Ion Current
0.2
Control technology. The integration of a high-power fan and louver
structure also achieves the fastest wide-area static elimination in its 0

class. −0.2
0 0.5 1 1.5 2
Static elimination time (s)

AF T E R
Cost-effectiveness of installing the SJ Series
Sample:
Cost per worker: Per hour: Production lines:
$18/h 3 min. 5 lines

Annual cost (8 hours per day × 250 days) would be: $9000/year
* As of July 2018

SJ Series feature 1 — Easy probe cleaning!

The SJ Series is also easy to maintain. Not only is it easy to clean, but replacement electrode probes are optionally available for all of
the bar type, spot type, and blower type. Anyone can easily replace the electrode probe without using any special tools.

3
 Case 3
Eliminating static before post-forming painting

BEFORE

❙❙PROBLEM
After bumpers are formed, in the course of being conveyed to the painting
process, they may pick up a charge and attract foreign particles.
Clinging foreign particles can cost additional man-hours for wiping and in the
worst case result in having to dispose of the bumper.
❙❙SOLUTION
(1) Humidity control ’ Causes condensation on equipment and/or products
(2) Conventional static eliminators ’ Insufficient static elimination

Solve this problem by introducing KEYENCE’s SJ Series

static eliminator and reduce costs!

I.C.C. ensures stable static elimination.

Easy maintainability to keep the probe clean

AF T E R
Cost-effectiveness of installing the SJ Series

Sample:
Bumper disposal cost: Personnel cost per line: Annual cost would be:
$455/month $182/month $7644/year
* As of July 2018

Sheath air guide structure reduces maintenance downtime

[5× less maintenance than conventional models]
The supplied clean, dry air is conveyed through a sheath air guide structure to generate a laminar flow, which encloses the probe in a
sheath and provides an excellent protective effect. This structure can significantly reduce the adhesion of foreign particles to the
electrode probe and maximise the efficiency of static elimination.

Conventional models Sheath air guide structure

Cross-section of electrode probe cap Cross-section of electrode probe cap

Air supply

Air supply
(24-hour operation for (24-hour operation for
2.5 months) 2.5 months)

4
 Case 4
Blowing off dust in the assembly process

BEFORE

❙❙PROBLEM
When cutting resin parts such as instrument panels, chips can stick to the parts.
These chips can cause scratches.
❙❙SOLUTION
Air blowers are commonly used.
’ Chips blown off reattach to the parts, preventing full removal of foreign particles.
Dust removal in assembly process

Solve this problem by introducing KEYENCE’s SJ-M Series

static eliminator and reduce costs!

Blow away foreign particles with ionised air to prevent re-attachment!

The compact size makes it an easy addition to an existing environment.

AF T E R
Cost-effectiveness of installing the SJ Series

Sample:

Disposal cost from

adhesion of foreign particles 12 months $5460/year Air Cost
$455/month
* As of July 2018

Before using SJ After using SJ

Shortened work time 60 seconds 45 seconds

What makes static more or less likely to develop?

Static electricity occurs when materials come into contact and rub against each other.
Depending on the individual properties of the material, this generates positive or negative charges. The following table shows a
triboelectric series chart that summarises the positive and negative charges of materials.

Positive (+) Negative (−)

Ai

G n

Fu

Le

Si

Al

C iniu

St n

Am

N r

Ti l/C

G ilve er

Su Pla

Ac ur m

Po te

C ste

U loid

Vi ane

Si

Te n
um

yl

ot

ic

el

re
la

n/

ol
lk

ny

lic
oo
r

um

ee

flo
r

ad

lp tin

ly
et
on

be

ke

lu r
ss

to m

d/

th
S pp

o
e

l
d
l

n
a

r
o

For example, friction between glass and cotton will produce a positive charge on the glass and a negative charge in the cotton. On the
other hand, rubbing cotton on Teflon will positively charge cotton and negatively charge Teflon. As in these examples, the same
material can be charged positively or negatively. The closer the materials are in the triboelectric series chart, the stronger the charge
they tend to generate.

5
 Case 5
Eliminating static before PCB coating

BEFORE

❙❙PROBLEM
If foreign particles are attached to PCBs when applying coating material,
poor coating can occur and result in serious complaints.
❙❙SOLUTION
Use a humidifier.
’ Can cause condensation and does not remove foreign particles
that have already adhered.

Solve this problem by introducing KEYENCE’s SJ-H Series

static eliminator and reduce costs!

Blow away foreign particles with ionised air to prevent re-attachment!

Yield rate can be improved.

AF T E R
Cost-effectiveness of installing the SJ Series

Sample:
Recall cost (transportation and
Disposal cost for defective lots
on-site service travel costs)
$4545/year $4545/month
* As of July 2018

Did you know that not only adhesion on probes, but also probe wear can reduce the
effectiveness of static elimination?
Deterioration of static elimination probes can be caused by particle adhesion or wear, which occur for different reasons, and therefore
they are dealt with through different maintenance procedures. Cleaning is recommended for adhesion on probes, while probe
replacement is recommended for wear. Both reduce the amount of ions generated and consequently cause deterioration in the
effectiveness of static electricity elimination, but the I.C.C. function works to prolong the anti-static effect. The ion level alarm will
activate when the static elimination effect drops below the critical level.

+ electrode – electrode

Wear

6
 Case 6
Preventing ESD damage to chip components

BEFORE

❙❙PROBLEM
ESD damage can occur during chip picking and produce defective products.
❙❙SOLUTION
Install a static eliminator.
’ Static eliminators lose their effectiveness over time.

Solve this problem by introducing KEYENCE’s SJ-M Series

static eliminator and reduce costs!

I.C.C. ensures stable static elimination.

Various sensor heads allow for selecting a solution for even the most
specific needs.

AF T E R
Cost-effectiveness of installing the SJ Series

Sample:
Disposal cost due to ESD damage
$909/month

Annual cost would be: $10908/year

* As of July 2018

What is ESD damage? The reason KEYENCE’s ionisers are

When a static electricity discharge hits an electronic preferred: I.C.C. function
component such as an IC, a large current temporarily
KEYENCE’s ionisers are equipped with a function that
passes through it, breaking the insulation layer and
automatically senses the state of charge on workpieces
destroying the circuit inside. For example, MOS
and provides feedback. Because the I.C.C. function
semiconductors lose their function with approximately
constantly supplies the optimal balance of ions, it does not
100 V of static electricity.
require any additional set-up during installation or
maintenance and also enables effective static elimination.

Standard operation

Humans feel
a sting from an
ESD at 3000 V!
When detected target has a positive charge

Gate oxide destruction

7
 KEYENCE’s Static Related Products

Sensing ionisers

Bar type SJ-H Series Blower type SJ-F2000 Series Spot type SJ-M Series

Optimal static elimination capability that Ultra-high-speed static elimination over A rich line-up of static eliminators with
enables performance in a wide variety a wide area with a high-precision ion 8 different head types to choose from.
of situations. balance of ±5 V over the entire area.

Electrostatic sensors
Industry-first simultaneous measurement of static electricity and humidity
Best-in-class high-precision/wide-range measurement

Hand-held type SK-H050 In-line type SK-050/1000

Laser pointer to identify Ultra-compact sensor head

the reference distance Supports a variety of open field networks
Equipped with a charge
monitor function

RS-232C BCD NEW TCP/IP NEW

EtherCAT® is registered trademark and patented technology, licensed by Beckhoff Automation GmbH, Germany.

SAFETY INFORMATION
Please visit: www.keyence.com Please read the instruction manual carefully in
order to safely operate any KEYENCE product.

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The information in this publication is based on KEYENCE’s internal research/evaluation at the time of release and is subject to change without notice. WW11-1037
Company and product names mentioned in this catalogue are either trademarks or registered trademarks of their respective companies.
Copyright © 2018 KEYENCE CORPORATION. All rights reserved. SJCostReduceExampleAutomotive-WW-TG-GB 1098-1 600R07