Proposal & Building of Production Systems

KATAKEN SEIKO CO., LTD. > Proposal & Building of Production Systems

Cold Forging Production System

In the production of products made of thick workpieces, the strongest load is applied to the press machine (die) during the material crushing process. In conventional manufacturing of thick products, the center of load of the die deviates from the center of load of the press machine, meaning that the press machine is always subjected to an unbalanced load. As a result, the slide of the press machine tilts, leading to damage die parts.

Our original manufacturing system for thick products uses different press machines for the crushing process and later cutting/bending/drawing processes—the crushing process, to which the strongest load is applied to press machines or dies, is performed on a casting press machine, and the later processes are performed on a general-purpose press machine. This production system ensures that the center of load on the die and that of casting press machine are almost identical during the crushing process, preventing an excessive unbalanced load on the press machine and damage to die parts. Because a large load isn’t needed for processes with a general-purpose press machine using dies, the machine isn’t subjected to an excessive unbalanced load. This prevents damage to die parts, and ultimately ensures a stable production of thick products.

Cold Forging Production System for Stable Manufacturing of Thick Products

Automotive Parts (PINION) Production System

Stampers, which manufacture pressed products, are in demand for manufacturing products with higher added value that are caulked with multiple materials and parts in a press die, rather than products that are manufactured solely by pressing. In order to achieve the production of composite pressed products, we have developed supply devices that bring multiple materials and parts together into a die. In addition, we have proposed and built production systems that combine said supply devices with die technology for caulking materials and parts and a broad range of transfer devices.

The following is an example of a production system for automotive parts (Pinion). The production system brings an initial pressed product into a transfer press die as a workpiece by an initial parts supply device, and transfers it to the next process with our high-speed servo transfer system. The workpiece then receives necessary pressing, is caulked with another initial pressed product fed into the process at the middle of the transfer die by a secondary parts supply device, and is further pressed. After these steps, a pinion part is complete. Finished parts are discharged into a storage box outside the die. The quantity of the discharged parts is counted and empty storage boxes are automatically set, making continuous production possible.

Production System for Continuous Production of Automotive Parts (PINION)

Pressed Products: Wide Range of Storage Systems

It takes many hands and a lot of time to arrange, stack, and store pressed products in trays. In order to save time for such storage, we propose and build peripheral devices for press machines, such as systems for automatically arranging and storing pressed products in trays and systems for stacking and storing products.

Production System for Continuous Production of Automotive Parts (PINION)

Semiconductor Manufacturing Equipment: FLEX T/C & T/F System

The Flex T/C (tie bar cut) & T/F (trim & foam) system is the equipment used in the final stage of semiconductor production.

Semiconductor manufacturing consists of the chip mounting process, where chips cut off from silicon wafers are mounted on lead frames manufactured with pressing or etching; the wire bonding process, where aluminum electrodes formed on the chips and inner leads of lead frames that fix semiconductor chips in place are connected with thin metal wires; and the molding process, where resin for protecting the chips and wires are packaged with molds. This is followed by the tie bar cutting process, where tie bars (or dam bars) are cut with press dies using the T/C & T/F system. These act as a dam for preventing resin used in the molding process from leaking to outer leads and hanging points (pinch cut points) at the four corners of a package. Then there’s the trimming/forming process, where packaged chips are cut off from lead frames and outer leads are bent using press dies (trimming & forming). Complete IC packages are automatically stored in trays and tubes. It is possible to add the laser marking process, where a laser marker is used on the IC packages to etch information such as customer trademarks and product names.

Medical Parts (PET Laminate) Die-Cutting System

This system is for die-cutting medical parts (PET laminate), which we started manufacturing after receiving requests from customers saying that they wanted to produce medical products by die-cutting non-metal multiple sheet PET materials laminated with adhesive.

The system consists of three processes—the first being for die-cutting five-layer PET materials, the second for putting laminators on the PET materials, and the third for die-cutting seven-layer PET materials and laminators.

PET material is loaded into a die using a supply device, pressed sequentially in accordance with the above processes, and made into medical products.

All of the components other than press machines are manufactured in house.