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CURRENT PRODUCTIONTOYOTA
PRODUCTIONTOYOTA
• Stamping produces 172 different panels.
• 2 Blanking lines.
• 3 - A class robot transfer presses (3500 ton ).
• 1 - A class transfer press (4600 ton).
• 2 - C class transfer presses (2300 ton).
• Produces 80,000 panels per day.
STAMPING SHOPTOYOTA
STAMPING SHOPTOYOTA
STAMPING SHOPTOYOTA
• Form the panel by drawing a sheet of material over a punch to produce the shape.
• Control the quality and finish of the panel.
STAMPING DIESTOYOTA
Die Punch
Cross sectionPlane viewLower Binder Ring
BlankLower PunchUpper Cavity
FORMING SIMULATIONTOYOTA
• Maintain the condition of dies established at SOP.
• Trouble shoot and correct quality and production issues.
• Make changes.
• Performs preventive maintenance.
DIE MAINTENANCETOYOTA
• ATOS II Triple Scan.
• Leica 840 tracker, T-scan and T-probe.
SCANNING EQUIPMENTTOYOTA
• SNK RB4NS Machining Center.
MACHINING TOYOTA
• No CAD data for machining.
• CAD data is not correct.
• Scan data is used for…
– Repairs
– Engineering changes
– Trouble shooting
DIE SCANNNINGTOYOTA
TROUBLE SHOOTINGTOYOTA
Compare Left and Right Sides
REPAIRSTOYOTA
REPAIRSTOYOTA
REPAIRSTOYOTA
Weld Repair Weld Repair Machining
ENGINEERING CHANGETOYOTA
Before After
ENGINEERING CHANGETOYOTA
Panel with change (CAD)
TOYOTA ENGINEERING CHANGE
Scan of the Punch (Mesh)
TOYOTA ENGINEERING CHANGE
TOYOTA ENGINEERING CHANGE
Panel with change (CAD)
TOYOTA ENGINEERING CHANGE
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TOYOTA ENGINEERING CHANGE
TOYOTA ENGINEERING CHANGE
TOYOTA ENGINEERING CHANGE
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Scan of the Punch (Mesh)
TOYOTA ENGINEERING CHANGE
Panel with change (CAD)
Panel CAD compared to punch scan
TOYOTA ENGINEERING CHANGE
Panel CAD compared to punch scan
Weld & Machine affected area
TOYOTA ENGINEERING CHANGE
TOYOTA ENGINEERING CHANGE
Panel with change (CAD)
TOYOTA ENGINEERING CHANGE
Destination Object Punch (Mesh)
Source ModelPanel (CAD)
TOYOTA ENGINEERING CHANGE
Destination Object Punch (Mesh)
Source ModelPanel (CAD)
TOYOTA ENGINEERING CHANGE
Destination Object Punch (Mesh)
Source ModelPanel (CAD)
TOYOTA ENGINEERING CHANGE
Destination Object Punch (Mesh)
Source ModelPanel (CAD)
TOYOTA ENGINEERING CHANGE
Destination Object Punch (Mesh)
Source ModelPanel (CAD)
TOYOTA ENGINEERING CHANGE
TOYOTA ENGINEERING CHANGE
Panel with change (CAD) Merged into Punch Scan (Mesh)
Punch with CAD data (morphed)compared to punch (previous)
Weld & Machine affected area
TOYOTA ENGINEERING CHANGE
• Panel CAD data does not match the die surface 100%
• Use the die scan to machine back if a die is damaged.
• Make changes to the scan if panel changes are needed.
• Die scan is updated to the current shape in case of die damage later.
TOYOTA SUMMARY
Questions
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