KOYO METALTEC CO.,LTD.

Product Info

Bearings

Bearings are used in many fields for a wide variety of purposes. For example, more than 100 bearings, both small and large, are normally used in an automobile. Making full use of its abundant experience and state-of-the-art technology in the field of bearing manufacture, we offer high-precision, high-quality products ranging from hot forgings to cold rolling products and turning products, all through an integrated system.
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Tapered roller bearings

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Ball bearings

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Hub unit bearings

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Other automotive parts

Equipment

In addition to a hot pressing rolling line, we have 3,000-ton, 2,500-ton, and 1,600-ton transfer presses that are capable of processing hot forgings for medium-size bearings all on one line. We have established a production system that integrates everything from billet cutting, to heating, pressing, annealing, and shot blasting, then turning, rolling, inspection, and shipping, and then delivery.
1,600-ton transfer line
Large press line with multiple stations
Molding can be performed all in one go, enabling fast production.
2,500-ton transfer line
This is a line that can also flexibly accommodate a large variety of types and forms of products.
3,000-ton transfer line
This is a combined line that is capable of making shared use of 1,600-ton and 2,500-ton molds.
Vertical press rolling line (R150W)
A high material yield rate is achieved by making workpieces that are closer in form to the final product, by pressing hot billets, rotating the forged blanks after the pressing, and then performing accurate roll molding.
Horizontal press rolling line (R320)
Molds are used in common in order to produce products with a large variety of types or in small lots. This line shortens the lead time from receiving the order to delivery as far as possible.
Continuous annealing furnace
Annealing is performed in order to stabilize the metallic structure of the bearing steel and increase the efficiency of the turning process.
Hub turning quenching line
This is an outer ring and inner shaft line that directly connects the lathe turning and quenching/tempering processes.
CR line
This is a ring processing line in which blanks are rolled without being heated, that is, while they are still cold (at room temperature).
NC lathe line
Once it has been programmed in, the same work will be repeated, so this line offers stable quality and work time. High-precision, special-form parts can be processed.
Cold rolling turning line
This is a ball bearing inner ring and outer ring line that achieves a high material yield rate and high quality, by reducing the turning process through cold rolling.

Steering

“Run, turn, and stop.” These are the basic functions of a car. Among these, the “turn” functions are handled by steering devices. Compared with conventional hydraulic power steering, electric power steering and electric pump hydraulic power steering are outstanding in terms of fuel consumption and compactness, and provide safe, comfortable operation and running performance.
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Input shafts

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Lower shafts

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Power boxes

 

Equipment

Our company produces a variety of high-quality parts at high efficiency, for electric power steering, power steering, and manual steering. This line has many types of equipment, such as an NC lathe, machining, boring, and threading grinding machines, and machines we have developed in-house, to suit the forms and quality of the products.
Input shaft line
This is an integrated forging and turning line that takes full advantage of the company’s integrated approach to these two areas.
It is a fully automated, high-efficiency line that links material supply, processing, and inspection through the use of automatic transfer devices.
Lower shaft line
This is a fully automated, high-efficiency line that links material supply, an NC lathe, a serration rolling machine, thread rolling, a grinding machine, an inspection machine, and more, all through the use of automatic transfer devices.
Power box line
In this line, we have combined highly-efficient, dedicated machines that we have developed in-house to suit the product conditions. The finished products are suitable for direct assembly and shipping without any post-processing, and guarantee a high level of quality.

Mold design/manufacture

Our company conducts everything from mold design to manufacture in an integrated way, regardless of whether it is for special products or bearings with unusual shapes.
We spare no effort in order to create high-quality molds, for example using 3D CAD for the mold design, creating processing programs using CAM for the mold fabrication, and securing an accuracy of 1/100 mm or less through processing by means of high-performance machine tools. All the finished molds are stored in an automated warehouse, and we have established a quick line setup system controlled by computer.

Equipment

Machining center
For metallic fabrication, we have introduced a machining center for metal processing, in order to meet the need to achieve high precision and high speed.
Turning center
We have introduced a turning center that achieves highly efficient turning processing, and use it to create high-precision molds.

Quality control

“Supply even better products in a timely manner.” This is the basic principle of Japanese-style manufacturing (“monozukuri”).
With a view toward the eternal theme of “absolute quality,”in terms of the hard-side aspects, we have introduced automatic inspection machines for performing accurate dimensional control with greater efficiency, and in terms of the soft-side aspects, we have raised the awareness, independence, and creativity of our employees through “improvement proposal system” and “QC circle activities.” We also deploy activities to build in stable quality in all processes, and have established our own quality control system. This kind of outstanding product manufacturing is supported by a high level of awareness on the part of our employees.

Equipment

3D measuring instrument
Geometrical characteristics that are difficult to measure by the usual means, such as complex shapes, precision dimensional measurements, and concentricity positional tolerance, can be measured to an accuracy of 1/10,000 mm.
Micro-Vickers hardness tester
This measures the surface hardness and the depth of hardening layers on quenching sections of hub unit after induction quenching. The measurement results can be processed immediately and printed out as an inspection sheet.
Automatic visual inspection machine
Using lasers and camera images, this equipment automatically inspects for flaws in the outer and inner ring race ways of bearings, and for faults in the product stamps.