Major Components

Unit-field Stamping/Bonding

History

Year
Stamping
Bonding
Processing technology
Processing technology
Facilities
1951
Super-large 2,000-ton press
 
 
1953
 
 
Automatic-clamping jig
1955
 
Submerged arc welding
Automatic arc welder
1958
Thick plate blanking press
 
 
1961
 
CO2 arc welding
 
1963
Press line with 3 super-large presses
 
 
1965
1,500-ton transfer press
Friction welding
 
1967
 
 
Transfer automatic welding line
1969
 
Electron beam welding
 
1974
 
TIG arc welding
Arc welding robots
1977
 
Plasma arc welding
 
1982
 
Pulse-metal active gas (MAG) arc welding
 
1985
General purpose high-speed robot loaders
 
NC jig
1986
Variable-pitch transfer press
Laser beam welding
Weld-line tracking robot
1987
Anti-corrosion performance of suspension member improved (10-5 measure)
Galvanneal steel sheets (for suspension members)
 
Rotary arc welding (for exhaust front pipes)
1988
 
Fixed-phase friction pressure welding (for propeller shaft ends)
Magnetic suction device (for spatter removal)
1989
Box-shaped-section suspension arm
100Kgf-class high-tensile steel (for bumper reinforcement)
Multi-station laser welding system (for A/T components)
Flange end face coining technology
Double-cross-type rear suspension members
North American catalytic converter case (at TABC)
100Kgf-class high-tensile steel bumper
1990
Production expanded globally (for suspension members, fuel tanks and bumper reinforcements)
 
 
1991
120Kgf-class high-tensile steel bumper reinforcement
Ring projection welding (replacing fuel tank soldering process)
 
Double-cross-type front suspension members
Double-cross-type front suspension member commences
1992
High-tensile steel lower arm
Laser welding (for oil pan)
Generalized arc welding line (featuring pallet change method)
Jig-less cooperative robot (for arm welding)
1993
Pipe rear suspension member
 
Off-line CAE for arc welding equipment (ROBCAD)
FEM forming analysis
1994
 
Cu-P anti-corrosion steel pipe (for rear suspension members)
YAG laser (for cutting and piercing suspension members)
Twin-arc cooperative robots (for arm welding)
1995
Pipe hydraulic forming (for torsion beams)
Sheet-metal-constructed exhaust manifold
Maintenance support system POPINS (for frames)
O-shaped section, lightweight, single-piece suspension arm
Arc voltage sensing-type seam trace
Optimized weld posture by rolling method (for frames)
1996
Segment-type truck frames
 
Periodical overhaul operation system for arc robot
Sequential forming of bumper reinforcements
1997
HV motor core line
Aluminum metal inert gas (MIG) arc welding (for intake manifolds)
Cassette-type electron beam welding (EBW) (vacuuming time reduction for A/T components)
U-O bending technology (for trailing arms)
Pipe material hydro-forming
1998
P, Bj socket-unified lower arm
Pipe spinning process (for catalytic converter cases)
Robot adoption for circumference seam welding (for fuel tanks)
Spring seat unified trailing arm
1999
Single-piece suspension arm
 
Digital factory (for considering facilities of Toyota Motor Manufacturing France [TMMF])
Hydro-form suspension member
DME for maintenance training
Robot seam (for Toyota Motor Manufacturing Indiana (TMMI) fuel tanks)
2000
Double acting press forming (for CVTs, pistons and cylinders)
Dual closed coupled converter-type exhaust manifold (at Shimoyama Plant)
Cell-type welding equipment (for arms)
Super-high- tensile steel lower arm
2001
Global production (of arms and torsion beams)
Exhaust manifold SE center activity
Catalytic converter plant in South Africa (for converter cases for Europe)
2002
Multi-roller gear shape forming technology (for A/T clutch hubs)
Eccentric and off-angle spinning forming (for catalytic converter cases)
 
Banjo single-piece forming technology
Laser welding (bonding of plastic intake manifold)
3-segment super-high tensile steel frame (780MPa)
2003
 
 
Improved generalized ratio of chassis arc welding equipment (adoption of parent-child-grandchild jigs)
Push/pull smoke exhaust (arc welding)
2004
Pipe-made front lower arm
Seam trace technology by reflected-electron method and wide-angle double inclination welding method for EBW (for A/T components)
Special arc robot (single line conduit, curved torch with forced feeding)
2005
Measuring equipment introduced, making possible data gathering and visualization of quality
Tube making for arms and torsion beams (in-house plasma welding)
EBW line installed at TMMWV
2006
A/T carrier forming line
Activity for absolute best-quality arc welding
Laser 3D cutting (for torsion beam ends)
High-precision and pipe-made torsion beam
Chassis assembly's accuracy improved (accuracy of all rear suspension members measured)
2007
 
 
Arc welding condition collection introduced
2008
Decision to promote global chassis materials
Long-life contact tip for arc welding
 
2009
Development of bonding materials for thick sheets commenced
 
Automatic-inspection device for weld bead appearance introduced (for front suspension member)
2011
In-house production of small HV motor
 
General-purpose medium-volume line (for intermediate beam) developed and production commenced
In-house production of aluminum cooler for small HV motor

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