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我們採用中央熔爐,使用單一材料,確保因兩種以上不同材質而誤混。由熔爐集中溶解鋁料,相較於單一熔爐來得有效率,節省能源。此時鋁湯溫度最高為攝氏720 °C
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Mold maintenance
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Mold maintenance
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Mold maintenance
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Mold maintenance
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製程特色
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鋁料比例把關
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鋁料比例把關
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Air leakage testing
in the Camlock production line
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Air leakage testing
in the Camlock production line
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人工研磨
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SOP (Standard
Operating Procedure) Document
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Utilizing both manual
grinding and
automatically
grinding to effectively
eliminate burrs.
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Quality Control Management during the die casting process
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Precision
measurement room
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The measurement accuracy
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Zero-point clamping system for CNC machining
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Die-casting machine (Step 5)
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Automatically Grinding
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Manual Grinding
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Sample Room
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Second CNC Plant
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X-ray inspection machine
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2H Patrol Inspection Rack
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Mould Management
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Our R&D team optimizes mold designs
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Air Leak Tester
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The fourth axes
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Air leakage testing
in gas-product line
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Aluminum ingot (Step 1)
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Automatic Carrier(Step 3)
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Automatic cycle production
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Control of Aluminum Material Ratios
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Control of Indoor Temperature
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Dedicated production line
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Die casting plant.
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Electronic holding furnace(Step 4)
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Gas Compression Steel Cylinder
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In-house CNC Manufacturing Facility
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Mould Surface temperature detection
with an IIoT system
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Primary Melting Furnace(Step 2)
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Quality Inspection
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Removing the scraps (Step 6.)
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SGS Regular
Instrument Calibration Sticker
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SOP Board
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Shot Blasting
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Step 3. Soaking in 80°C water to prevent oxidation, and thereby eliminate water residue
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Step 4. Full Visual Inspection
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Step 5. Assembly process
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Surface Treatment
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Surface Treatment
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Sustainable operations
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The final sample,
and the sample storage space
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Vacuum machine
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step 6. Packaging for export purposes
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SIP Board
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搭配人工研磨除毛邊
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製程特色
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24小時內的生產過程履歷追朔
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Step 1:
鑽孔
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Step 2 :
增壓氣密測試
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X光檢驗機器
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「零點夾持」
快速換線系統
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三次元儀器
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人工研磨
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人工研磨
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人工研磨
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固定品保人員把關
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壓鑄機
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模具開發設計能力
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空氣洩漏測試器
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第二CNC廠區
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第四軸
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精密量測室
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自動研磨
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雙扣式快速接頭(Camlock)
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The final sample
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Die-casting machine (Step 5)
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Precision measurement room
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Quality Control Management
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The measurement accuracy
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Zero-point clamping
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Utilizing both manual grinding
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X-ray inspection machine
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中央熔爐
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以自動循環生產
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品質檢驗
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壓鑄廠區
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專線生產
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工業物連網監控
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投資願景
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撥料SOP
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撥料作業
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末件樣品庫
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模具開發設計能力
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滾式噴沙機
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瓦斯氣密測試
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真空機
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自建的CNC廠
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表面處理
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表面處理
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配湯機
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鋁料比例把關
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鋁錠
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電子保溫爐
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模具儲位架
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樣品室
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研磨沙袋機
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SGS定期儀器校正貼紙
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Step 3 :
防止氧化流程
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Step 4 :
外觀全撿
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Step 5 :
為客戶組裝雙扣懸臂
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Step 6 :
出口打包
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冷氣機
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氣體壓縮鋼瓶
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Air leakage testing in gas-product line
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Control of Indoor Temperature
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Dedicated production line
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Gas Compression Steel Cylinder
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In-house CNC Manufacturing Facility
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SGS Regular Instrument
Calibration Sticker
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Surface Treatment
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Surface Treatment
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Surface Treatment
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Aluminum ingot (Step 1)
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Automatic Carrier(Step 3)
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Automatic cycle production
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Control of Aluminum Material Ratios
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Die casting plant.
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Electronic holding furnace(Step 4)
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Mould Surface temperature detection
with an IIoT system
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Our R&D team optimizes mold designs
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Primary Melting Furnace(Step 2)
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Removing the scraps (Step 6.)
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SOP Board
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Sustainable operations
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Vacuum machine
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2H Patrol
Inspection Rack
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Air Leak Tester
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Automatically Grinding
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Manual Grinding
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Manual Grinding
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Mould Management
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SIP Board
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Sample Room
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Second CNC Plant
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Mold maintenance
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The fourth axes
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Step 3. Soaking in
80°C water to prevent oxidation,
and thereby eliminate water residue
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Step 4. Full Visual Inspection
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Step 5. Assembly process
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step 6. Packaging for export purposes
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Step 1.
Drilling holes to make a cam pin for a self-locking function
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Step 2.
Testing for air leakage by ensuring a pressure
difference of
nearly 100 PSI
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SGS定期儀器校正貼紙
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Step 3 :
防止氧化流程
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Step 4 :
外觀全撿
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Step 5 :
為客戶組裝雙扣懸臂
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Step 6 :
出口打包
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冷氣機
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品質檢驗
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專線生產
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氣體壓縮鋼瓶
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瓦斯氣密測試
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自建的CNC廠
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表面處理
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表面處理
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表面處理
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中央熔爐
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以自動循環生產
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壓鑄廠區
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工業物連網監控
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投資願景
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撥料SOP
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撥料作業
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末件樣品庫
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模具開發設計能力
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真空機
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配湯機
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鋁料比例把關
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鋁錠
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電子保溫爐
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24小時內的生產過程履歷追朔
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Step 1:
鑽孔
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Step 2:
增壓氣密測試
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「零點夾持」
快速換線系統
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三次元儀器
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人工研磨
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人工研磨
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人工研磨
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固定品保人員把關
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壓鑄機
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模具儲位架
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模具開發設計能力
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空氣洩漏測試器
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第二CNC廠區
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精密量測室
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自動研磨
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雙扣式快速接頭
(Camlock)
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製程特色
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X光檢驗機器
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搭配人工研磨
除毛邊
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第四軸
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研磨沙袋機
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Quality Inspection
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我們內建的模具廠,可在量產時提供模具保養與修復的即時回饋,負責調度模具,以及模具量產後的保養
在壓鑄量產過程時,我們管理及保養模具,包括內保養及清洗,以確保量產時隨時保持良好狀態。
完工下模的維護過程為 :
1.拆解模具
2.清洗模具
3.模仁修善及保養
4.模具入儲位
完工後的模具保養可以確保您的產品:不會因模穴積碳或缺陷影響,以確保下次生產的品質
HTMLText_96563BD5_3F93_02B3_41CE_5402105A2B54.html =
•Camlock 為世界通用的快速接頭規格


•琪泰穩定供應了世界名石油公司OPW長達十年,並起已經交貨200萬pcs


•我們的快速接頭以高度管理卓稱,具有高度穩定的品質,在製造中確保砂孔的最小化,並且再出貨前執行氣密全撿,品質有保證


•我們的產品能保證出貨後符合客戶需求


•我們有高度產品開發能力,我們曾經在2-3年內為此客戶開了90個產品


•此產品已經量產十年,出貨過150w pcs,沒有在客戶端出現過漏氣的不良品


HTMLText_8A12B400_BAC8_3447_41E3_AED71258E2A0.html =
•Camlock 為世界通用的快速接頭規格


•琪泰穩定供應了世界名石油公司OPW長達十年,並起已經交貨200萬pcs


•我們的快速接頭以高度管理卓稱,具有高度穩定的品質,在製造中確保砂孔的最小化,並且再出貨前執行氣密全撿,品質有保證


•我們的產品能保證出貨後符合客戶需求


•我們有高度產品開發能力,我們曾經在2-3年內為此客戶開了90個產品


•此產品已經量產十年,出貨過150w pcs,沒有在客戶端出現過漏氣的不良品


HTMLText_8FCC47D2_3F97_02B6_41C2_43B5CB81068F.html =


HTMLText_D26D1FDD_8B5A_E517_41C8_95029BE38F13.html =
研磨目的
•砂布研磨目的是處理鑄品的分模線、入料口、溢料口,達到修飾鑄品外觀的缺陷,達到整體表面美化的需求。


自建研磨廠
•其加工量非常大,因此我們在2005年投資研磨廠,能夠自我管理研磨製程,以及省去運輸往來外部廠商的運輸成本,達到品質穩定並且兼具競爭力。
•廠內設立研磨廠的另一個目的,是可以讓製造排程好調度,減少委外廠商影響,達到穩定的交期。
•此區配置人力為9人。
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•CNC自建第四軸,能夠在不更換治具狀況下,完成X,Y,Z面的加工,提供更佳生產效率與與品質穩定性。
HTMLText_BFF5CD6F_9B0A_2CCA_41E1_3CD5D14E05AB.html =
•Camlock為世界通用的快速接頭規格。


•琪泰穩定供應了世界名石油公司OPW長達十年,並起已經交貨200萬pcs。


•我們的快速接頭以高度管理卓稱,具有高度穩定的品質,在製造中確保砂孔的最小化,並且再出貨前執行氣密全撿,品質有保證。


•我們的產品能保證出貨後符合客戶需求。


•我們有高度產品開發能力,我們曾經在2-3年內為此客戶開了90個產品。


•此產品已經量產十年,出貨過150w pcs,沒有在客戶端出現過漏氣的不良品。
HTMLText_B8B43E3A_9B36_2C4A_41BA_CFE8E72B3094.html =
•Cosmo LS-R700 儀器是用來檢查產品氣密性的。差壓式空氣洩漏測試器壓力最高可達到250 PSI。



HTMLText_B9BD97C3_9B3A_1C39_41CD_8A54731E2B59.html =
•位置設立在CNC與品保辦公室的中間,因此產品在加工完之後只需要在有限空間內移動。



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•使用將近100PSI的壓差去測試漏氣。
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•在毛邊處理上,我們同時搭配自動研磨、與人工研磨,兼顧品質穩定、效率、與彈性
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•壓鑄件因為以流體做高壓填充的方法,沙孔成為鑄件勢必會有的問題。好在配合X光機器的使用,可以讓我們檢驗外表看不出來的沙孔。
HTMLText_841552B7_9B16_3459_41C3_EA7E07B631B8.html =
•壓鑄廠配置固定的品保人員把關品質,日夜輪班各兩人,專門負責做鑄品尺寸及外觀的檢驗,他們遵從RD團隊設計的SIP標準檢驗,確保在製造過程中的量產鑄品,是穩定的符合客戶規格。
HTMLText_86C39A7C_9B3A_14CE_41D5_250BA77F6C05.html =
•壓鑄機可以執行金屬鑄造功能,其特點是將熔融金屬灌入模具,高壓下壓入模具成型。


•廠內壓鑄機為150~420頓數機台,能造出市場上大部分的規格鑄件。


•配合我們緊密合作的供應鍊,總共的產能有 50 台壓鑄機。


•琪泰可製造最大達1200頓數的鑄件。
HTMLText_B9A23605_9B36_1C39_41D7_B8AF9B20F8A5.html =
•廠內總計總共6台CNC,並且進幾年有添購 CNC設備的中長期計畫。
HTMLText_8E2365A6_9B0F_FC7B_419B_ACC23FEF4EA9.html =
•我們內建的模具廠,可在量產時提供模具保養與修復的即時回饋,負責調度模具,以及模具量產後的保養


•在壓鑄量產過程時,我們管理及保養模具,包括內保養及清洗,以確保量產時隨時保持良好狀態。


•完工下模的維護過程為:
1.拆解模具
2.清洗模具
3.模仁修善及保養
4.模具入儲位


•完工後的模具保養可以確保您的產品:不會因模穴積碳或缺陷影響,以確保下次生產的品質
HTMLText_11860F09_7851_AAFB_41DE_E53F935319EC.html =
•我們廠內的模具儲位架,可以容納1000付以上模具。


•配合管理系統之軟體,搭配管理系統的模具儲位及標籤的建置,因此我們有能力迅速、精準的調度模具。
HTMLText_86DB77FC_9B36_1BCE_41CA_C1A2B5673213.html =
•我們自己的研發團隊,具備修改模具設計的能力,因此可提供優化模具設計、鑄品優化設計、及即時維修模具的能力。


•該團隊在製定模具設計方面,擁有豐富的的技術經驗,包括 :
1. 模具中的入料系統設計
2. 模具預留加工量的設計,以避免鑄件因加工而出現的縮孔問題
HTMLText_B93C4E02_9B3A_6C3A_41D2_BFBE7F9B3D45.html =
•測量精度,能達到+-2 um



HTMLText_B9B68D51_9B0A_6CD6_41D9_4A877FCB05D9.html =
•琪泰廠內的CNC機台,皆設有零點夾持系統,達到快速換線,發揮單機多工、智慧生產系統的秘密武器。


•每當換線時,治具的校正時間最為花時間,而在導入此系統後,可以省去零點校正時間,原本需要4小時的換線時間,在琪泰廠內只需要30分鐘即可完成換線,且定位精確度達5u。因此琪泰的產線,對於多樣性的產品線也能應變到位。
HTMLText_8489F84E_9B0E_14CB_41CD_0571489569EC.html =
•經由我們的品質管控,我們將樣品集中管理,讓現場能參考SOP與樣品,確保量產的穩定性。
HTMLText_845C4C99_9B16_EC49_41C7_3BFB349EF798.html =
•鑄件巡檢人員會保存每2小時經檢驗完成的鑄品,將其放置檢驗儲架待審,並由品管員做覆驗確認,用來做為不良品生產時的追朔。主要用來追朔24小時內的生產過程履歷。若品保人員發現巡檢樣品有問題,可以往前回朔量產異常的產品。


•因此在量產過程中,透過量產的首件和樣品比對,有24小時內每時段的巡檢產品可以追朔,以確保不良品流出。


•琪泰在這邊長期達成落實管理,讓第一關的壓鑄能確保都是輸出良品。


•存放
1. 標準樣品:是首批小量產試產時,客戶端承認的樣品,當回朔到首件還是有問題時,可以跟標準樣品比對
2. 首件樣品:使用該模具生產的此批鑄件中,第一件良品
3. 巡迴檢驗樣品:每兩小時蒐集一個樣品,用來往回追朔不良品樣品
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優化工作環境
•在2019年,我們引進Yaskawa 安川六軸機械手臂,並且整合研磨週邊設備,將部份人工研磨改由機械手臂完成,減少人員暴露在惡劣的粉塵環境下工作。


車用等級六軸機械手臂
•機械手臂搭配進階的六軸力感測器,使手臂能模仿人手的動作,做到真正的自動化研磨。可以克服直線、平面、弧度、同心度、厚度之精密要求。
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研磨目的
•砂布研磨目的是處理鑄品的分模線、入料口、溢料口,達到修飾鑄品外觀的缺陷,達到整體表面美化的需求。


自建研磨廠
•其加工量非常大,因此我們在2005年投資研磨廠,能夠自我管理研磨製程,以及省去運輸往來外部廠商的運輸成本,達到品質穩定並且兼具競爭力


•廠內設立研磨廠的另一個目的,是可以讓製造排程好調度,減少委外廠商影響,達到穩定的交期


•此區配置人力為9人
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我們採用中央熔爐,使用單一材料,確保因兩種以上不同材質而誤混。由熔爐集中溶解鋁料,相較於單一熔爐來得有效率,節省能源。此時鋁湯溫度最高為攝氏720 °C。
HTMLText_BF73E402_9B36_FC3A_41E2_F84DCFA2DC43.html =
•對於瓦斯類有氣密需求的產品,我們使用壓差式量測,進行全撿,確保出貨的零件符合客戶需求。
HTMLText_BB2E10A3_9B1A_F47A_41C6_6BBDFAF153A7.html =
•廠內7台壓鑄機所生產的鑄品,經由輸送帶運往此區域集中處理,方便落實管理與節省人力成本。


•為了讓鑄件的邊料能整模成型,內有設計流道、澆注口和益料池,需要去除。鑄件經由壓鑄機生產後,會由輸送帶運送到集中撥料台,以人工去除,或是以沖壓來自動去除。
HTMLText_8428FC61_9B0E_2CF9_41D5_50F1D7B0CFE1.html =
•廠內維持使用7成原料鋁錠,與3成的回收二次鋁料 (鋁錠/回收料之比例 7:3)。
HTMLText_B80F8BC4_9B0E_743E_41E2_D2BCE7DCB527.html =
•廠內自建CNC廠,其中CNC所使用的加工的程式、治具都由琪泰自行設計/製作,因此若在量產發現不良,debug可以很迅速完成。


•我們能管理自建的CNC廠,因此也將管理經驗用在委外的供應商管理,以琪泰的合作供應鏈,全部有40台CNC銑床的產能,因此顯現委外管理的重要性。
HTMLText_818A7EEC_9B1A_2DCE_41B3_63C0EE3BA8DA.html =
•我們使用的鋁料為A383(又稱ADC12),是世界上通用度最廣的鋁料,因流動性極優特性適合壓鑄成型。


•鋁料品質上,我們的原料採用琪泰多年經驗中,品質最穩定的鋁料供應商。相較於便宜的鋁料供應商,他們的鋁料為我們提供穩定品質。
HTMLText_B97461E3_8955_3D33_41AD_C55C7EB9BD61.html =
•我們自己的研發團隊,具備修改模具設計的能力,因此可提供優化模具設計、鑄品優化設計、及即時維修模具的能力


•該團隊在製定模具設計方面,擁有豐富的的技術經驗,包括 :
1. 模具中的入料系統設計
2. 模具預留加工量的設計,以避免鑄件因加工而出現的縮孔問題
HTMLText_BA402E49_9B7A_2C36_41A0_FFC1D9FA1F8E.html =
•投資此先進的設備,代表我們有永續經營的決心,並近幾年有陸續引進其他的機械手臂。


•發展自動化生產,嚴防日後少子化帶來的人力資源不足的衝擊,穩定產能。


•因此,我們能成為您穩定且永久的供應商。
HTMLText_BF1AF106_9B0A_743A_41C4_DB6EF3DFD1D2.html =
•此實驗室恆溫20度,待測的物品,必須在此提前靜置16小時,以確保測試品是在標準環境與條件下測試。
HTMLText_84B2579E_9B1E_1C4A_41DD_F0DE98A3E8D0.html =
•此批生產的最後一件良品。是用來當下一次量產的首件標準(要在模具壽命條件相同時,達到上一次量產末件時的狀態),會留到下一次量產。
HTMLText_851BB067_9B36_14FA_41DF_5B2E2ED7735C.html =
•每一台壓鑄機配置一台真空機,穩定孔洞率降至最低。作用目的是在射出鋁料前,將模穴內空氣抽取達到接近真空,讓模穴空氣减低,確保鋁湯在壓鑄成型時不會將空氣捲入鑄品,以減少砂孔/氣孔產生。
HTMLText_BB38E8DF_9B1A_15CA_41C0_05B6A7931DCA.html =
•每個產品都有由RD開發人員製作的撥料SOP,確保所有的產品的處理方法,都是遵從開發人員設定的標準,達成量產的製品穩定,不會因為人事實地物所影響。
HTMLText_851A74DD_9B3A_1DCE_41C9_EBB8444F3944.html =
•溶解的鋁料以自動配湯機24小時配送,降低人員的工作風險。
HTMLText_851A69EC_9B3A_37CF_41CD_DE6E57609E31.html =
•溶解的鋁湯由電腦連線自動控制分配到各站的保溫爐備用,由機械手臂送到壓鑄機的注料管,再注入模具後壓鑄成型。每台壓鑄機機配置一台電子保溫爐,此功能是將溶解的鋁湯保持660±10 °C恆溫,讓鑄造因子穩定精準,以確保品質穩定。
HTMLText_BA3298CB_9B7A_15C9_41BC_FAB6A8A18A36.html =
•滾式噴砂操作簡單,不需特別吊掛鑄品,因此價格比吊式噴砂便宜70%。可以用在不會因有碰撞造成傷痕考量的鑄品。
HTMLText_B9D65536_9B0A_7C5B_41D3_903A47BB3BFF.html =
•琪泰為客戶提供專線生產服務,瓦斯碼表即是其中一個專線


•鑄品依序經過自動研磨→CNC加工→全撿測漏→精密量測→直接出貨,都在此區域一氣呵成,構成一個專線的生產。所有後製程皆在此區完成,因此製造成本具備競爭力,也兼具最穩定的品質。
HTMLText_BDFD1845_9B16_3439_416C_FB5BF125B174.html =
•產品在此產線打包之後,並直接堆疊碊板,運送到港口。
HTMLText_86A340A8_9B3E_3476_41C1_600C2FA6862D.html =
•而模具保養廠與壓鑄廠區相連接,模具很容易在兩個廠區之間轉移,大大的縮短了搬運時間,因此不須承擔在運送過程中損壞的風險,因此我們能兼具品質與成本。
HTMLText_868CF957_9B37_F4D9_41AB_1D0E0A0F7C2A.html =
•藉由工業物連網系統偵測,我們能確保模具表面溫度依不同需求維持確保在150~250 °C溫度,讓量產過程中力求以穩定。
HTMLText_B89FACE9_9B3E_EDF6_41C0_F033D9FFB1A5.html =
•遵照ISO 標準,每個儀器會定期執行校正
1. 內校:內部有受過執照訓練的人員,一年校正一次
2. 外校:外部專業人原來量測,貼有黃色貼紙
HTMLText_BFFB0CCF_9B0A_6DC9_41D2_B1FFC4A052ED.html =
•鋼瓶也必須保持20度的恆溫。
HTMLText_840C0477_9B0A_FCD9_41DF_558AF6491DDD.html =
•鑄件由機械手臂,經由輸送帶送往集中撥料區,處理完畢後,下腳料會經由輸送帶送往中央熔爐回溶。
HTMLText_BE3E22F1_9B0A_35D6_41E2_5B5AC6601496.html =
•零件經過氣密測試後,會使用高溫水(80度C)浸泡,再以噴槍去除零件上的水,防止水密測試的水氧化鋁鑄件。
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噴砂功能
•藉由噴砂破壞表面硬化層,可達到物件表面的一致性,並且可以幫助增加後續的表面處理(例如烤漆)的附著度。


•能直接達到美觀效果。


吊式噴砂
•吊式噴砂優點:能防止鑄件彼此撞傷。
HTMLText_BAB3231F_9B7A_F44A_41DF_FAACB29D8499.html =
噴砂珠
•噴砂珠使用 0.4 mm 不鏽鋼砂,不會像是鐵會有生鏽問題,或是較小的 0.2 mm 會殘留在表面。
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*The castings are conveyed to the centralized workbench .


*After removing the scraps manually, they will be sent back to the primary melting furnace to be recycled. The parts and scraps are transported via the conveyor belt to achieve the most efficient use of manpower.


*Centralized work bench: where scraps are removed, and then placed into baskets
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*There are more than 1000 storage spaces for moulds in these storage racks.
*We are able to access and return the moulds back onto the shelves quickly and efficiently.
This is because we can organize the mould storage racks by labeling the different moulds, as well as record the reference to the management software system.
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•我們內建的模具廠,可在量產時提供模具保養與修復的即時回饋,負責調度模具,以及模具量產後的保養。


•在壓鑄量產過程時,我們管理及保養模具,包括內保養及清洗,以確保量產時隨時保持良好狀態。


•完工下模的維護過程為:
1.拆解模具
2.清洗模具
3.模仁修善及保養
4.模具入儲位


•完工後的模具保養可以確保您的產品:不會因模穴積碳或缺陷影響,以確保下次生產的品質。
HTMLText_934D3991_BA58_7E85_41DD_47E3BA136EFC_mobile.html =
噴砂功能:
•藉由噴砂破壞表面硬化層,可達到物件表面的一致性,並且可以幫助增加後續的表面處理(例如烤漆)的附著度。


•能直接達到美觀效果。


吊式噴砂:
•吊式噴砂優點:能防止鑄件彼此撞傷。
HTMLText_90A873C2_BA48_32E8_41D9_63CDC3A817B9_mobile.html =
噴砂珠:
•噴砂珠使用 0.4 mm 不鏽鋼砂,不會像是鐵會有生鏽問題,或是較小的 0.2 mm 會殘留在表面。
HTMLText_9037B472_BA48_75A5_41D2_E901D56B6645_mobile.html =
滾式噴沙機:
•滾式噴砂操作簡單,不需特別吊掛鑄品,因此價格比吊式噴砂便宜70%。可以用在不會因有碰撞造成傷痕考量的鑄品。
HTMLText_96EF4C14_BA48_74E1_41D9_EE21BD8C032F_mobile.html =
•對於瓦斯類有氣密需求的產品,我們使用壓差式量測,進行全撿,確保出貨的零件符合客戶需求。
HTMLText_913173AE_B9C7_F26D_41DD_AA0F5C1A79E2_mobile.html =
•廠內7台壓鑄機所生產的鑄品,經由輸送帶運往此區域集中處理,方便落實管理與節省人力成本。


•為了讓鑄件的邊料能整模成型,內有設計流道、澆注口和益料池,需要去除。鑄件經由壓鑄機生產後,會由輸送帶運送到集中撥料台,以人工去除,或是以沖壓來自動去除。
HTMLText_91247F27_B9D8_121C_41AB_3F1BFF8E7987_mobile.html =
•廠內維持使用7成原料鋁錠,與3成的回收二次鋁料 (鋁錠/回收料之比例 7:3)。
HTMLText_916629CE_BA48_3ED5_41E0_61796C0673EC_mobile.html =
•廠內自建CNC廠,其中CNC所使用的加工的程式、治具都由琪泰自行設計/製作,因此若在量產發現不良,debug可以很迅速完成。


•我們能管理自建的CNC廠,因此也將管理經驗用在委外的供應商管理,以琪泰的合作供應鏈,全部有40台CNC銑床的產能,因此顯現委外管理的重要性。
HTMLText_A690E34B_B9F8_122B_41D4_98AFD57478D0_mobile.html =
•我們使用的鋁料為A383(又稱ADC12),是世界上通用度最廣的鋁料,因流動性極優特性適合壓鑄成型。


•鋁料品質上,我們的原料採用琪泰多年經驗中,品質最穩定的鋁料供應商。相較於便宜的鋁料供應商,他們的鋁料為我們提供穩定品質。
HTMLText_99D520FA_B9F8_0FF5_419F_AE61CC80B3DE_mobile.html =
•我們採用中央熔爐,使用單一材料,確保因兩種以上不同材質而誤混。由熔爐集中溶解鋁料,相較於單一熔爐來得有效率,節省能源。此時鋁湯溫度最高為攝氏720 °C。
HTMLText_92897701_BA58_338F_41D4_AE90E261F522_mobile.html =
•投資此先進的設備,代表我們有永續經營的決心,並近幾年有陸續引進其他的機械手臂。


•發展自動化生產,嚴防日後少子化帶來的人力資源不足的衝擊,穩定產能。


•因此,我們能成為您穩定且永久的供應商。
HTMLText_96D3A30D_BA58_0CC9_41D1_EB9C6FFD0EBF_mobile.html =
•此實驗室恆溫20度,待測的物品,必須在此提前靜置16小時,以確保測試品是在在標準環境與條件下測試。
HTMLText_9EBE16C5_B9C8_121F_41E4_B1647B21D233_mobile.html =
•此批生產的最後一件良品。是用來當下一次量產的首件標準(要在模具壽命條件相同時,達到上一次量產末件時的狀態),會留到下一次量產。
HTMLText_9F1C1A62_B9C8_1214_41E1_A18BD92350CA_mobile.html =
•每一台壓鑄機配置一台真空機,穩定孔洞率降至最低。作用目的是在射出鋁料前,將模穴內空氣抽取達到接近真空,讓模穴空氣减低,確保鋁湯在壓鑄成型時不會將空氣捲入鑄品,以減少砂孔/氣孔產生。
HTMLText_90EA6000_B9C8_0E15_41E3_B9BFA6922E6C_mobile.html =
•每個產品都有由RD開發人員製作的撥料SOP,確保所有的產品的處理方法,都是遵從開發人員設定的標準,達成量產的製品穩定,不會因為人事實地物所影響。
HTMLText_99F313E8_B9F8_1215_41A4_3AD19F71CA60_mobile.html =
•溶解的鋁料以自動配湯機24小時配送,降低人員的工作風險。
HTMLText_930EA5EE_B9C8_31EC_419C_BF38273363A4_mobile.html =
•溶解的鋁湯由電腦連線自動控制分配到各站的保溫爐備用,由機械手臂送到壓鑄機的注料管,再注入模具後壓鑄成型。每台壓鑄機機配置一台電子保溫爐,此功能是將溶解的鋁湯保持660±10 °C恆溫,讓鑄造因子穩定精準,以確保品質穩定。
HTMLText_90B9E9E1_BA48_1EDC_41E1_99E1EB1BAF1A_mobile.html =
•琪泰為客戶提供專線生產服務,瓦斯碼表即是其中一個專線


•鑄品依序經過自動研磨→CNC加工→全撿測漏→精密量測→直接出貨,都在此區域一氣呵成,構成一個專線的生產。所有後製程皆在此區完成,因此製造成本具備競爭力,也兼具最穩定的品質。
HTMLText_8A047C79_BAC8_34BC_4181_B6352D4F237B_mobile.html =
•產品在此產線打包之後,並直接堆疊碊板,運送到港口。
HTMLText_17615793_429C_9F52_41BE_A90C521482B2_mobile.html =
•產品在此產線打包之後,並直接堆疊碊板,運送到港口。
HTMLText_86A340A8_9B3E_3476_41C1_600C2FA6862D_mobile.html =
•而模具保養廠與壓鑄廠區相連接,模具很容易在兩個廠區之間轉移,大大的縮短了搬運時間,因此不須承擔在運送過程中損壞的風險,因此我們能兼具品質與成本。
HTMLText_9F726A85_B9C8_321C_41E4_B177231B12F8_mobile.html =
•藉由工業物連網系統偵測,我們能確保模具表面溫度依不同需求維持確保在150~250 °C溫度,讓量產過程中力求以穩定。
HTMLText_96847765_BA78_3338_41DB_02100048A470_mobile.html =
•遵照ISO 標準,每個儀器會定期執行校正:


1. 內校:內部有受過執照訓練的人員,一年校正一次 。
2. 外校:外部專業人原來量測,貼有黃色貼紙。
HTMLText_9714BFA0_BA58_13F4_4199_EC91BD347CDB_mobile.html =
•鋼瓶也必須保持20度的恆溫。
HTMLText_9E8DFF0C_B9DB_F22D_41D8_53CC11AD7D1E_mobile.html =
•鑄件由機械手臂,經由輸送帶送往集中撥料區,處理完畢後,下腳料會經由輸送帶送往中央熔爐回溶。
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•零件經過氣密測試後,會使用高溫水(80度C)浸泡,再以噴槍去除零件上的水,防止水密測試的水氧化鋁鑄件。
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•零件經過氣密測試後,會使用高溫水(80度C)浸泡,再以噴槍去除零件上的水,防止水密測試的水氧化鋁鑄件。
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優化工作環境
•在2019年,我們引進Yaskawa 安川六軸機械手臂,並且整合研磨週邊設備,將部份人工研磨改由機械手臂完成,減少人員暴露在惡劣的粉塵環境下工作。


車用等級六軸機械手臂
•機械手臂搭配進階的六軸力感測器,使手臂能模仿人手的動作,做到真正的自動化研磨。可以克服直線、平面、弧度、同心度、厚度之精密要求。
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•CNC自建第四軸,能夠在不更換治具狀況下,完成X,Y,Z面的加工,提供更佳生產效率與與品質穩定性。
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•Camlock為世界通用的快速接頭規格。


•琪泰穩定供應了世界名石油公司OPW長達十年,並起已經交貨200萬pcs。


•我們的快速接頭以高度管理卓稱,具有高度穩定的品質,在製造中確保砂孔的最小化,並且再出貨前執行氣密全撿,品質有保證。


•我們的產品能保證出貨後符合客戶需求。


•我們有高度產品開發能力,我們曾經在2-3年內為此客戶開了90個產品。


•此產品已經量產十年,出貨過150w pcs,沒有在客戶端出現過漏氣的不良品。
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•Cosmo LS-R700 儀器是用來檢查產品氣密性的。差壓式空氣洩漏測試器壓力最高可達到250 PSI。



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•位置設立在CNC與品保辦公室的中間,因此產品在加工完之後只需要在有限空間內移動。



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•使用將近100PSI的壓差去測試漏氣。
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•使用將近100PSI的壓差去測試漏氣。
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•壓鑄件因為以流體做高壓填充的方法,沙孔成為鑄件勢必會有的問題。好在配合X光機器的使用,可以讓我們檢驗外表看不出來的沙孔。
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•壓鑄廠配置固定的品保人員把關品質,日夜輪班各兩人,專門負責做鑄品尺寸及外觀的檢驗,他們遵從RD團隊設計的SIP標準檢驗,確保在製造過程中的量產鑄品,是穩定的符合客戶規格。
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•壓鑄機可以執行金屬鑄造功能,其特點是將熔融金屬灌入模具,高壓下壓入模具成型。


•廠內壓鑄機為150~420頓數機台,能造出市場上大部分的規格鑄件。


•配合我們緊密合作的供應鍊,總共的產能有 50 台壓鑄機。


•琪泰可製造最大達1200頓數的鑄件。
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•廠內總計總共6台CNC,並且進幾年有添購 CNC設備的中長期計畫。
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•我們廠內的模具儲位架,可以容納1000付以上模具。


•配合管理系統之軟體,搭配管理系統的模具儲位及標籤的建置,因此我們有能力迅速、精準的調度模具。
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•我們自己的研發團隊,具備修改模具設計的能力,因此可提供優化模具設計、鑄品優化設計、及即時維修模具的能力。


•該團隊在製定模具設計方面,擁有豐富的的技術經驗,包括 :
1.模具中的入料系統設計
2.模具預留加工量的設計,以避免鑄件因加工而出現的縮孔問題
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•測量精度,能達到+-2 um。



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•琪泰廠內的CNC機台,皆設有零點夾持系統,達到快速換線,發揮單機多工、智慧生產系統的秘密武器。


•每當換線時,治具的校正時間最為花時間,而在導入此系統後,可以省去零點校正時間,原本需要4小時的換線時間,在琪泰廠內只需要30分鐘即可完成換線,且定位精確度達5u。因此琪泰的產線,對於多樣性的產品線也能應變到位。
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•經由我們的品質管控,我們將樣品集中管理,讓現場能參考SOP與樣品,確保量產的穩定性。
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•經由我們的品質管控,我們將樣品集中管理,讓現場能參考SOP與樣品,確保量產的穩定性。
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•鑄件巡檢人員會保存每2小時經檢驗完成的鑄品,將其放置檢驗儲架待審,並由品管員做覆驗確認,用來做為不良品生產時的追朔。主要用來追朔24小時內的生產過程履歷。若品保人員發現巡檢樣品有問題,可以往前回朔量產異常的產品。


•因此在量產過程中,透過量產的首件和樣品比對,有24小時內每時段的巡檢產品可以追朔,以確保不良品流出。


•琪泰在這邊長期達成落實管理,讓第一關的壓鑄能確保都是輸出良品。


•存放 :
1. 標準樣品:是首批小量產試產時,客戶端承認的樣品,當回朔到首件還是有問題時,可以跟標準樣品比對。
2. 首件樣品:使用該模具生產的此批鑄件中,第一件良品。
3. 巡迴檢驗樣品:每兩小時蒐集一個樣品,用來往回追朔不良品。
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•在毛邊處理上,我們同時搭配自動研磨、與人工研磨,兼顧品質穩定、效率、與彈性。
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•我們自己的研發團隊,具備修改模具設計的能力,因此可提供優化模具設計、鑄品優化設計、及即時維修模具的能力


•該團隊在製定模具設計方面,擁有豐富的的技術經驗,包括 :
1. 模具中的入料系統設計
2. 模具預留加工量的設計,以避免鑄件因加工而出現的縮孔問題
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研磨目的
•砂布研磨目的是處理鑄品的分模線、入料口、溢料口,達到修飾鑄品外觀的缺陷,達到整體表面美化的需求。


自建研磨廠
•其加工量非常大,因此我們在2005年投資研磨廠,能夠自我管理研磨製程,以及省去運輸往來外部廠商的運輸成本,達到品質穩定並且兼具競爭力。
•廠內設立研磨廠的另一個目的,是可以讓製造排程好調度,減少委外廠商影響,達到穩定的交期。
•此區配置人力為9人。
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•經由我們的品質管控,我們將樣品集中管理,讓現場能參考SOP與樣品,確保量產的穩定性
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•The measuring room is set up between the CNC plant and the quality assurance office. The advantage is that the casting movement is limited.
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2.5D影像量測儀
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Automatically Grinding


•The Yasakawa six-axis robotic arm was introduced in 2019. The grinding peripheral equipment is integrated to support various grinding requirements. Some products could therefore be processed by using a robotic arm for automatic grinding. Besides, personnel could also avoid the risk of being exposed to heavy amounts of aluminum dust in the workplace environment.


Automotive Grade Six-Axis Robotic Arm


•The robotic arm is equipped with an advanced six-axis force sensor, so that this arm can replicate the movement of a human hand, and stage real automatic grinding.


•It can fulfill the precision requirements for machining a straight line, a plane, a radial shape, as well as maintain prescribed concentricity and thickness.
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Every casting sample will be placed on a shelf every 2 hours to trace and detect the production of any defective products. The production history is therefore traced within 24 hours. If the quality assurance personnel find that there is a problem during these regular spot checks, they can detect any defects, and then review all of the mass-produced products. The quality assurance inspector can then halt production if there is any defect among these samples, and then address the issue thereafter, before production can resume. (TODO)


•The following die-casting
samples are stored on a shelf:


1. Standard samples: these are samples(S)
that(motivation) clients approve of after the
small scale trial production of the first batch
of samples. If there are any defects in this
first production batch, then the plant
personnel can compare it with the
standard sample.


2. The first sample: the first good sample from
this batch is produced by using this
master sample mould.


3. Temporary samples: these are samples
that are collected every two hours during
the production process for the purpose of
tracing back defective products.


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The Cosmo LS-R700 instrument is used to inspect the air tightness of products.


The differential pressure air leak tester can reach a maximum pressure of 250 PSI.


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•Camlock, the universal quick connector specification worldwide, is a highly airtight product, and full inspection of air leakage testing is one of methods to assure its quality.


•This is one of the dedicated specialized lines for one-stop production.


•The features of this product are as follows:


1. Chi-Tai has supplied camlocks for OPW for
over 10years, and has manufactured over
2 million camlocks until the present.


2. There is a high degree of quality control.


3. Our production involves maintaining
both quality control and assurance processes.
This is to ensure dealing with any aluminum
part porosity problems in our products.


4. Our aluminum camlock devices are known
for their reliability. We can guarantee there will
not be any air leakage after shipment.


•Furthermore, we have a high level of product development capabilities.


There are 90 products for this client we have developed for a period of 2 to 3 years.


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•Die casting machines can perform a metal casting function that is characterized by pressing molten metal under high pressure into a mold cavity.


•There are several die cast
machines. The locking force of ranges from 150 to 1,250 ton.
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•Our own CNC machines are all equipped with a zero point clamping system to achieve rapid line changing.


This is a great mechanism to achieve single machine multitasking and operate an intelligent production system.


•The correction time on the jig is the most time consuming task whenever the product line is changed. The zero point correction time can be saved after the system is introduced. The time for production line change could be accelerated to only 30 minutes from the original 4 hours. Furthermore, the positioning accuracy could reach ±5u.


Therefore, we save on production management time and costs.
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•Our quality control
measures involve centralizing samples to optimize management, allowing personnel to refer to SOP and samples for ensuring production stability.
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•The implementation of the high-pressure fluid filling technique
in die casting inevitably results in the occurrence of porosity in castings.


Thankfully, the utilization of X-ray machines enables us to effectively examine sand holes that remain imperceptible to the naked eye.
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•The measurement accuracy of the three dimensional instrument can reach +-2 um.
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•The measuring room is set up between the CNC plant and the quality assurance office. The advantage is that the casting movement is limited.
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•There are four axes in the CNC equipment. The X, Y, Z surface processing can be completed without changing the jig by rotating the machined part.


This allows for improved production efficiency and quality stability.
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•Within this factory, a total of 10 CNC machines are installed, and there is a medium to long-term plan to purchase additional CNC equipment in the coming years.
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•我們廠內的模具儲位架,可以容納1000付以上模具


•配合管理系統之軟體,搭配管理系統的模具儲位及標籤的建置,因此我們有能力迅速、精準的調度模具。
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•我們廠內的模具儲位架,可以容納1000付以上模具


•配合管理系統之軟體,搭配管理系統的模具儲位及標籤的建置,因此我們有能力迅速、精準的調度模具。
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•我們廠內的模具儲位架,可以容納1000付以上模具


•配合管理系統之軟體,搭配管理系統的模具儲位及標籤的建置,因此我們有能力迅速、精準的調度模具。
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•我們廠內的模具儲位架,可以容納1000付以上模具


•配合管理系統之軟體,搭配管理系統的模具儲位及標籤的建置,因此我們有能力迅速、精準的調度模具。
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•There is a SIP (standard inspection process) for each manufactured part to verify the critical dimensions that were designed by R&D team.
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The purpose of grinding


•The purpose of grinding is to deal with the parting line and the casting gates.
Any defects in the casting could therefore be refined and then ensure having a smooth surface.


•Manual Grinding is performed manually by using a grinding wheel machine.


•The grinding process amount is very high, so we acquired a grinding plant in 2005 to be able to self-manage the grinding manufacturing process, and thereby contribute to maintaining quality control in the plant.


•Another purpose of setting up a grinding plant is to improve production for scheduling efficiency by having greater control over the production process.
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There are dedicated
quality assurance personnel in the die casting plant who monitor the quality of die casting samples.


Two operators are on duty on both day and night shifts.


They are responsible for inspecting the critical dimensions of the die casting samples to ensure that the mass produced castings in the manufacturing process are stable and meet the client's requirements.
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This includes regularly cleaning the mould interiors to ensure that they are kept in good condition at all times during mass production.


•The maintenance will start after mass production. The process is as follows:


(1) Disassembling the mold:
(2) Cleaning the mold by diesel fuel
(3) Repairing and maintaining the mold core:
(4) Storing the mould on the storage area shelves


•Mould maintenance is to ensure there will not be any defects on any products that are caused by carbon deposits, or the potential presence of any defects in the mould cavity.


This is so that we can guarantee quality control for the next production schedule.


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•The grinded samples are managed in a sample room, so that the manufacturing procedures and samples can be examined on site to ensure the efficiency of mass production on the basis of a master sample mould. production stability.
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•There are more than 1000 storage spaces for moulds in these storage racks.


•We are able to access and return the moulds back onto the shelves quickly and efficiently.


This is because we can organize the mould storage racks by labeling the different moulds, as well as record the reference to the management software system.


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•Therefore, we can offer both automatic grinding and manual grinding to deal with any form of casting. We could thereby take stability, measurement efficiency, as well as flexibility into account.


•Developing automated production to minimize potentially depending excessively on manual labour operators, and also stabilize production capacity.
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For products that must not allow for gas escape and have an air tightness requirement, we use a differential pressure measurement to perform a full inspection to ensure that the products clearly meet the client's requirement.


The maximum pressure can reach up to 250 PSI.
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The blasting sand
•The blasting sand we use is 0.4 mm stainless steel sand.


The advantage is that there will not be any rust problems, as with iron. Another advantage is that the sand clusters are large enough to be removed, and not remain on the surface, as with 0.2 mm sand.
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The function of blasting process


•The consistency of the surface of the die-cast parts can be directly achieved just by applying the blasting process. This modifies the surface hardened layer through applying a high speed abrasive action to create a smooth surface. Another function is increasing the adhesion of subsequent surface treatments, such as adding coating.


•Sandblasting can directly provide a clear effect on the die-cast surfaces.
There are two kind of blasting process:
Sandblasting:


•The term “sandblasting” refers to the process of propelling stainless sand with compressed air with stainless sand clusters.
These clusters therefore modify the surface through applying extremely high speed impacts.


• This cleaning and preparation procedure takes compressed air as a power source and directs a high-pressure stream of stainless sand toward the surface of castings.
•The advantages of sandblasting are this process can prevent the castings from colliding with each other because the casting is hung.
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The steel cylinder must also be maintained at a constant temperature of 20 degrees Celsius.
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There are the final approved samples that are produced among this batch by using this mold. It will be used as the standard for the approved sample for the next scheduled mass production.


This sample will be stored in the sample storage space until the next scheduled mass production. The purpose of the final sample is for the plant personnel to ensure the uniformity of the sample condition, before this sample will go back into the next scheduled production.
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There is a SOP (standard operating procedure) for each separate part of the process for removing scraps that is designed by the R&D personnel to ensure that all of the product processing methods are in compliance with the standards that the clients require.


This could also ensure that production is stable during mass-production, and will not be affected by any additional human errors .
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•2.5D Image Measurement Instrument(Projector)
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•Each die-casting machine is equipped with a vacuum machine to minimize porosity.
The purpose of this function is to extract air from any cavities present in a mold, and then die-casting machine will injecte the molten aluminum into the vacuum space.


This process ensures that air will not permeate into the molten aluminum and then cause sand or air holes to appear during the die-casting process.


This will therefore minimize porosity in the die-casting sample.
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•In our internal operations, we uphold a precise balance between 70% primary aluminum ingots and 30% recycled secondary aluminum materials (Aluminum Ingot/Recycled Material ratio of 7:3).
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•Investing in this advanced form of equipment represents our determination to maintain long term stable operation


•Development of automated production could help prevent human errors, and also stabilize production capacity.


•Chi-Tai can pledge to be a stable and permanent supplier.
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•Shot Blasting has an entirely different pressurizing system in comparison to sandblasting. This abrasive treatment method entails using a device similar to a spinning wheel to centrifugally accelerate shot-like material and blast it against a surface.


•Shot blasting is thereby easier to operate because we do not need to hang casting parts by using additional devices. The price is therefore 70% more inexpensive than applying hanging sandblasting. Shot blasting is usually used in the castings that will not be damaged due to collisions during machine operations.
HTMLText_535A2D4A_3E91_0796_41CF_1B4601DA7615.html =
•The castings are conveyed to the centralized workbench .


•After removing the scraps manually, they will be sent back to the primary melting furnace to be recycled. The parts and scraps are transported via the conveyor belt to achieve the most efficient use of manpower.


•Centralized work bench: where scraps are removed, and then placed into baskets
HTMLText_B32B5D76_3EB3_067E_41BB_03C021D0DC45.html =
•The gas production line is an example of one-stop manufacturing production line in our plant


•The castings undergo automatic grinding → CNC processing → leakage full-inspection → precision measurement → direct shipment.


All of these steps all take place in this area, and thereby forming a dedicated production line.
HTMLText_A4857E57_3E71_05BE_41B2_B89C3A8D824C.html =
•The instrument calibration is implemented regularly in accordance with ISO standards


1. Internal calibration: we have licensed training personnel in our company who set the calibration
once a year.


2. Outside calibration: the calibration is performed by professionals from outside the plant.
HTMLText_617DFF8B_3EAF_0296_41C8_E6EE772378E4.html =
•The molten purified aluminum is then poured into a separate electronic holding furnace to maintain it in heated liquid form, before it is going to be poured into die-casting machines where it is going to take solid shapes.


This process ensures maintaining the molten aluminum at a constant temperature of 660±10°C, so that the manufacturing element of the process is kept stable at all times.
HTMLText_BEBA6A2F_3EEF_0DEF_41B7_A18E07CE2771.html =
•There is a specially designed biscuit,a runner, and an overflow well in die-casting mould to allow parts to be moulded inside a mould .


After the die-casting molding is undertaken by using a die-casting machine, it will be transported by the conveyor belt to the centralized workbench , and the scraps will be removed manually or by using a stamping machine.
HTMLText_5959EAAE_3EB3_0291_41BF_A46C0C09B26C.html =
•We can ensure that the mould surface temperature is maintained at exactly 250 °C while using the IIoT(Industrial Internet of Things) sensor to detect temperatures at all times.
Therefore, mass production can remain stable.
We maintain quality control during the manufacturing process by tracking digital data on this IIoT system.
HTMLText_B325B4FC_3EB1_0671_41CE_6227BD763951.html =
•We have our own CNC equipment, and the code is programed by our own personnel.
CNC jigs are all designed by our own personnel.
Therefore we can debug any issues quickly and completely if thereis a defect found in mass production.


•There is a total of 10 CNC machines in the factory, and there is a long-term plan to purchase additional CNC equipment in the next few years.


•In addition to managing our own CNC equipment, we also use our management experience to manage production by potentially relying on outside machining specialists.
There are a total of 40 CNC machines among Chi-Tai’s cooperative supply chain partners.
HTMLText_A244CDDE_3F91_06B1_41C4_4C5109D109B5.html =
In this laboratory, the temperature is maintained at a constant 20 degrees Celsius.
The test item must be left to settle in this environment for 16 hours in order to ensure that the testing is conducted under standard environmental conditions.
HTMLText_0D49509D_3E71_3EB2_41C0_73176E3CBE11.html =
The mould maintenance plant is connected to the die casting plant.


The moulds can therefore be easily transferred between the two plant areas, which greatly shortens the handling time.


Therefore, there is no need to face the risk of damage during handling, so we can ensure both quality assurance and cost savings.
HTMLText_7E751BDB_3E91_02B7_41C2_42CCA0C7FD80.html =
We have our own research and development team that can offer the ability to optimize the mould design and the ability to change the design.


This team has advanced technical expertise on formulating mould design.


This includes setting the following:


1. improving the feeding system design in any mould;


2. designing how to machine process a specialized space into a mould to help prevent having
porosity issues in the inner casting layers.
HTMLText_723D9848_3E9F_0D92_418D_94EF43E4BD54.html =
•The Aluminum material we use is A383, which is also known as ADC12.


•This is an aluminum alloy that is composed of different materials, which is the most versatile die-casting aluminum material in the world. Its characteristics are very suitable for die casting.


•Our components are only made with this aluminum compound material with sufficient alloy contents to ensure that this mixture of aluminum with reinforcing alloy compound elements will not be mistakenly mixed with other contents during the production process, and therefore maintain its purity.


•Our supplier is the Fa-Chia Metal Enterprise, which is the most stable aluminum material supplier in our years of experience. Compared with more inexpensive(formal) aluminum material suppliers, Fa-Chia 's aluminum material is known for providing stable quality materials.
HTMLText_6D50F090_3E91_7EB1_41C6_96CE159CE84D.html =
•The molten aluminum material is automatically conveyed on an automatic carrier device for 24 hours, rather than being handled by plant personnel, and therefore reducing the risk of human error during this phase of the production process.
HTMLText_756F8327_3E91_039F_41C8_AB890337BEF2.html =
•This powerful furnace is used to melt aluminum ingots, which is more efficient than using different furnaces, and also saves energy. The furnace temperature for aluminum smelting reaches 720°C.


•Our company only uses our primary melting furnace, which we can use to maintain a stable temperature and efficient energy consumption.
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•廠內維持使用7成原料鋁錠,與3成的回收二次鋁料 (鋁錠/回收料之比例 7:3)
HTMLText_9DF1BF66_822C_F6C6_41C3_176D907404DA.html =
•每一台壓鑄機配置一台真空機,穩定孔洞率降至最低。作用目的是在射出鋁料前,將模穴內空氣抽取達到接近真空,讓模穴空氣减低,確保鋁湯在壓鑄成型時不會將空氣捲入鑄品,以減少砂孔/氣孔產生
HTMLText_8BAC532F_BA38_0C51_41E5_16E44FE67558_mobile.html =
•零件經過氣密測試後,會使用高溫水(80度C)浸泡,再以噴槍去除零件上的水,防止水密測試的水氧化鋁鑄件
HTMLText_8A4EC629_BAC8_345F_41E1_158C3902F6C8_mobile.html =
•零件經過氣密測試後,會使用高溫水(80度C)浸泡,再以噴槍去除零件上的水,防止水密測試的水氧化鋁鑄件
HTMLText_0F02F19A_42AC_9353_41D0_2A9C82390A0B_mobile.html =
•零件經過氣密測試後,會使用高溫水(80度C)浸泡,再以噴槍去除零件上的水,防止水密測試的水氧化鋁鑄件
HTMLText_20D52CD1_4295_B12E_41C2_C3D631FA8E07_mobile.html =
•零件經過氣密測試後,會使用高溫水(80度C)浸泡,再以噴槍去除零件上的水,防止水密測試的水氧化鋁鑄件
HTMLText_037808E3_42B5_92F2_419C_52F11CE39A13_mobile.html =
•Camlock 為世界通用的快速接頭規格
•琪泰穩定供應了世界名石油公司OPW長達十年,並起已經交貨200萬pcs
•我們的快速接頭以高度管理卓稱,具有高度穩定的品質,在製造中確保砂孔的最小化,並且再出貨前執行氣密全撿,品質有保證


•我們的產品能保證出貨後符合客戶需求


•我們有高度產品開發能力,我們曾經在2-3年內為此客戶開了90個產品


•此產品已經量產十年,出貨過150w pcs,沒有在客戶端出現過漏氣的不良品
HTMLText_8A5DD0C7_BA38_0DE0_41C1_8CAEC99DE481_mobile.html =
•Camlock 為世界通用的快速接頭規格
•琪泰穩定供應了世界名石油公司OPW長達十年,並起已經交貨200萬pcs
•我們的快速接頭以高度管理卓稱,具有高度穩定的品質,在製造中確保砂孔的最小化,並且再出貨前執行氣密全撿,品質有保證


•我們的產品能保證出貨後符合客戶需求


•我們有高度產品開發能力,我們曾經在2-3年內為此客戶開了90個產品


•此產品已經量產十年,出貨過150w pcs,沒有在客戶端出現過漏氣的不良品
HTMLText_92582BDF_BA48_1269_41D2_8A91185BA2B0_mobile.html =
•經由我們的品質管控,我們將樣品集中管理,讓現場能參考SOP與樣品,確保量產的穩定性
HTMLText_FDF7B648_CEBE_E489_41E7_EE59EACFC145_mobile.html =
•There is a SIP (standard inspection process) for each manufactured part to verify the critical dimensions that were designed by R&D team.
HTMLText_83534694_3FB3_02B2_4169_A70DB26D9C20_mobile.html =
* The Aluminum material we use is A383, which is also known as ADC12.


* This is an aluminum alloy that is composed of different materials, which is the most versatile die-casting aluminum material in the world. Its characteristics are very suitable for die casting.


*Our components are only made with this aluminum compound material with sufficient alloy contents to ensure that this mixture of aluminum with reinforcing alloy compound elements will not be mistakenly mixed with other contents during the production process, and therefore maintain its purity.


* Our supplier is the Fa-Chia Metal Enterprise, which is the most stable aluminum material supplier in our years of experience. Compared with more inexpensive(formal) aluminum material suppliers, Fa-Chia 's aluminum material is known for providing stable quality materials.
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2.5D Image Measurement Instrument(Projector)
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Shot Blasting


* Shot Blasting has an entirely different pressurizing system in comparison to sandblasting. This abrasive treatment method entails using a device similar to a spinning wheel to centrifugally accelerate shot-like material and blast it against a surface.


* Shot blasting is thereby easier to operate because we do not need to hang casting parts by using additional devices. The price is therefore 70% more inexpensive than applying hanging sandblasting.


Shot blasting is usually used in the castings that will not be damaged due to collisions during machine operations.
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The blasting sand


*The blasting sand we use is 0.4 mm stainless steel sand. The advantage is that there will not be any rust problems, as with iron.


Another advantage is that the sand clusters are large enough to be removed, and not remain on the surface, as with 0.2 mm sand.
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The function of blasting process


*The consistency of the surface of the die-cast parts can be directly achieved just by applying the blasting process. This modifies the surface hardened layer through applying a high speed abrasive action to create a smooth surface. Another function is increasing the adhesion of subsequent surface treatments, such as adding coating.


*Sandblasting can directly provide a clear effect on the die-cast surfaces.


There are two kind of blasting process:
Sandblasting:


*The term “sandblasting” refers to the process of propelling stainless sand with compressed air with stainless sand clusters.
These clusters therefore modify the surface through applying extremely high speed impacts.


* This cleaning and preparation procedure takes compressed air as a power source and directs a high-pressure stream of stainless sand toward the surface of castings.


*The advantages of sandblasting are this process can prevent the castings from colliding with each other because the casting is hung.


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For products that must not allow for gas escape and have an air tightness requirement, we use a differential pressure measurement to perform a full inspection to ensure that the products clearly meet the client's requirement.


The maximum pressure can reach up to 250 PSI.
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In this laboratory, the temperature is maintained at a constant 20 degrees Celsius.


The test item must be left to settle in this environment for 16 hours in order to ensure that the testing is conducted under standard environmental conditions.
HTMLText_806FAB1B_3FB3_03B6_41B8_4A1F630E2B34_mobile.html =
The mould maintenance plant is connected to the die casting plant.
The moulds can therefore be easily transferred between the two plant areas, which greatly shortens the handling time.
Therefore, there is no need to face the risk of damage during handling, so we can ensure both quality assurance and cost savings.
HTMLText_00BE23FA_42BC_F6D3_41A9_DCF79C6F4AC4_mobile.html =
The steel cylinder must also be maintained at a constant temperature of 20 degrees Celsius.
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There are the final approved samples that are produced among this batch by using this mold. It will be used as the standard for the approved sample for the next scheduled mass production.


This sample will be stored in the sample storage space until the next scheduled mass production. The purpose of the final sample is for the plant personnel to ensure the uniformity of the sample condition, before this sample will go back into the next scheduled production.
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There is a SOP (standard operating procedure) for each separate part of the process for removing scraps that is designed by the R&D personnel to ensure that all of the product processing methods are in compliance with the standards that the clients require.


This could also ensure that production is stable during mass-production, and will not be affected by any additional human errors .
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*Each die-casting machine is equipped with a vacuum machine to minimize porosity.


The purpose of this function is to extract air from any cavities present in a mold, and then die-casting machine will injecte the molten aluminum into the vacuum space.


This process ensures that air will not permeate into the molten aluminum and then cause sand or air holes to appear during the die-casting process.


This will therefore minimize porosity in the die-casting sample.
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*In our internal operations, we uphold a precise balance between 70% primary aluminum ingots and 30% recycled secondary aluminum materials (Aluminum Ingot/Recycled Material ratio of 7:3).
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*Investing in this advanced form of equipment represents our determination to maintain long term stable operation


*Development of automated production could help prevent human errors, and also stabilize production capacity.


*Chi-Tai can pledge to be a stable and permanent supplier.
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*The gas production line is an example of one-stop manufacturing production line in our plant


*The castings undergo automatic grinding → CNC processing → leakage full-inspection → precision measurement → direct shipment.


All of these steps all take place in this area, and thereby forming a dedicated production line.


HTMLText_0AB08BC8_42AC_F73E_41AA_B5B6B2B580E8_mobile.html =
*The instrument calibration is implemented regularly in accordance with ISO standards


1. Internal calibration: we have licensed training personnel in
our company who set the calibration once a year.


2. Outside calibration: the calibration is performed
by professionals from outside the plant.
HTMLText_862358AC_3F93_0E92_41CB_7F466F86801E_mobile.html =
*The molten aluminum material is automatically conveyed on an automatic carrier device for 24 hours, rather than being handled by plant personnel, and therefore reducing the risk of human error during this phase of the production process.
HTMLText_EF05F004_3F97_1D92_41B7_E1143E406FAA_mobile.html =
*The molten purified aluminum is then poured into a separate electronic holding furnace to maintain it in heated liquid form, before it is going to be poured into die-casting machines where it is going to take solid shapes. This process ensures maintaining the molten aluminum at a constant temperature of 660±10°C, so that the manufacturing element of the process is kept stable at all times.
HTMLText_E6F5939E_3FF3_02AE_41C6_1DE3C6114272_mobile.html =
*There is a specially designed biscuit,a runner, and an overflow well in die-casting mould to allow parts to be moulded inside a mould .


After the die-casting molding is undertaken by using a die-casting machine, it will be transported by the conveyor belt to the centralized workbench , and the scraps will be removed manually or by using a stamping machine.
HTMLText_8275C9F6_3FB1_0E7E_41B3_50C24F8E48F2_mobile.html =
*This powerful furnace is used to melt aluminum ingots, which is more efficient than using different furnaces, and also saves energy. The furnace temperature for aluminum smelting reaches 720°C.


*Our company only uses our primary melting furnace, which we can use to maintain a stable temperature and efficient energy consumption.
HTMLText_F98BD43F_3F93_05EE_41CA_7CA4F8346723_mobile.html =
*We can ensure that the mould surface temperature is maintained at exactly 250 °C while using the IIoT(Industrial Internet of Things) sensor to detect temperatures at all times.
Therefore, mass production can remain stable.


We maintain quality control during the manufacturing process by tracking digital data on this IIoT system.
HTMLText_3F46CC4D_3F91_0593_41C6_9B59184E130C_mobile.html =
*We have our own CNC equipment, and the code is programed by our own personnel.


CNC jigs are all designed by our own personnel.
Therefore we can debug any issues quickly and completely if thereis a defect found in mass production.


*There is a total of 10 CNC machines in the factory, and there is a long-term plan to purchase additional CNC equipment in the next few years.


*In addition to managing our own CNC equipment, we also use our management experience to manage production by potentially relying on outside machining specialists.


There are a total of 40 CNC machines among Chi-Tai’s cooperative supply chain partners.


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Automatically Grinding


*The Yasakawa six-axis robotic arm was introduced in 2019. The grinding peripheral equipment is integrated to support various grinding requirements. Some products could therefore be processed by using a robotic arm for automatic grinding. Besides, personnel could also avoid the risk of being exposed to heavy amounts of aluminum dust in the workplace environment.


Automotive Grade
Six-Axis Robotic Arm


*The robotic arm is equipped with an advanced six-axis force sensor, so that this arm can replicate the movement of a human hand, and stage real automatic grinding.


*It can fulfill the precision requirements for machining a straight line, a plane, a radial shape, as well as maintain prescribed concentricity and thickness.
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Every casting sample will be placed on a shelf every 2 hours to trace and detect the production of any defective products. The production history is therefore traced within 24 hours. If the quality assurance personnel find that there is a problem during these regular spot checks, they can detect any defects, and then review all of the mass-produced products. The quality assurance inspector can then halt production if there is any defect among these samples, and then address the issue thereafter, before production can resume. (TODO)


*The following die-casting samples are stored on a shelf:


1. Standard samples: these are
samples(S) that(motivation) clients
approve of after the small scale
trial production of the first batch
of samples. If there are any defects
in this first production batch,
then the plant personnel can
compare it with the standard sample.


2. The first sample: the first good
sample from this batch is produced
by using this master sample mould.


3. Temporary samples: these are
samples that are collected every
two hours during the production
process for the purpose of
tracing back defective products.


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The Cosmo LS-R700 instrument is used to inspect the air tightness of products. The differential pressure air leak tester can reach a maximum pressure of 250 PSI.
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There are dedicated quality assurance personnel in the die casting plant who monitor the quality of die casting samples.
Two operators are on duty on both day and night shifts.
They are responsible for inspecting the critical dimensions of the die casting samples to ensure that the mass produced castings in the manufacturing process are stable and meet the client's requirements
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This includes regularly cleaning the mould interiors to ensure that they are kept in good condition at all times during mass production.


* The maintenance will start after mass production. The process is as follows:


(1) Disassembling the mold:
(2) Cleaning the mold by diesel fuel
(3) Repairing and maintaining the
mold core:
(4) Storing the mould on the
storage area shelves


*Mould maintenance is to ensure there will not be any defects on any products that are caused by carbon deposits, or the potential presence of any defects in the mould cavity.


This is so that we can guarantee quality control for the next production schedule.


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• Our quality control measures involve centralizing samples to optimize management, allowing personnel to refer to SOP and samples for ensuring production stability.
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• The grinded samples are managed in a sample room, so that the manufacturing procedures and samples can be examined on site to ensure the efficiency of mass production on the basis of a master sample mould.
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•Within this factory, a total of 10 CNC machines are installed, and there is a medium to long-term plan to purchase additional CNC equipment in the coming years.
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*Camlock, the universal quick connector
specification worldwide, is a highly airtight product, and full inspection of air leakage testing is one of methods to assure its quality.


*This is one of the dedicated specialized lines for one-stop production.


*The features of this product are as follows:


1. Chi-Tai has supplied camlocks
for OPW for over 10years, and has
manufactured over 2 million
camlocks until the present.


2. There is a high degree of quality
control.


3. Our production involves
maintaining both quality control
and assurance processes.
This is to ensure dealing with any
aluminum part porosity problems
in our products.


4. Our aluminum camlock devices are
known for their reliability.
We can guarantee there will not
be any air leakage after shipment.


*Furthermore, we have a high level of product development capabilities.
There are 90 products for this client we have developed for a period of 2 to 3 years.


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*Die casting machines
can perform a metal casting function that is characterized by pressing molten metal under high pressure into a mold cavity.


*There are several die cast machines. The locking force of ranges from 150 to 1,250 ton.
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*Our own CNC machines are all equipped with a zero point clamping system to achieve rapid line changing.


This is a great mechanism to achieve single machine multitasking and operate an intelligent production system.


*The correction time on the jig is the most time consuming task whenever the product line is changed. The zero point correction time can be saved after the system is introduced. The time for production line change could be accelerated to only 30 minutes from the original 4 hours.


Furthermore, the positioning accuracy could reach ±5u.


Therefore, we save on production management time and costs.


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*The implementation
of the high-pressure fluid filling technique
in die casting inevitably results in the occurrence of porosity in castings.


Thankfully, the utilization of X-ray machines enables us to effectively examine sand holes that remain imperceptible to the naked eye.
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*The measurement accuracy of the three dimensional instrument can reach +-2 um
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*The measuring room is set up between the CNC plant and the quality assurance office.


The advantage is that the casting movement is limited.
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*There are four axes in the CNC equipment. The X, Y, Z surface processing can be
completed without changing
the jig by rotating the machined part.


This allows for
improved production efficiency and quality stability.
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*Therefore, we can offer both automatic grinding and manual grinding to deal with any form of casting.


We could there by take stability,
measurement efficiency, as well
as flexibility into account.


*Developing automated production
to minimize potentially depending excessively on manual labour operators, and also stabilize production capacity.


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We have our own research and development team that can offer the ability to optimize the mould design and the ability to change the design.


This team has advanced technical expertise on formulating mould design.


This includes setting the following:


1. improving the feeding system design in any mould;
2. designing how to machine process a specialized space
into a mould to help prevent having porosity issues in
the inner casting layers.


HTMLText_D8B77225_3FF1_7D92_41B2_9C680CAF3110_mobile.html =
The purpose of grinding


*The purpose of grinding is to deal with the parting line and the casting gates.


Any defects in the casting could therefore be refined and then ensure having a smooth surface.
*Manual Grinding is performed manually by using a grinding wheel machine.


*The grinding process amount is very high, so we acquired a grinding plant in 2005 to be able to self-manage the grinding manufacturing process, and thereby contribute to maintaining quality control in the plant.


*Another purpose of setting up a grinding plant is to improve production for scheduling efficiency by having greater control over the production process.
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Contact Us


Chi-Tai Industrial Co., Ltd.


TEL:886-4-2557-4366
FAX:886-4-2556-9468
No. 96-4, Yuehu Rd., Houli Dist., Taichung City 42146, Taiwan
E-Mail:business@mail.chi-tai.com.tw


HTMLText_AD82254A_B899_7906_41C5_A7A884B8A9E2.html =


Contact Us


Chi-Tai Industrial Co., Ltd.


TEL:886-4-2557-4366
FAX:886-4-2556-9468
No. 96-4, Yuehu Rd., Houli Dist., Taichung City 42146, Taiwan
E-Mail:business@mail.chi-tai.com.tw


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聯絡我們



琪泰工業股份有限公司


TEL:886-4-2557-4366


FAX:886-4-2556-9468


42146 台中市后里區月湖路96-4號


E-Mail:business@mail.chi-tai.com.tw


HTMLText_7298498F_473B_9B1B_41C9_2F5742881CD4.html =


聯絡我們



琪泰工業股份有限公司


TEL:886-4-2557-4366


FAX:886-4-2556-9468


42146 台中市后里區月湖路96-4號


E-Mail:business@mail.chi-tai.com.tw


HTMLText_7298498F_473B_9B1B_41C9_2F5742881CD4_mobile.html =


聯絡我們



琪泰工業股份有限公司


TEL:886-4-2557-4366


FAX:886-4-2556-9468


42146 台中市后里區月湖路96-4號


E-Mail:business@mail.chi-tai.com.tw


HTMLText_21722633_47C9_E904_41A5_229C2FE8C3E0.html =


聯絡我們



琪泰工業股份有限公司


TEL:886-4-2557-4366


FAX:886-4-2556-9468


42146 台中市后里區月湖路96-4號


E-Mail:business@mail.chi-tai.com.tw


HTMLText_BB1A66B9_9B0E_1C56_41D4_C71C7E1E0198.html =
人工研磨
HTMLText_96578BD4_3F93_02B1_41A0_8D9D18EB4E6A.html =
Step 1.
Drilling holes to make a cam pin for a self-locking function
HTMLText_8FCDA7CF_3F97_02AE_41C4_46654AA7166A.html =
Step 2.
Drilling holes to make a cam pin for a self-locking function
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地址:42146 台中市后里區月湖路96-4號


電話 : +886-4-25574366
傳真 : +886-4-25569468
E-mail : business@mail.chi-tai.com.tw
HTMLText_974EB319_B2B0_7E9A_41E3_54ED22EC6262_mobile.html =
地址:42146 台中市后里區月湖路96-4號


電話 : +886-4-25574366
傳真 : +886-4-25569468
E-mail : business@mail.chi-tai.com.tw
HTMLText_974EB319_B2B0_7E9A_41E3_54ED22EC6262.html =
地址:42146 台中市后里區月湖路96-4號


電話 : +886-4-25574366
傳真 : +886-4-25569468
E-mail : business@mail.chi-tai.com.tw
HTMLText_6C2B0ECF_7424_38DE_41D3_60CA47992001.html =
地址:42146 台中市后里區月湖路96-4號


電話 : +886-4-25574366
傳真 : +886-4-25569468
E-mail : business@mail.chi-tai.com.tw
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### Tooltip IconButton_3BCC196F_742C_39DF_41C0_E17FE9F88F63.toolTip = 全螢幕 IconButton_3BCC196F_742C_39DF_41C0_E17FE9F88F63_mobile.toolTip = 全螢幕 ## Tour ### Description ### Title tour.name = 琪泰工業股份有限公司