Vol.

15

TOYOTA

T EXT I L E

M A CHI NER Y

B U L L E T I N

2 Special Feature
JAT710s IT Functions

4 Technical News 5 Whats New

Toyota Spun Sizer Pre-Wet Sizing System

DX8 High-Speed Drawing Frame

6 Customer Support & Service

Electronic Parts Catalog Tips from the Service Department

7 Thoughts & Feelings

User Report Part 14: Shandong Weiqiao Textile Group Co., Ltd. (China)

8 Toyota @ Work

Introducing Toyotas Businesses Part IV: Engine Division

S P E C I A L

F E A T U R E

Introducing the JAT710s IT Functions

The JAT710 Air Jet Loom boasts a powerful CPU, a function panel with built-in Web browser and the newly developed TMS (Toyota Monitoring System)all of which contribute to next-generation factory management.
The JAT710s IT functions not only allow operators to gather data from each loom with a PC (monitoring), but also enable two-way communication between looms and direct connection to networks inside and outside the customers company.

JAT710 Network System

External Network Customer Internal Network
Customer head office
Customer server

Mobile PC
Customer mobile PC

Customer sales division

Customer PC

Customer R&D division

Customer PC

Customer mill office

Customer PC Customer printer

Internet

Customer Mill Network

JAT710 function panel Customer textile mill

The function panel screen displays a variety of information

Monitoring

Instruction manual

Technical information

TICS

Parts catalog

Camera view

Note: Date of availability differs with each item.

TMS (Toyota Monitoring System)

By connecting the JAT710 to a network with a standard LAN cable and installing Toyotas proprietary software, the operator is able to monitor loom shift data and connect to networks both inside and outside the company. This system also enables looms to exchange data with one anothera world-first. TMS can be used with the customers existing PCs*, making it easy for them to introduce a high-performance network system into their mills. Consequently, many JAT710 owners have already adopted TMS.
*PCs running Windows 2000/Windows XP

Monitoring Function

The operator can view data such as production volume, efficiency ratio and warp out forecast of each loom from a PC. The data is displayed as a Microsoft Excel file for easy editing and processing.

Shift report

Stop analysis graph

Production graph

Efficiency graph

Warp out forecast

World First

Two-Way Communication between Looms

Two-way communication between looms, a feature not possible with conventional monitoring systems, is now available for the first time in the world. The operator can check data such as efficiency and production volume, as well as view and change the settings of a remote loom from the function panel of another loom. Loom settings can be copied onto different looms without the use of memory cards.

World First

Two-Way Communication with Internal/External Networks

Direct two-way communication with networks outside of the mill is now possible for the first time in the world. Communication with other divisions, such as sales and R&D divisions, is now possible, which means the operator can view mill data such as production volume and efficiency from a remote location. The operator can also exchange information with sales and R&D divisions from inside the mill. Through an Internet connection, the operator can communicate with various locations outside the mill using the JAT710s function panel. This makes it possible to exchange information with customers mobile PCs as well as exchange technical information with Toyota. Operators can directly view the function panel screen of a given loom from anywhere in the world to confirm loom settings.

The contents of the function panel screen can be printed out, allowing the operator to save loom settings for a variety of fabric types.

Technical News

Toyota Spun Sizer Pre-Wet Sizing System

Cuts Sizing Costs and Helps Keep the Environment Clean
What is Pre-Wet Sizing?
Pre-wet sizing involves passing the yarn through hot water and squeezing out excess moisture before applying size. Running the yarn through a preliminary hot water box removes cotton wax and foreign matter, which allows the size to penetrate the yarn more smoothly, and enables a thinner, more uniform size application. This makes it possible to cut size consumption, and also provides the added benefit of reducing the amount of size that must be removed in the finishing process that would normally enter the industrial waste stream, resulting in a cleaner environment.
Squeezing Sizing

Soaking in hot water

Hot water box

Size box

Toyota Pre-Wet Sizing System Features

SIZE-NAVI System
This system controls the size concentration in the size box to ensure that a consistent amount of size is applied to the yarn. The system constantly checks the moisture content of the yarn following the pre-wet process and the amount of size pick-up to the yarn, and compares these values to the estimated size concentration in the size box. Based on the results, the pre-wet squeezing pressure is adjusted according to the type of product being loomed, and the size concentration in the size box is maintained at a consistent level.
Calculation of actual moisture content Target size concentration Estimated size concentration Calculation of size pick-up rate

Flow meter

Flow meter

Size supply Water supply Squeezing pressure control Sizing length Concentration of size to be supplied Warp yarn unit volume Water supply control Yarn production volume calculation Pre-wet moisture control Size supply control

Easy Change-Over
Switching over to the pre-wet sizing system only involves replacing the existing carrier roller system. (Note: Only possible on our sizing machines delivered after 1985.)

Existing Equipment
Top squeezing roller Bottom squeezing roller

Multi-Purpose System
For products that require no pre-wet sizing, the pre-wet sizing system can be used as a conventional carrier roller system.

Compact Roller Arrangement

Carrier roller frame Sizing frame

After Upgrade
Top squeezing roller Squeezing rollers Bottom squeezing roller

The roller configuration is designed to minimize the distance between the point where pre-wet squeezing takes place and the point where the yarn is immersed in the size. This roller configuration makes the moisture content following squeezing less likely to be affected by factors in the external environment. It also offers the additional advantage of making it easier for the operator to deal with machine stops, such as repairing warp breaks.

Eliminates Pre-Drying
Super-high-pressure squeezing and precise control of squeezing pressure in the pre-wet section ensure consistent, stable moisture content in the yarn following squeezing. This eliminates the need to pass the yarn through a predrying stage and provides sufficient pre-wetting effect resulting in excellent yarn handling characteristics and greater energy efficiency.

Pre-wet frame

Sizing frame

Pre-Wet Sizing Benefits

Cuts Size Consumption
The effectiveness of pre-wet sizing will vary depending on the type of yarn, yarn count, size used, and the actual amount of size pick-up to the yarn, but reductions of 20% to 40% in the amount of size required can be expected. Cutting size consumption facilitates the desizing process and reduces finishing costs. In addition, the benefits of resource conservation and reduced industrial waste also contribute to a cleaner natural environment.
Yarn count

Typical Examples Using Cotton Yarn

No. of ends Standard pick-up rate
4 8 8 9 9 7

Typical Examples Using Polyester/Cotton Blended Yarn

Yarn count
45s 34s 30/2

Pre-wet pick-up rate

3 6 6 6 6 4

Size concentration
11 10 11 10 10 8

No. of ends
6260 4992 6600

Standard pick-up rate

13 12 7

Pre-wet pick-up rate

9 8 4

Size concentration
12 12 8

160/2 13800 60s 60s 50s 40s 20s 8840 13200 6976 6368 5200

25 25 25 33 33 42

30 33 42

What's New

DX8

High-Speed Drawing Frame Debuts

The Toyota DX8 High-Speed Drawing Frame takes quality, productivity and ease of use to even higher levels, precisely meeting diverse customer needs.

Offers High Levels of Both Quality and Productivity

Optimized sliver feed path (feed, draft, coiling, etc.)
Twist-free in-line sliver feed enables precise weight measurement. Newly designed sliver guides provide optimal sliver feed width. Newly designed gatherer forms slivers with fleece wrapped inside and with no fuzz.

Precision Auto Leveler dramatically improves the accuracy of sliver weight fluctuation corrections.

Fast CPU cuts the scanning length needed to sense variations in sliver weight to one-third the previous distance for higher accuracy. Improved servomotor responsiveness provides further boosts in accuracy.

The Highest Standards for Ease of Operation and Maintenance

New machine status monitor lets the operator check key data parameters anytime. Stainless-steel coiler plates offer superior abrasion resistance.

High SpeedsUp to 1,000 Meters/Minute

5-Over 4+ Pressure Bar Draft

The optimized sliver feed path and Auto Leveler ensure high-quality sliver forming, enabling fast, efficient operation at speeds of up to 1,000 m/min. under actual operating conditions.

The 5-Over 4+ Pressure Bar Draft is highly rated for delivering stable, consistent drafting. Separating the main draft zone and break draft zone allows the top rollers to grasp the fleece reliably, ensuring stable, consistent draft.

Type 100% cotton Synthetic fiber Combed Carded Polyester/cotton blend 100% polyester 100% acrylic 100% rayon

Drawing speed (m/min.)

400 500 600 700 800 900 1000

6 to 8 Main draft

1.02

1.1 to 1.7 Break draft

Improved Servomotor Responsiveness

Pressure bar draft

Servomotors designed to provide superior responsiveness and tracking characteristics offer better accuracy in compensating for variations in sliver weight.

Comparative Servomotor Responsiveness

rpm 450 400 350 300 250 200 150 100 50 0 0 200 400 600 800 1000 1200 1400 1600 1800 2000 Elapsed time (units: 0.5 ms) Conventional model DX8

Monitoring System

An advanced monitoring system enables the operator to change settings such as switching the Auto Leveler ON or OFF, and to enter operating conditions. The system can also store a diverse range of operating data, including production control and spinning quality control items, maintenance data, and machine downtime statistics. Necessary data can be readily retrieved for use whenever needed.

Customer Support & Service

Electronic Parts Catalog

(for the JAT710)

Designed for Customer Convenience

We have recently created an electronic version of the parts catalog for the new JAT710 Air Jet Loom. This CD-ROM is designed to make using the catalog as easy as possible for our customers, and includes convenient features such as part lists linked to part illustrations, as well as the ability to search by part number and/or description and generate parts order lists. Customers can use the illustrations contained in the catalog to create documents such as operation sheets and factory reports. The CD-ROM also contains the catalog data in printable form for customers who wish to have a hardcopy version of the catalog available.

Users Guide
Provides instructions on how to use the parts catalog. Available in three languages: Japanese, Chinese and English

Search
Specify a part number, part name or remarks as search parameters. Wildcard searches are also possible (use to indicate any text before or after, and ? to indicate any single character).

Parts Order
An Order List can be generated automatically simply by checking the appropriate checkbox in the column next to a needed part. Enter the quantity needed and click the SAVE button to save the file in CSV format. Send the Order List by e-mail, or upload the file from the TICS (Toyota Internet Customer System) screen*.

Part Numbers Linked to Part Illustrations

In addition to the parts catalog, the instruction manual is also provided in electronic form. The instruction manual can also be printed out, if desired. Application software needed to view the CD-ROM versions of the parts catalog and instruction manual is also provided on the CD-ROM.

*You must sign a basic services agreement to use TICS.

Key nos. in part illustrations are linked to the part number list. Selecting one automatically causes the other to be selected, as indicated by a color change.

Maintenance Tips from the Service Department

Air Jet Looms
1. Air compressors form the heart of air jet looms. These devices are susceptible to contamination from oil and condensed moisture, and even a small amount entering the unit will make it impossible for the compressor to deliver maximum performance. Be sure to change the mist separator and filters on the compressor outlets on a regular basis. Regular replacement of these maintenance items will ensure stable, consistent operation, save energy, and enable you to maintain high uptime ratios. 2. When the reed is washed on the loom, be very careful to ensure that no washing solution splashes on the weft yarn detector or valves. Water splashing onto electrical components will reduce reliability significantly. When washing, be sure to use protective caps and waterproof sheeting to protect these components. 3. Damaged healds coming into contact with the heald frame have the potential to cause catastrophic damage. Be sure to remove and replace damaged healds immediately.

Mitsuhiro Iwasaki, Service Department Manager

Thank you very much for choosing textile machinery from Toyota. Continuing from the previous issue, we are pleased to offer a few helpful maintenance tips selected by our service personnel.

Water Jet Looms

1. Cushion washers located inside magnetic pins installed on two-color or BLD measuring systems must be checked (or replaced) at least once a year. If neglected, a worn or damaged washer may cause failure/damage or abrasion problems on cores or plungers. 2. Lint or waste yarn wrapped around the outside of the main shaft coupling (right side) can damage the oil seal tip, allowing moisture to penetrate into the gear box. When the beams become empty, be sure to completely remove any lint or yarn waste, and perform an oil check. 3. On occasion, customers may switch to contactortype inching on their inverter-type inching models. This mode of operation shortens the service life of magnetic contactors, and we strongly advise against this kind of usage.

Spinning Machinery
1. Uniform roving tension during spinning is essential to ensure stable operation. Running equipment with improper tension will cause increased downtime resulting from roving breaks and lead to poor yarn quality in downstream processes. Be sure to pay careful attention to roving tension. 2. Items to check when roving tension is out of specifications: 1) Abrasion on flyer cap (recommended replacement period: every 3 to 5 years) 2) Abrasion on flyer presser (recommended replacement period: every 3 to 5 years) 3) Increased contact resistance due to cotton wax adhering to the flyer. 4) Out-of-level condition of bottom conveyor drum and/or faulty building motion adjustment. 5) Inner surface abrasion on conveyor belts and/or increased slippage resulting from the use of other than genuine factory parts.

THOUGHTS & FEELINGS User Report

China
Beijing Shanghai

Part 14 China

Shandong Weiqiao Textile Group Co., Ltd.

In this issue, we introduce the Shandong Weiqiao Textile Group Co., Ltd, the leader in net sales and manufacturing volume in the Chinese textile industry. Located in the southern part of North Shandong Plain, Shandong Province, the company has a 2,000-hectare site and 60,000 employees. Shandong Weiqiao has plants for spinning, weaving, dyeing, as well as its own thermal power plant. The groups annual capacity is 300,000 tons of cotton yarn and 1.1 billion meters of cotton cloth. Shandong Weiqiao was the first company in China to use our RX240NEW-EST ring spinning frame, and now has 20,000 spindles. This year, the company ordered more than 900 of our new JAT710 air jet looms.

Shandong Weiqiao Textile Group Co., Ltd.

No. 34 Qidong Road, Weiqiao Town, Zouping County, Shandong Province, China

Zhang Shiping, Chairman

Zhang Hongxia, General Manager

Tell us about the products you make.

We make more than 2,000 kinds of cloth, including pure cotton cloth, polyester cloth, fine-count/high-density stretch cloth, denim (standard yarn, stretch yarn, slub yarn), corduroy, and synthetic fiber cloth. With ISO 9001 quality management certification, we make the Weiqiao brand, which we ship to more than 20 countries, including the US, Japan, and Korea and which is highly rated among customers for its superb quality. Our quality policy is with people as our capital, take the utmost care in the manufacture of all yarn and cloth, and work with sincerity to create new products that will satisfy customers.

raise our own level of technology. With the market today demanding the very highest quality fabric, our goal is to use Toyota machinery to produce a higher grade of compact yarn that gives our customers added value and that makes us a leader in the high-end market. We look forward to continued support from Toyota.

What are your companys plans for the future?

In 2000, we made it our goal to become a pioneer in the worldwide spinning and weaving industries in the 21st century. Another goal is to raise our earnings in 2005 to quadruple those of 2000. In other words, were aiming for net sales in 2005 of 15 billion yuan (US$1.814 billion), with US$600 million of that being exports. On a foundation of spinning and weaving, we hope to make our company grow in two major areas: spinning, weaving, dyeing, and sewn products; and thermal power, aluminum electrolysis, and aluminum processing.
Toyota air jet looms at work in the Shandong Weiqiao plant

What do you think of the Toyota products you use?

Toyota has the highest level of technology and we have complete faith in its products. We purchased 20,000 spindles of Toyotas compact RX240NEW-EST ring spinning frame in efforts to further

T O Y O T A

W O R K

Introducing Toyotas Businesses

Part IV

Engine Division

This is the 4th installment in our series on Toyota business divisions. The Engine Division develops and manufactures diesel and gasoline engines from 1.5 to 4.7 liters. These engines go into Toyota Motor Corporation passenger cars and Toyota Industries forklifts.

Engine Division History

1953 Kyowa Plant begins manufacturing passenger car engines. 1982 Hekinan Plant goes on line manufacturing diesel engines for passenger cars. 1991 Engine production reaches 5 million. 1998 Engine production reaches 8 million. 2001 Engine production reaches 9 million.

Based on its motto of Quality No. 1, the Engine Division constantly strives to make high-power, fuelefficient, low-noise and low-vibration engines that are constructed from recyclable materials and that thus achieve both environmental friendliness and superb efficiency. The Hekinan Plant, which started operation in 1982, boasts lines equipped with unmanned transport machinery and rest and relaxation facilities, giving employees an environment conducive to healthy, productive work.

Main Products

1CD-FTV

2,000 cc engine for small passenger cars

2UZ-FE

4,700 cc engine for large RVs

4Y

2,200 cc engine for industrial vehicles

A direct diesel-injection engine used in cars like the Estima and Corolla in Japan, and in the Avensis, RAV4, and Corolla in Europe.

Used in both the domestic and export versions of all Land Cruiser models except the Prado. This diesel engine is also used in the Coaster.

Used in industrial vehicles like forklifts, and for driving gas heat pumps and bus coolers.

About the Cover: Japanese DesignIn Style to Stay

2-1, Toyoda-cho, Kariya-shi, Aichi 448-8671, Japan Tel: 81-566-27-5326 Fax: 81-566-27-5307 URL: http://www.toyota-industries.com/textile E-mail: kaoru.kumamoto@mail.toyota-shokki.co.jp Please send your comments or questions regarding the Toyota Textile Machinery Bulletin to any of the above addresses. Contact person: Ms. Kaoru Kondo Art direction and editorial assistance: Cs Inc. Printing: Okamura Printing Industries Co., Ltd.
The Western fashion world has witnessed a wave of Japonismthe love of things Japanesein recent years. No longer merely relegated to the realm of the kitsch, esoteric, and foreign, todays Japanese fashion boasts patterns of intricate, graceful beauty and is equal in status to its Western counterpart. Visitors to Japan love to take home not only Japanese-patterned clothing but also knick-knacks like hand mirrors and fans.

TOYOTA TEXTILE MACHINERY BULLETIN Vol.15

Published July 2003 All rights reserved. Reproduction in whole or in part without written permission is prohibited. This bulletin is printed on recycled paper. Printed in Japan