toyota
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T @ RW O KT O OY A Vol.15
B U L L E T I NT O Y O T A T E X T I L E M A C H I N E R Y
About the Cover: Japanese Design—In Style to StayThe Western fashion world has witnessed a wave of “Japonism”—the love of things Japanese—in recent years. No longer merely relegated to the realm of the kitsch, esoteric, and foreign, today’s 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.
2-1, Toyoda-cho, Kariya-shi, Aichi 448-8671, JapanTel: 81-566-27-5326 Fax: 81-566-27-5307URL: http://www.toyota-industries.com/textileE-mail: [email protected]
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: C’s Inc.Printing: Okamura Printing Industries Co., Ltd.
TOYOTA TEXTILE MACHINERY BULLETIN Vol.15Published July 2003©All rights reserved. Reproduction in whole or in part without written permission is prohibited. This bulletin is printed on recycled paper.
Introducing Toyota’s Businesses Part IV Engine Division
Based on its motto of “Quality No. 1,” the Engine Division constantly strives to make high-power, fuel-efficient, 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
A direct diesel-injection engine used in cars like the Estima and Corolla in Japan, and in the Avensis, RAV4, and Corolla in Europe.
1CD-FTVUsed in both the domestic and export versions of all Land Cruiser models except the Prado. This diesel engine is also used in the Coaster.
2UZ-FEUsed in industrial vehicles like forklifts, and for driving gas heat pumps and bus coolers.
4Y
Engine Division History1953 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.
Special FeatureJAT710’s IT Functions
Technical NewsToyota Spun Sizer Pre-Wet Sizing System
What’s NewDX8 High-Speed Drawing Frame
Customer Support & Service Electronic Parts CatalogTips from the Service Department
Thoughts & FeelingsUser Report Part 14: Shandong Weiqiao Textile Group Co., Ltd. (China)
Toyota @ WorkIntroducing Toyota’s BusinessesPart 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.
Printed in Japan
2,000 cc enginefor small passenger cars 2,200 cc engine for industrial vehicles4,700 cc engine for large RVs
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S P E C I A L F E A T U R E
Note: Date of availability differs with each item.
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 JAT710’s 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 customer’s company.
JAT710 Network System
By connecting the JAT710 to a network with a standard LAN cable and installing Toyota’s 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 another—a world-first. TMS can be used with the customer’s 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
TMS (Toyota Monitoring System)
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.
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.
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 JAT710’s 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.
Shift report Stop analysis graph
Production graph Efficiency graph Warp out forecast
The function panel screen displays a variety of information
External Network Customer Internal Network
Customer Mill Network
Mobile PC
Customer mobile PC
Customerhead office
Customersales division
CustomerR&D division
Customer server
Customer PC
Customer PC
Internet
Customermill office
Customer PC Customer printer
Customertextile mill
Camera viewParts catalogTICSTechnical informationInstruction manualMonitoring
World First
World First
JAT710function panel
Introducing the JAT710’s IT Functions
2 3
S P E C I A L F E A T U R E
Note: Date of availability differs with each item.
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 JAT710’s 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 customer’s company.
JAT710 Network System
By connecting the JAT710 to a network with a standard LAN cable and installing Toyota’s 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 another—a world-first. TMS can be used with the customer’s 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
TMS (Toyota Monitoring System)
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.
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.
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 JAT710’s 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.
Shift report Stop analysis graph
Production graph Efficiency graph Warp out forecast
The function panel screen displays a variety of information
External Network Customer Internal Network
Customer Mill Network
Mobile PC
Customer mobile PC
Customerhead office
Customersales division
CustomerR&D division
Customer server
Customer PC
Customer PC
Internet
Customermill office
Customer PC Customer printer
Customertextile mill
Camera viewParts catalogTICSTechnical informationInstruction manualMonitoring
World First
World First
JAT710function panel
Introducing the JAT710’s IT Functions
00 200 400 600 800 1000 1200 1400 1600 1800 2000
50
100
150
200
250
300
350
400
450
What's NewTechnical News
既設台
DX8 High-Speed Drawing Frame Debuts
High Speeds—Up to 1,000 Meters/Minute
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.
Improved Servomotor Responsiveness
Servomotors designed to provide superior responsiveness and tracking characteristics offer better accuracy in compensating for variations in sliver weight.
5-Over 4+ Pressure Bar Draft
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.
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.
Toyota Spun SizerPre-Wet Sizing SystemCuts 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.
Pre-Wet Sizing BenefitsCuts Size ConsumptionThe 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.
Multi-Purpose SystemFor products that require no pre-wet sizing, the pre-wet sizing system can be used as a conventional carrier roller system.
Compact Roller ArrangementThe 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-DryingSuper-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 pre-drying stage and provides sufficient pre-wetting effect resulting in excellent yarn handling characteristics and greater energy efficiency.
Typical Examples Using Cotton Yarn Typical Examples Using Polyester/Cotton Blended Yarn
Yarncount
160/2
60s
60s
50s
40s
20s
13800
8840
13200
6976
6368
5200
Standard pick-up rate
4%
8%
8%
9%
9%
7%
Pre-wetpick-up rate
3%
6%
6%
6%
6%
4%
Sizeconcentration
11%
10%
11%
10%
10%
8%
ー25%
ー25%
ー25%
ー33%
ー33%
ー42%
Yarncount
45s
34s
30/2
6260
4992
6600
Standard pick-up rate
13%
12%
7%
Pre-wetpick-up rate
9%
8%
4%
Sizeconcentration
12%
12%
8%
ー30%
ー33%
ー42%
Easy Change-OverSwitching 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.)
Comparative Servomotor Responsivenessrpm
Elapsed time(units: 0.5 ms)
DX8
Conventional model
Calculation ofactual moisture content
Target size concentration
Estimated size concentration
Calculation ofsize pick-up rate
Flow meter
Size supply
Concentration ofsize to be supplied
Warp yarn unit volume
Yarn productionvolume calculation
Pre-wet moisture control
Sizing length
Size supply controlWater supply control
Water supply
Squeezingpressure control
Flow meter
Size boxHot water box
Squeezing
Soaking inhot water
Sizing
Carrier roller frame
Sizing frame
Sizing frame
Pre-wet frame
Existing Equipment
After Upgrade
Squeezing rollers
Bottom squeezing roller
Top squeezing roller
Bottom squeezing roller
Top squeezing roller
Toyota Pre-Wet Sizing System Features
SIZE-NAVI SystemThis 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.
No. of ends
No. of ends
400 500 600 700 800 900 1000
Combed
Carded Polyester/cotton blend
100% polyester
100% acrylic
100% rayon
Type
100% cotton
Drawing speed (m/min.)
Synt
hetic
fiber
6 to 8 1.02 1.1 to 1.7
Main draft Break draft
Pressure bar draft
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.
4 5
00 200 400 600 800 1000 1200 1400 1600 1800 2000
50
100
150
200
250
300
350
400
450
What's NewTechnical News
既設台
DX8 High-Speed Drawing Frame Debuts
High Speeds—Up to 1,000 Meters/Minute
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.
Improved Servomotor Responsiveness
Servomotors designed to provide superior responsiveness and tracking characteristics offer better accuracy in compensating for variations in sliver weight.
5-Over 4+ Pressure Bar Draft
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.
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.
Toyota Spun SizerPre-Wet Sizing SystemCuts 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.
Pre-Wet Sizing BenefitsCuts Size ConsumptionThe 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.
Multi-Purpose SystemFor products that require no pre-wet sizing, the pre-wet sizing system can be used as a conventional carrier roller system.
Compact Roller ArrangementThe 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-DryingSuper-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 pre-drying stage and provides sufficient pre-wetting effect resulting in excellent yarn handling characteristics and greater energy efficiency.
Typical Examples Using Cotton Yarn Typical Examples Using Polyester/Cotton Blended Yarn
Yarncount
160/2
60s
60s
50s
40s
20s
13800
8840
13200
6976
6368
5200
Standard pick-up rate
4%
8%
8%
9%
9%
7%
Pre-wetpick-up rate
3%
6%
6%
6%
6%
4%
Sizeconcentration
11%
10%
11%
10%
10%
8%
ー25%
ー25%
ー25%
ー33%
ー33%
ー42%
Yarncount
45s
34s
30/2
6260
4992
6600
Standard pick-up rate
13%
12%
7%
Pre-wetpick-up rate
9%
8%
4%
Sizeconcentration
12%
12%
8%
ー30%
ー33%
ー42%
Easy Change-OverSwitching 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.)
Comparative Servomotor Responsivenessrpm
Elapsed time(units: 0.5 ms)
DX8
Conventional model
Calculation ofactual moisture content
Target size concentration
Estimated size concentration
Calculation ofsize pick-up rate
Flow meter
Size supply
Concentration ofsize to be supplied
Warp yarn unit volume
Yarn productionvolume calculation
Pre-wet moisture control
Sizing length
Size supply controlWater supply control
Water supply
Squeezingpressure control
Flow meter
Size boxHot water box
Squeezing
Soaking inhot water
Sizing
Carrier roller frame
Sizing frame
Sizing frame
Pre-wet frame
Existing Equipment
After Upgrade
Squeezing rollers
Bottom squeezing roller
Top squeezing roller
Bottom squeezing roller
Top squeezing roller
Toyota Pre-Wet Sizing System Features
SIZE-NAVI SystemThis 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.
No. of ends
No. of ends
400 500 600 700 800 900 1000
Combed
Carded Polyester/cotton blend
100% polyester
100% acrylic
100% rayon
Type
100% cotton
Drawing speed (m/min.)
Synt
hetic
fiber
6 to 8 1.02 1.1 to 1.7
Main draft Break draft
Pressure bar draft
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.
4 5
Customer Support & Service
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 group’s 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.
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.”
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 Toyota’s compact RX240NEW-EST ring spinning frame in efforts to further
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 company’s 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, we’re 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.
Maintenance Tips from the Service Department 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.
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.
Air Jet Looms1. 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 contactor-type 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.
Water Jet Looms1. 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.
Spinning Machinery
T H O U G H T S & F E E L I N G S
Shandong Weiqiao Textile Group Co., Ltd.No. 34 Qidong Road, Weiqiao Town, Zouping County, Shandong Province, China
Zhang Hongxia, General ManagerZhang Shiping, Chairman
Toyota air jet looms at work in the Shandong Weiqiao plant
ChinaElectronic Parts Catalog(for the JAT710)
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*.
*You must sign a basic services agreement to use TICS.
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).
Part Numbers Linked to Part Illustrations• 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.
User Report
Part 14 China
Shandong Weiqiao Textile Group Co., Ltd.
Beijing
Shanghai
Designed for Customer ConvenienceWe 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.
• 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.
6 7
Customer Support & Service
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 group’s 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.
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.”
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 Toyota’s compact RX240NEW-EST ring spinning frame in efforts to further
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 company’s 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, we’re 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.
Maintenance Tips from the Service Department 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.
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.
Air Jet Looms1. 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 contactor-type 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.
Water Jet Looms1. 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.
Spinning Machinery
T H O U G H T S & F E E L I N G S
Shandong Weiqiao Textile Group Co., Ltd.No. 34 Qidong Road, Weiqiao Town, Zouping County, Shandong Province, China
Zhang Hongxia, General ManagerZhang Shiping, Chairman
Toyota air jet looms at work in the Shandong Weiqiao plant
ChinaElectronic Parts Catalog(for the JAT710)
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*.
*You must sign a basic services agreement to use TICS.
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).
Part Numbers Linked to Part Illustrations• 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.
User Report
Part 14 China
Shandong Weiqiao Textile Group Co., Ltd.
Beijing
Shanghai
Designed for Customer ConvenienceWe 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.
• 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.
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T @ RW O KT O OY A Vol.15
B U L L E T I NT O Y O T A T E X T I L E M A C H I N E R Y
About the Cover: Japanese Design—In Style to StayThe Western fashion world has witnessed a wave of “Japonism”—the love of things Japanese—in recent years. No longer merely relegated to the realm of the kitsch, esoteric, and foreign, today’s 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.
2-1, Toyoda-cho, Kariya-shi, Aichi 448-8671, JapanTel: 81-566-27-5326 Fax: 81-566-27-5307URL: http://www.toyota-industries.com/textileE-mail: [email protected]
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: C’s Inc.Printing: Okamura Printing Industries Co., Ltd.
TOYOTA TEXTILE MACHINERY BULLETIN Vol.15Published July 2003©All rights reserved. Reproduction in whole or in part without written permission is prohibited. This bulletin is printed on recycled paper.
Introducing Toyota’s Businesses Part IV Engine Division
Based on its motto of “Quality No. 1,” the Engine Division constantly strives to make high-power, fuel-efficient, 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
A direct diesel-injection engine used in cars like the Estima and Corolla in Japan, and in the Avensis, RAV4, and Corolla in Europe.
1CD-FTVUsed in both the domestic and export versions of all Land Cruiser models except the Prado. This diesel engine is also used in the Coaster.
2UZ-FEUsed in industrial vehicles like forklifts, and for driving gas heat pumps and bus coolers.
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Engine Division History1953 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.
Special FeatureJAT710’s IT Functions
Technical NewsToyota Spun Sizer Pre-Wet Sizing System
What’s NewDX8 High-Speed Drawing Frame
Customer Support & Service Electronic Parts CatalogTips from the Service Department
Thoughts & FeelingsUser Report Part 14: Shandong Weiqiao Textile Group Co., Ltd. (China)
Toyota @ WorkIntroducing Toyota’s BusinessesPart 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.
Printed in Japan
2,000 cc enginefor small passenger cars 2,200 cc engine for industrial vehicles4,700 cc engine for large RVs
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