Automatic Loom Research Articles

Origins and Development of Japanese Automotive Industry in 1920-1945, the Case of Toyota Motor Company

The paper addresses the issue of Japanese automotive industry development focusing the case of Toyota Motor Company. The historical background effected the emergence of national automakers is described. The main internal and external factors (industrial policy, socio-economic problems, Chino-Japanese and Pacific Wars and etc.) that have influenced the process of establishing of the Japanese automobile industry. The author points out the role of Toyoda Kiichiro, the founder of Toyota Motor Company, who defined the unique approach to company development and managed to adapt its operations to dramatically changing circumstances of wartime economy. The two main periods of company evolution are revealed. The first period characterizes the performance of Toyota as a structural division of Toyoda Automatic Loom Company emphasizing the design of passenger automobile. The second period illustrates the activities of an independent automotive company fully incorporated into a war-oriented economy. It concludes that, state policy towards automotive industry created the favorable environment for national companies.

Structural Performance Optimization Design of Continuously Accelerating Electromagnetic Weft Insertion System

This paper addresses the problem of low electromagnetic weft insertion acceleration performance of extra-large width automatic looms. Based on single-stage electromagnetic weft insertion and multi-stage intermittent electromagnetic weft insertion, a sectional combined continuous acceleration electromagnetic weft insertion design plan is proposed. First, a new type of weft gripper for electromagnetic weft insertion is designed on the basis of the traditional projectile, and a segmented combined structure optimization design is carried out on the 90 mm single-stage coil. Next, the electromagnetic weft insertion movement model is established to analyze the force and movement speed of the gripper during the movement. The amount of work done by the electromagnetic force of the combined coil determines the exit speed of the weft gripper. Finally, in order to find the best parameters of the combined coil structure to meet the requirements of the launch speed, the steady state and transient performance of the segmented combined continuous acceleration coil are analyzed using Maxwell simulation software. The launch performance of the combined coil with different axial lengths of 45 mm, 30 mm, and 15 mm is compared. The results show that the entire acceleration process is more stable and efficient when the combined coil length is 30 mm, the inner diameter is 18 mm, and the number of turns is 600.

DETERMINATION OF TENSION FOR ARAMID AND CARBON YARNS WHILE WEAVING INDUSTRIAL FABRICS

Resulting from researches conducted to determine tension for para-aramid, meta-aramid, and carbon multifilament yarns during their contact with the operative parts of the weaving looms as part of the industrial fabrics formation process, we have found out that in threading areas the tension is increasing driven by variation of values of the friction forces in the contact area. It has been proven that tension degree of para-aramid, meta-aramid, and carbon multifilament yarns before industrial fabric formation area is influenced by (1) tension before cylindrical guide surface of an operative part, (2) radius of the cylindrical guide surface curve of the operative part, (3) contact angle between yarns and cylindrical guide surface of an operative part, (4) mechanical, physical and structural properties of para-aramid, metaaramid, and carbon multifilament yarns. It allowed (yet at the initial stage of design of technological process of industrial fabric formation) to determine para-aramid, meta-aramid, and carbon multifilament yarns tension before formation area depending on (1) form of threading line for yarns at the weaving loom, (2) mechanical, physical and structural properties of para-aramid, meta-aramid, and carbon multifilament yarns and industrial fabrics. The paper contains experimental research of interaction of para-aramid, metaaramid, and carbon multifilament yarns and cylindrical guide surfaces of the operative parts of automatic weaving looms. Based on experimental researches regression dependencies have been obtained between para-aramid, meta-aramid, and carbon multifilament yarns tension value after cylindrical guide surfaces of the operative part and (1) tension before cylindrical guide surface of the operative part, (2) radius of the cylindrical guide surface curve of the operative part, (3) contact angle between yarns and cylindrical guide surface of the operative part. Consecutive application of these regression dependencies allows to determine para-aramid, meta-aramid, and carbon multifilament yarns tension before industrial fabrics formation area. Analysis of regression dependencies allowed to find out values of technological parameters when para-aramid, meta-aramid, and carbon multifilament yarns tension before industrial fabrics formation area will be of minimum value. It will allow to minimize tension of para-aramid, metaaramid, and carbon multifilament yarns while manufacturing resulting in (1) yarn breakages reduction, (2) better productivity of weaving looms due to reduced stoppage time, (3) improved quality of manufactured industrial fabrics. Therefore, we can argue that suggested technological solutions are practically attractive. In view of this, it is reasonable to say that it is possible to directionally regulate the process of para-aramid, meta-aramid, and carbon multifilament yarns tension change while manufacturing industrial fabrics on the weaving looms through selection of values of guides’ geometrical parameters.

Technological Innovation and Industrial Decline: The Case of the Automatic Loom in the British Cotton Industry

ABSTRACT Designing an automatic loom that replenishes weft mechanically without operative intervention challenged the ingenuity of engineers and technologists from the middle of the 19th century until about 1970, when further development ceased in favour of shuttleless alternatives. Although well established in the United States for manufacturing basic cotton fabrics by 1914, and sufficiently well advanced for producing a wide range of fabrics by 1930, the diffusion of the automatic loom in the British cotton industry was sluggish until the 1950s. The reasons are best understood by examining the operational prerequisites, provision of which in Britain was confounded by longstanding rigidities in accounting policy and industrial relations at the level of the firm, and in strategic management at the level of the industry. At the heart of this was the longevity of the traditional non-automatic Lancashire loom, both in design and operation. The article is a counterpoise to the orthodox economic analyses that tend to be dismissive of technological constructs.

Consideration of Toyoda Power Loom, Type Y

Toyoda Power Loom, Type Y is the small and narrow power loom invented by Sakichi TOYODA in 1915. Sakichi TOYODA has developed high-speed high-performance loom of the wide cloth represented by Power Loom, Type L, Type N and Automatic Loom, Type G, but on the other hand small power loom like Type Y has been also developed even small business can use conveniently. A small type of power loom is used for a subsistence store such as working clothes and a Japanese towel as local stockbroker's material of the traditional industry and for fabrics again, and a small and narrow power loom also keeps being converted into power loom from homespun and using it at present. The structure, a system, a mechanism and convenience were considered about this Toyoda Power Loom, Type Y, compared to the high-speed high-performance loom Type N and Type G, so it will be reported in this time.

Development of 3D hollow woven fabrics with superior mechanical properties by using nitinol and steel wire core hybrid yarns

In this study, nitinol and steel wire core hybrid yarns were produced from wires having two different diameters and used as warp yarns to weave 3D woven fabrics in two different fabric constructions. The steel bars with two different diameters were placed into the gaps between fabric layers to create a hollow form after fabric production. The fabrics produced with cold-worked nitinol wire were exposed to heat treatments at high temperatures to provide them shape memory property according to data obtained from DSC analysis. Conventional textile fibers are not durable to these temperatures; for this reason, carbon fiber was used both as sheath material of hybrid yarns and additionally as warp and weft carbon fiber yarns. All yarn and fabric tests were carried out simultaneously to evaluate the mechanical properties of nitinol and steel wire core hybrid yarns, and wire-reinforced fabrics. Tensile tests were applied to all wire and hybrid yarn samples, DSC and DMA analyses were conducted for only heat-treated nitinol wires. Low-velocity impact, tensile and pull-out tests were applied to fabric samples. Reference fabrics with no wire were produced and evaluated by comparing with wire-reinforced samples to provide a point of comparison to the data from the mechanical properties of wire-reinforced 3D fabrics. The study's results were analyzed with regression analysis using the backward method, and the parameters such as wire type, wire diameter, and fabric gap width for optimum fabric production were determined. Data obtained from all mechanical tests demonstrate that fabric samples with steel wire, thinner wire, and narrow gaps have better results than others. The effect of wire thickness was also found the same for the nitinol wire. DMA analyses show that the thinner nitinol wire is better than, the thicker one. Finally, an innovative technique has been developed in this study to weave carbon fiber on a conventional automatic sample loom without fiber breakage by twisting PVA yarn around the wire core hybrid and twisted carbon fiber yarns.

Developing a real-time accuracy monitoring system for industrial robot arms based on lean principles

In the Robot Laboratory of Mechatronics Department during practical classes of robot programming, the participants observed that the KUKA KR5 Arc robot arm’s practicing tool does not accurately follow the programmed path in every case. In accordance to Lean approaches, the observations of the participants were taken into consideration and the possible sources of error were identified. One of them is the robot arm itself, which is responsible for the execution of the programmed movements. The goal of this research is to develop a system which makes it possible to exclude the robot arm as a potential source of error from the error analysis. For this purpose, a monitoring system was developed which supports the Lean production by implementing one of the main pillars of the Toyota Production System. Jidoka is one of the main pillars, which means that the production process is automatically stopped if an error condition arises. The method was first implemented by Sakichi Toyoda in 1896, who developed a simple device for automatic looms, which stopped the machine if the thread broke. Using this principle, the autonomation – automation with human touch – of the robot arm is achieved.

3D warp interlocks p-aramid fabrics for composite reinforcement and ballistic vest applications: Effect of yarn density on its formability characteristics

The material forming capability becomes one of the most important characteristic of textile performance in the manufacturing of three-dimensional (3D) components to fit a 3D surface in various technical applications. In this study, different forming characteristics of 3D warp interlock fabrics in dry fabric condition were investigated. 3D warp interlock architecture with different areal density from same para-aramid yarn with a linear density of 168dtex were systematically designed and produced on automatic dobby loom with standard atmospheric conditions. The approach utilizes a low speed forming process with a predefined hemispherical shape of punch for the analysis of different forming behaviour of the fabrics specimen. The same blank-holder pressure was chosen for all the samples for better comparisons. Among several forming properties, some important characteristics have been observed, measured and analysed for a better understanding of the material forming behaviour of the different samples specimen. The research results with independent warp and weft yarn densities show a significant impact on the forming behaviours 3D warp interlock fabric. Moreover, the result of the investigation also will give a better understanding on different forming behaviours of 3D warp interlock fabric with various densities while applying in different textile application including women soft body armour.

Consideration about the main mechanism of Type G Automatic Loom

Consideration about the main mechanism of Type G Automatic Loom

High-Pass Sub-mmWave Filtering by Woven Textile Metamaterials

Textile metamaterials produced by a weaving of metallic and dielectric yarns are considered for filtering operations in the sub-millimeter band. A woven metamaterial was designed by parametric simulations aimed at producing a high-pass filter with a cutoff frequency at around 500 GHz above a high-reflective band and a strong rejection. The woven metamaterial is analyzed by means of an equivalent circuit formed by two resonant impedances, which are responsible of the rejection and high-pass features. A textile metamaterial was produced by an automatic weaving loom in a semi-industrial environment and it was electromagnetically characterized in free space. Experimental results are in good agreement compared with simulation and a phase-advance in transmission is evidenced. The phase of the reflection coefficient is also experimentally investigated thanks to a de-embedding process using a double-sided reflective mirror as a reference. Finally, the equivalent circuit of the fabricated textile is computed from the complex experimental reflection and transmission coefficients.

About parts process machines for Type G Automatic Loom.

About parts process machines for Type G Automatic Loom.

Dynamic Model of Automatic Loom on SimulationX

Dynamic Model of Automatic Loom on SimulationX

Development of single-layer 3D ‘T’ profile with fillet for composite ‘T’ joints

This paper details about weaving of single-layer 3D ‘T’ profile with fillet for use as insert in composite ‘T’ joints and ‘T’ stiffeners. The ‘T’ insert with fillet was woven using 3 K carbon tows on a narrow width multi-beam automatic loom. Weaving was carried out based on the double-cloth weaving principle. Novelty of the work lied in the approach adopted for designing of the weave architecture in developing 3D ‘T’ profile with fillet portion, arriving at the pick cycle diagram for weave design development which has been detailed in this paper. Test results of composite ‘T’ joints fabricated incorporating the insert showed strength improvement as well as change in crack propagation mode as compared to conventional ‘T’ joint. The continuous insert with fillet acted as a bridging member among the three sections of the ‘T’ joint, thus contributing to performance improvement.

動かし続けることにこだわる博物館

Toyota Commemorative Museum of Industry and Technology is established enterprise museum in trace of Toyoda Automatic Loom Works, Ltd. Sako Plant. As well as buildings with red brick wall are preserved and utilized as an industrial heritage, and a technological change in a textile machinery and an automobile are introduced. Importance of "Being Studious and Creative" and "Making things" are imparted through real mechanical movement exhibition and a various demonstration. In order to do movement preservation of an exhibition machine such as Toyoda Non-stop Shuttle-change Automatic Loom Type G which was also authorized by a Mechanical Engineering Heritage, maintenance and repair, acquisition of consumable parts, arrangements of a raw material for demonstration, handing of operator's technology and skill are being performed ourselves. Those efforts are introduced.

전통 반자동식 동다회직기의 특성과 구조 분석에 관한 연구

Dahoe is a traditional Korean term for cords and Dongdahoe for round cords. The main purpose of this study is to analyze the structure of a semi-automatic loom depicted in the paintings of Jun Geun Kim, and verify whether it actually worked or not. Jun Geun Kim is a genre painter of the late Joseon Dynasty. His nom de plume is Gisan and he drew genre paintings for foreigners who visited Korea in the late 19th century. These paintings are important in understanding the lifestyle and custom of the times. His paintings at the Staatliche Museen zu Berlin in Germany and the British Museum in England both depict a semi automatic loom that operates two looms at the same time. This is a unique loom that is not found in any other country and currently no artifacts of such loom exist in Korea. The study went through the following steps: We first analyzed the structure and the operating mechanism of the loom in the painting. The structure of each parts and their roles were also analyzed. Then a loom that was similar in structure and size was made to check if it was operational. The loom depicted in the paintings had some problems, and adjustments to fix the said problems were made accordingly. Wood was primarily used to make the <TEX>$80{\times}90cm$</TEX> loom. The loom was used to make Dahoe and the study confirmed that there were no differences between the handmade Dongdahoe and the Dongdahoe made with the semi automatic loom.

Control System Semi-Automatic Palembang Songket Shawl Using Splay Tree Algorithm Based ATMega 8

Songket shawl is handcrafted hereditary in South Sumatra, but is also a manufacture shawls for songket which is also typical of Palembang. Songket shawls  device consists of makers crutch, stick motif maker, dividers, and bobbin. Furthermore, researchers will apply a calculation using the splay tree algorithm to identify, to detected and stop the process of command at the time of semi-otomamatis will be work, researchers will also discuss well with experts. Semi-automation weaving machines are expected to contribute the craftsmen to improve results weaving  it’s , such as looms and supplies sensors and application programs that can be used and then will make the craft of weaving typical areas of South Sumatra. This research is expected to produce a patent for songket and scarf with a semi-automatic machine patents and developed with several motifs. This research will measure  are performance of semi-automatic by showing  results of measurement of the strength or speed DC motor to throw and pull the threads, be it gold thread and yarn. Limar, regulated Pulse Width Mudulation (PWM) so that the performance of motor speed can be adjusted, from measurement results are known in the hurling thread from a distance of 0 - 30 cm. When a thread already determined the maximum distance that the duty cycle of the PWM value of 0 cm distance position obtained 0 % duty cylce and from a distance of 30 cm till maximum gained 3.12% duty cycle. Furthermore, measuring the value of the AT Mega 8 is connected to the amplifier IC L293D DC motor with which the process of making a semi automatic loom requires a 12 MHz crystal so that the cycle speed to 12 MHz/12 = 1 MHz, which means time is 1 microsecond pulse period. Loom’s will be connected to a computer for programming process as data base in terms of the AT Mega 8 language in use, so that the output of the weaving songket shawl can be arranged with advance determined motives that would be desirable is useful to prevent or protect hurling thread - the thread excessive, so that motifs are in use should be appropriate.

An integrated framework for mechatronics based product development in a fuzzy environment

New product development (NPD) is a term used to describe the complete process of bringing a new concept to a state of market readiness. Mechatronics based product requires a multidisciplinary approach for its modeling, design, development and implementation. An integrated and concurrent approach focusing on integrating the mechanical structure with basic three components namely sensors, controllers and actuators is required. This paper aims at developing a framework for a new Mechatronics product development. For conceptual design of Mechatronics system, various tools like Fuzzy Delphi Method (FDM), Fuzzy Interpretive Structural Modeling (FISM), Fuzzy Analytical Network Process (FANP) and Fuzzy Quality Function Deployment (FQFD) are used. Based on the prioritized design requirements, the functional specifications of the required components are developed. Then, Computer Aided Design and control system software are used to develop the detailed system design. Then, a prototype model is developed based on the integration of mechanical system with Sensor, Controller and Electrical units. Performance of the prototype model is monitored and Fuzzy failure mode and effect analysis (FMEA) is then used to rank the potential failures. Based on the results of fuzzy FMEA, the developed model is redesigned. The proposed framework is illustrated with a case study related to developing automatic power loom reed cleaning machine.

Electromagnetic Shielding Effectiveness of Physical Property PET/Stainless Steel Composite Fabrics

The electronic appliance is capable of emitting electromagnetic waves that will cause the damage of electrical equipment and influence peoples health. In this study, stain steel filament (SS filament) and 75D PET filament were used to manufacture SS/PET composite yarn The SS/PET composite yarn were made by the wrapping machine, which the core yarn is stain steel filament, wrapped yarn is 75D PET filament and the wrapping layers is varied as one and two. After that, the composite yarn is fabricated by the automatic sampling loom into composite woven fabrics. The composite SS/PET woven fabrics were under the tests of electromagnetic shielding effectiveness (EMSE) and air permeability. The test results revealed that the EMSE of the one-layer composite woven fabric is 9.5 dB at 900 MHz, but the EMSE decreases as test frequency increases. When laminating layer added to three layers, the EMSE raise up to 12.6 dB. The EMSE of composite woven fabric reached at 29.9 when the laminated angle is 45°. And the air permeability decreases as the laminate layer increases, which the thickness of sample affect air to pass through the sample.

Manufacturing Technique and Properties Evaluation of Ni-Coated Copper Composite Fabrics

The existence of the electromagnetic radiation may lead to diseases, which also includes cancer and cause the repellence of electrical compatibility. The textiles which have electromagnetic shielding effectiveness become more important in modern life. In the research, the PET/ Ni-coated Copper composite yarn were made by the wrapping machine, which the core yarn is Ni-coated Copper wire and the wrapped yarn is PET filament. After that, the composite yarn is fabricated by the automatic sampling loom into woven fabrics and had the tests of mechanical properties and electromagnetic shielding effectiveness. The test results revealed that the EMSE of the PET/Ni-Cu complex woven fabrics is 32.28dB, which the test frequency is 900 MHz, laminated layer number is 3 and the laminated angles are 0°/45°/90°, respectively.

Lean Managers Must be Teachers

Since Sakichi Toyoda first began developing automatic looms and improving them through relentless kaizen in the 1890s, the company he founded and its eventual spinoff, Toyota Motor Company, have been revolutionizing products and the way we think about work and organizing. While it is easy to envision lone inventors at their work benches creating breakthrough products, Toyota's model has always been that of teams focused on what seems an impossible goal experimenting with many ideas until they eventually discover their way to the goal. Kaizen is a team sport, and the team must be highly motivated and highly trained. It is the responsibility of leadership to motivate and develop the staff and team. Toyota does not leave leadership to chance; as we discuss in this article, the company is very intentional about developing leaders who acquire over time the corporate DNA and learn to live the role of Toyota leaders.