Section 1.1 Drive Mechanism - toyotatextilemachinery.com...1.1 Drive Mechanism 1.1 - 5 1.1.4 Adjusting the Belt Tension on the Driving Pulley (1) Press the emergency stop button down

Section 1.1Drive Mechanism

MARCH, 2007 Ver. 1.00

1.1.1 Wiring ................................................................................ 1.1-3

1.1.2 Checking the Motor Cover ................................................. 1.1-3

1.1.3 Checking the Rotation Direction of Main Motor ................. 1.1-4

1.1.4 Adjusting the Belt Tension on the Driving Pulley ............... 1.1-5

1.1.5 Lubrication ......................................................................... 1.1-6

1.1.6 Integrated SC Inverter (Option) ......................................... 1.1-8

[ 1 ] Setting Procedure on the Function Panel................. 1.1-8

[ 2 ] Troubleshooting for the SC Inverter ......................... 1.1-11

1.1.7 Group-control Inverter (for Slow Operation) 1.1-13

1.1.8 Trial Run ............................................................................ 1.1-14

1.1.9 Pulling Out the Motor Pulley .............................................. 1.1-16

1.1 - 1

1. PREPARATION

1.1 Drive MechanismRotation of the main motor 1 is transmitted via the V-belt 2 to the driving pulley 3 which drives the sheddingmotion 4 and each driving shaft in the right-hand (RH) gearing box 5.

The rotation of the driving shafts in the RH gearing box is further transmitted via the connecting shafts to thosein the left-hand (LH) gearing box.

1.1 - 2

1.1 Drive Mechanism

1.1.1 Wiring

(1) Connect the main power line with the primaryterminal of main circuit breaker CB1 locatedinside the control box 1.

(2) When the group-control inverter is to be used,connect the inverter power line with the termi-nal board TB3 located inside the control box 1.

NOTE: This wiring work is not necessary for an SCinverter since it has been finished before deliveryfrom the factory.

REFERENCE: Some weaving machines have anoptional circuit breaker CB4 for a group-controlinverter right next to main circuit breaker CB1. Insuch a case, connect the inverter power line withthe primary terminal of CB4.

1.1.2 Checking the Motor Cover

In some weaving machines, the installation positionof switch 2 may be slightly different.

1

CB1

1

CB1

CB4

Make sure that the main switch on the work-shop switchboard is turned OFF and put up the “DON’T TURN THE SWITCH ON” notice tag.

DON’T TURN THE SWITCH ON

2

1

Removing motor cover 1 activates switch 2, preventing dangerous accidental starts.

Always install cover 1 for operating the machine, except when checking the rotation direction of the main motor (see Subsection 1.1.3).

Take extra care not to crush your hand between the belt and pulley.

1.1 - 3

1. PREPARATION

1.1.3 Checking the Rotation Direction of Main Motor

(1) Remove motor cover 1 (see Subsection1.1.2). Then, turn on switch 2 and fasten itdown with adhesive tape.

(2) Taking special care, press the FORWARDinching switch and check that the main motorrotates counterclockwise when viewed fromthe right side of the weaving machine. (Check-ing the inverter power.)If the motor rotates clockwise, correct the wir-ing of O, P, and Q of terminal board TB3.

(3) Press the START switch and check that themain motor rotates counterclockwise whenviewed from the right side of the weavingmachine. (Checking the main power.)

NOTE: After checking the rotation direction,stop the weaving machine as soon as possi-ble. Never allow the machine to run any longerthan necessary.f the motor rotates clockwise, correct the wir-ing of the main circuit breaker CB1.

Main circuit breaker CB1 is supplied with 200 V or higher voltage. The wiring correction work below should be carried out by electrical experts or duly trained workers only.

1.1 - 4

1.1 Drive Mechanism

1.1.4 Adjusting the Belt Tension on the Driving Pulley

(1) Press the emergency stop button down until itlocks itself and the machine.

(2) Loosen motor bed clamping bolts 1.

(3) Apply the belt tension gauge 3 (J8201-06010-✽✽) to the belt.

(4) Tighten adjustment bolt 2 so that:

• the top of pin 4 of the belt tension gaugebecomes flush with area “A” and

• three points x (the bottom of pin 4 and bothends of the gauge) come into contact withthe belt.

(5) Temporarily tighten bolts 1 and the lock nuts.

(6) Release the emergency stop button and runthe weaving machine to check that the beltdoes not fluctuate abnormally.

(7) If the belt fluctuates abnormally, tightenadjustment bolt 2 by one more turn.

3

A4

x x x

1.1 - 5

1. PREPARATION

1.1.5 Lubrication(1) Shedding tappet box:

• Supply oil (approx. 10 l) up to the top of oillevel gauge 1, and at the same time, pour-ing some onto the tappet cam and tappetshaft. If the machine is equipped with a sel-vage cam, pour enough oil onto the sel-vage cam.

• Run the machine and check that the oillevel is at the middle of oil level gauge 1.

• For the oil types, refer to Chapter M, Sec-tion M.3.

(2) Let-off motion motor:When the machine is on halt, check that theoil level is at the middle of oil level gauge 2.

(3) RH gearing box:Check that the oil level is at the middle of oillevel gauge 3 when the machine is on halt.

1.1 - 6

1.1 Drive Mechanism

(4) LH gearing box:Check that the oil level is at the middle of oillevel gauge 4 when the machine is on halt.

NOTE: The weaving machine leaves the fac-tory with the let-off motion motor and both theRH and LH gearing boxes supplied with oil.However, if you still find that the oil is insuffi-cient, add more.For the oil types, refer to Chapter M, SectionM.3.

(5) Electrical take-up gear box (option):Check that the oil level is at the middle of oillevel gauge 5 when the machine is on halt.

For other options, refer to Chapter M, SectionM.3.

5

1.1 - 7

1. PREPARATION

1.1.6 Integrated SC Inverter (Option)The speed-control (SC) inverter controls the machine speed in normal operation as well as controlling the for-ward and reverse slow inching and the slow operation during gaiting. If you turn off the SC inverter, the weav-ing machine operates at the commercial frequency.The SC inverter is used to lower the machine speed for night operation or for special fabric style and to raisethe machine speed for production adjustment.You may easily set the SC inverter on the function panel.

[ 1 ] Setting Procedure on the Function Panel

(1) On the screen shown at left, touch [ FIXER ] –[ RUNSET ] (on BASIC menu).

(2) Touch [ INVERTER ] to show the screenshown at left.The default settings are as follows:

• Main drive mode: [ INV ]

• Torque boost: 3

• Time for rpm modification:10 sec. (100 rpm)

• Desired rpm: 800 rpm

Main drive mode

If [ INV ] is selected, the SC inverter operates tocontrol the machine speed (rpm).If [ AC ] is selected, the machine operates at thecommercial frequency so as to run according to therpm of the main motor pulley.

Torque boost

You may set the motor torque for the forward/reverse inching and the pick finder operation. Ifinching or pick finder operation cannot take placesmoothly due to insufficient torque, increase thesetting value.

If the overcurrent protector works so as to stop themachine, decrease the setting value.

If the main drive mode is set to [ AC ], the weaving machine will start at high speed.

1.1 - 8

1.1 Drive Mechanism

Time for rpm modification

You may change the machine speed by 100 rpmwhen it is in operation, by entering the length oftransition time required for that change.In the screen shown at left, the machine speedchanges by 100 rpm for 10 seconds.

Example:The graph shown at left indicates themachine speed change from 800 rpm to600 rpm for 15 seconds.

Desired rpm

In the screen shown at left, the desired rpm is set to800.The recommended setting range is from 500 to1,000 rpm (when taking the practical applicationinto account). The acceptable setting range is from400 to 1,250 rpm.You may calculate the minimum and maximumspeeds according to the formulae below, based onthe mounted motor pulley and the frequency (Hz) inyour factory.

(1) For 50 Hz

Example: If the frequency is 50 Hz and the rota-tion of the motor pulley is 850 rpm:

According to the calculation, the machinespeed range is from 425 to 850 rpm.

(2) For 60 Hz

Example: If the frequency is 60 Hz and the rota-tion of the motor pulley is 900 rpm:

According to the calculation, the machinespeed range is from 375 to 900 rpm. However,it should be from 400 to 900 rpm because ofthe setting range limit.

NOTE: If you run the weaving machine at a speedlower than the rpm determined by the main motorpulley (that is, at the commercial frequency), themotor output will decrease accordingly.To avoid it, you need to use a main motor pulleydesigned for the target rpm to be applied usually orhigher. (If the everyday rpm is 800, for example,use a main motor pulley designed for 800 rpm to900 rpm.)On the contrary, if you use a main motor pulleydesigned for excessively high rpm, the inverter’soperation frequency will decrease so that theweaving machine may not operate because of lowmotor output and load applied to the machineaccording to the fabric types.When replacing the main motor pulley, pressREST on the screen displayed by pressing[ FIXER ] – [ RUNSET ] – [ INVERTER ] on thefunction panel to initialize the internal data of theSC inverter.Without data initialization by resetting, the startingrpm is either too fast or too slow to cause rpmabnormality possibly resulting in starting failure.

rpm800

700

600

TimeStart of transition

End of transition

15 sec. 15 sec.

Min. rpm rpm of motor pulley( ) 25 Hz(constant)50 Hz

------------------------------------------×=

Max. rpm rpm of motor pulley( ) 50 Hz(constant)50 Hz

-------------------------------------------×=

Min. rpm 850 2550------× 425 rpm= =

Max. rpm 850 5050------× 850 rpm= =

Min. rpm rpm of motor pulley( ) 25 Hz(constant)60 Hz

------------------------------------------×=

Max. rpm rpm of motor pulley( ) 60 Hz(constant)60 Hz

--------------------------------------------×=

Min. rpm 900 2560------× 375 rpm= =

Max. rpm 900 6060------× 900 rpm= =

1.1 - 9

1. PREPARATION

Motor acceleration (at starting) and accel-eration limit time

(1) On the screen shown at left, touch [ FIXER ] –[ DELTA ] on STOP MARK menu.

(2) When High-speed starting (delta) is set to ON,the Motor acceleration (on starting) can beset. This setting is valid only when High-speedsetting (delta) is ON for the SC inverter speci-fication.

Motor acceleration (at starting): [ AUTO ], [ 1 ] to [ 7 ]

Generally use [ AUTO ] for motor acceleration.In case of [ AUTO ] setting, the SC inverterautomatically controls starting at the time ofdelta starting to determine the DELTA on timeat the optimum timing. For filling adjustment, select [ 1 ] to [ 7 ] forpositive alteration of the motor accelerationtime (DELTA on time) in the starting stage. The motor acceleration time increases as thesetting increases from [ 1 ] to [ 7 ]. Shorter motor acceleration results in lighter fil-ing, and longer acceleration coarser filling.Coarser filling may fail unless the motor pulleyis greater than the set rpm because accelera-tion to a greater rpm than the setting for stron-ger beating in the starting stage will bringabout coarser filling. As a guideline, select amotor pulley at about 1.1 × set rpm for effec-tive use of this function.

1.1 - 10

1.1 Drive Mechanism

[ 2 ] Troubleshooting for the SC InverterOn the SC inverter board are monitor LEDs (see below) whose ON/OFF or flashing states help you trouble-shoot for SC inverter problems.

(1) Monitor LED states and probable trouble

Monitor LED Monitors the following LED state Shows the following problems

LED1 Power supply for the control circuitry

ON if normal. If LED1 is OFF,• the voltage level between pins 1 and 3 on CN4

on the SC inverter board is out of the specification (200 VAC).

• the input voltage to CN4 is out of the specification (200 VAC).

LED2 3-phase input power voltage

ON if normal.(Remains ON for a while after the power is shut down.)

If LED 2 is OFF, no 3-phase AC power is fed.

LED3 Encoder A-phase signal Flashing while the machine is in operation.

If LED3 or LED4 is not flashing,• the encoder is defective.• the cable connection between the SC inverter

and the main control (between CN9 on the SC inverter board and CN25 on the IO1 board) is defective.

LED4 Encoder Z-phase signal Flashing while the machine is in operation.

LED5 Output of emergency stop signal to the main control

ON if normal.(OFF during an emergency stop)

If LED5 or LED6 is OFF,• the weaving machine has any error source.• the cable connection between the SC inverter

and the main control (between CN9 on the SC inverter board and CN25 on the IO1 board) is defective.

LED6 Input of emergency stop signal from the main control

ON if normal.(OFF during an emergency stop)

LED7 Machine start signal from the main control

ON when the machine is in operation.

If LED7 is OFF, the cable connection between the SC inverter and the main control (between CN9 on the SC inverter board and CN25 on the IO1 board) is defective.

LED8 Unused — —

LED9 Contactor signal ON if normal.(Always ON)

If LED9 is OFF, the SC inverter board is defective.

1.1 - 11

1. PREPARATION

(2) Location of monitor LEDs, rotary switches (SW), and connectors

Rotary switches SW1 and SW2 are also mounted on the SC inverter board.

• SW1 is set as shown in the table below according to the plant power cable and application type.

* Type 1 : Applicable to the weaving machine with crank, positive cam or positive dobby sheddingmotion with a motor capacity of 4.0 kW or less.

* Type 2 : Applicable to the weaving machine with a positive cam shedding, positive dobby shed-ding motion with a motor capacity of 5.0 kW, or to the jacquard weaving machine with anegative cam or negative dobby shedding motion with any motor capacity.

• SW2 is set according to the output frequency from the SC inverter upon inching.0: 5 Hz, 1: 6 Hz, 2: 7 Hz, 3: 8 Hz, 4: 9 Hz, 5: 10 Hz, 6 or more: 5 Hz

• When the power is turned ON after setting SW2 = F, the internal data of the SC inverter is initialized.(This function is equivalent to resetting on the function panel.)

Switch name Arrow mark position Specification(Power supply voltage/frequency, application type)

SW1

0 200 V/60 Hz * Type 11 200 V/50 Hz * Type 12 200 V/60 Hz * Type 23 200 V/50 Hz * Type 24 Unused5 400 V/60 Hz * Type 16 400 V/50 Hz * Type 17 400 V/60 Hz * Type 28 400 V/50 Hz * Type 2

9, A, B, C, D, E, F Unused

SW2 SW1

AC/INV output select

contactor

SC inverter board

Electrolytic capacitor

Charging contactor

Rush current preventing resistor

Current sensor

Power transistor

Diode array

SC inverter board

Radiation fin

SC inverter components

Inner plate

1.1 - 12

1.1 Drive Mechanism

1.1.7 Group-control Inverter (for Slow Operation)

The group-control inverter (1 in the illustrationshown at left) controls the forward and reverse slowinching and the slow operation during gaiting.Generally, a single inverter can cover many weav-ing machines 2 (e.g. 15 or 20 machines) althoughthe number of machines controllable will differdepending upon the inverter capacity.

NOTE: A single group-control inverter can covermany machines but cannot control all of them at thesame time. A standard inverter has no such capa-bility or does not require it. Practically, a singleinverter can control only 2 or 3 machines at thesame time.

Operation procedure

The conditions (e.g. frequency and output voltage)of the group-control inverter have been preset andadjusted at the time of shipment. For details, referto the “Inverter Instruction Manual” issued by themanufacturer.

(1) Touch [ FIXER ] – [ RUNSET ] (on BASICmenu) – [ INVERTER ] to call up the screenshown at left.

(2) Usually, set the Inverter to [ ON ]. Thisenables the forward and reverse slow inching.If you select [ OFF ], the weaving machineoperates at the commercial frequency so thatthe forward and reverse inching switches fromslow to quick.Do not select [ OFF ] except when the invertermalfunctions.

(3) Touch [ STANDARD ], and the items shown atleft will appear.Also if the Inching weft insertion is set to[ ON ], control commands will be issued to thegroup-control inverter so that the weavingmachine enables the slow inching in eachmotion.

If the Inverter is set to [ OFF ], the weaving machine will start at high speed.

1.1 - 13

1. PREPARATION

1.1.8 Trial RunThe trial run refers to running-in or idle running tobe carried out before practical operation.

The weaving machine undergoes running-in beforeit leaves TOYOTA. However, it is necessary to per-form a trial run to check your machine mainly con-cerning the load applied and the occurrence ofabnormal heat or unusual noise, since some timehas passed from delivery and the transportationmay have influenced the machine somewhat.Usually, a TOYOTA service person will be presentfor the trail run.

(1) (You should finish checking the motor rotatingdirection and water piping after the end oflubrication.)Touch [ FIXER ] – [ FEELER ] (on WEFTmenu) to call up the screen shown at left. Setfeeler to [ OFF ].

(2) Touch [ FIXER ] – [ WARP ] (on BASIC menu)to call up the screen shown at left.Enter 0 kg (instead of 150 kg) to the warp ten-sion.

(3) Idle running without yarn or water may causethe following parts to become defective. Toprevent defects, stop operation of the follow-ing parts. Start operation after checking stop-ping.

• Pump operation stop

• Cutter operation stop

• CC take-up gear

• Other special specifications requiring stop-ping

(4) Make the following sensors inoperable:

• Waste-selvage break sensor

• Leno yarn break sensor

• Warp detector

(5) Use the hand wheel to manually rotate themachine by 1 to 2 turnsCheck that:

• the load applied to the machine is notabnormally large.

• Is there any part interference in the vicinityof 0°

1.1 - 14

1.1 Drive Mechanism

(6) Hold down the FORWARD inching switch andcheck the items given in step (5) again.

NOTE: For those machines equipped with anelectronic dobby, take care not to move thoseheald frame hanger components from whichheald frames have been removed during thepicking pattern setting, then go into the trialrun.

(7) Check that:

• the bolts and nuts are securely tightened,

• the reeds clampers have been removed, and

• no tools are on the weaving machine.

(8) Press the START switch to run the machinefor 2 to 4 hours and check that:

• there is no abnormal heat or noise from theshedding cam box.

• there is no abnormal heat or noise from theRH and LH gear boxes.

• there is no abnormal noise from beatingand its related operation.

• there is no abnormal noise from sheddingand its related operation.

Perform trial running of the weaving machinefor 8 hours or more. Trial running is to let theoil run fully to each unit. As a rule, run theweaving machine at 600 rpm or less.

(9) During the trial run specified in step (8), lubri-cate the machine.When applying grease or oil, stop the machinewith the emergency stop button to lock itselfand the machine.

(10) During trial running, perform flushing the waterpiping for 4 hours or more before connectingthe water supply to the weaving machine floatbox tube.

NOTE: The running-in is idle running. If the shed-ding wire ropes go slack and vibrate during idle run-ning, increase the number of springs at each of theRH and LH sides (for the negative cam sheddingmotions).

1.1 - 15

1. PREPARATION

1.1.9 Pulling Out the Motor Pulley(1) Turn the power switch ON to activate the

brake.

(2) Press the emergency stop button down until itlocks itself and the machine for safe work.

(3) Remove nut 1 (that secures the motor pulley)and the washer.

NOTE: The nut on the upper-mounted motoris a left-hand thread; the nut on the lower-mounted motor is a right-hand thread. Theloosening direction is different.

(4) Screw pulley pull-out jig 2 into the motor shaftuntil the gap between the motor pulley and thejig comes to 5 mm.

• Pulley pull-out jig for upper-mounted motors:J8201-01050-00

• Pulley pull-out jig for lower-mounted motors:J8201-01060-00

(5) Insert bolts 3 (that come with pulley pull-out jig2) through holes “A” provided in jig 2 intoholes “B” in the motor pulley. While holdingdown handle 4 of jig 2, tighten bolts 3 uni-formly.After the motor pulley comes off from themotor shaft, loosen the belt and remove themotor pulley.

NOTE: When you are tightening bolts 3, themotor pulley may suddenly come off. Takecare not to drop it.

B

1

3

A

2

4

5 mm

1.1 - 16