JPRS ID: 9850 JAPAN REPORT

• Document Type: CREST
• Collection: JPRS
• Document Number (FOIA) /ESDN (CREST): CIA-RDP82-00850R000400030031-0
• Release Decision: RIF
• Original Classification: U
• Document Page Count: 141
• Document Creation Date: November 1, 2016
• Sequence Number: 31
• Content Type: REPORTS

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HOR OF'NI('IAI. USF: U14LY
JPRS L/9850
~ 1,5 July 1981
~ - Ja an R~ ort
p p
(FOUO 41 /81)
,
~`BIS FOREIGN BROADCAST INFORMATION SERViCE
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. enclosed in parentheses. Words or names preceded by a ques-
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~ MATERIALS REPRODUCED HEREIN REQUIRE THAT DISSEMINATION
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JPRS L/9850
15 July 1981
JAPAN REPORT
(FOUO 41/81)
CONTENTS
SCIEN(~ AND TEQiNOLOGY
Complicated Plate Ends Said To Cause Complicated Earthquakes
(TE(I-1NOCRAT, Apr 81) 1
- Ocean Development Creates Demands for Machinery ~ndustry
' (Riko Nagasaki; BUSINESS JAPAN, Jun 81) .............e........... 7
First Enrichment Plant Using (hemical Exchange Process
(TE(~-INOCRAT, Apr 81) 11
PNC's Uranium Ore Prospecting
( TE CHNO CRAT, Ap r 81) . . . . . . . .
12
SCC Study Under Reactor Environments
(TE(HNOCRAT, Apr 81) 14
Submerged Cutting of Steel Plates for Nuclear Reactor Pressure
Vessels
(TECHNOCRAT, Apr 81) 15
Testing, Inspection Using Electric, Electrical Equipment
(Shigeo Sakai, Kazumasa Nakamura; TEG'EII~iOCRAT, Apr 81)........... 16
Computer Makers Compete Over Market fo r Office Automation Equipment
(Yukto Shimura; CEiUO KORON, No 3, 1981) 25
~
On-Line Mc:asurement Inspection Centered on Automatic Sorting
System
(Masahiko Fukazawa; TE QiNOCRAT, Apr 81) 35
Automatic Inspection Using Microcomputers
(Oharu Suda; TE(~IIdOCRAT, Apr 81) 43
~
- a - [III - ASIA - 111 FOUO]
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Large-Scale Individual Credit In#ornQation. System BegJ.ns Operations
(TEQiNOCRAT, Apr 81) ..................o.......................... 50
LISP Processing Exclusive Computer Experimental Model
Manufactured
(TEQiNOCRAT, Apr 81) 51
All-Time Record for Plastics Machine Industry
(Katashi Aoki; BUSINESS JAPAN, J~ 81) 53
Brisk Demand Continues f~~r Plastic Processing Machines ~
(Atsushi Iida; BUSINESS JAPAN, Jim 81).~ 55
Biomass as an Energy 5ource
( TE(IiNOCRAT, Apr 81) . . . . . . . . . . . 60
Reorganizstion of Caustic Soda Induatry Suggested
(Masa~i Yamamoto; BUSINESS JAPAN, Jun 81) 80
Manual on Factory Noise Assessment Compiled
( T~ t~iNO CRAT, Ap r 81) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Highly Efficient Automatic Screw Gauge Meter
, ( TE CEIlJO CRAT, .Ap r 81) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Measuring Inatruments Related to Light Lase~
(TE(~IIdOCRAT, Apr 81) 91
20 kW Laser Machining System Adopted
(TEQiNOCRAT, Apr 81) 92
Automatic Measuring Control System for Large Machine Tools
(TE(HNOCRAT, Apr 81) 93
NC Robot for Applying Sealing Agents
(TE(~iNOCRAT, Apr 81) 94
Recording Traveling Locus of Automobiles
(TE(~iNOCRAT, Apr 81) 95
One of Nation's Largest Industria.l Aerodynamics Wind Tunnels
Completed
`1L' ~+Lll`I~CL~Lll~ ~r Ol> ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ w ~ ~ ~ ~ ~ ~ � 7V
Belts ~or Cars Reduce Car Body Weight by 15kg
(TE(~IIdOCRAT, Apr 81) 97
' High-Speed Encapsulation Device Developed
( TE Q~INO CRAT, Apr 81) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
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FOI2 OF'HICIAL USF, OhLY
Large Aperture Gap Single Crystal Development Completed
(TECFINOCRAT, Apr 81) 99
Capital Spending in Electrical Industry Reported
(TE(~IldOCRAT, Apr 81).....e..........o.......~ 100
Elongated Image Fiber Permits Direct Image Transmission
(TE(~iNOCRAT, Apr 81) 101
High-Speed LSI Light Data Link Developed
' (TE(~INOGRAT, Apr 81) 102
Development of Academic Info~ation System Earnestly tcrsued
(TE(~iNOCRAT, Apr 81) 103
Development of Biocell Dis crimination, Separation Equipment
(TE Q~NOCRAT, A~r 81) 104
Automatic Analyzing System fo r Laboratories
(TE(~IIdOCRAT, Apr 81) 1Q5
Development of Methanol Qiemistry
(TE(~iNOCRAT, Apr 81) 106
Corrosion Test of Super Hard Ceram:c With Zhermal Resistance
(TECEiNOCRAT, Apr 81) 107
Control System of Power Procesz: by Computer
(TE(~iNOCRAT, Apr 81) 108
~ Industrial Productiion of Carbon Fiber ~o Commence Soon
(TE(HNOCRAT, Apr 81) ......................a..................... 109
Electric Conductive Fiber Begins Gommercial Production
(TE(~iNOCRAT, Apr 81) 110
N1pde1 System for Recycling Industrial Waste I3nder Development
(TE(~iNOCRAT, Apr 81) 111
Experimentu With Disaolved Air Flotation in Activated Sludge
{TE(~INOCRAT, Apr 81) 112
Government Building Up Marine Development
(TE(xNOCRAT, Apr 81) 113
Joint Study for Current Pawer Generation Utilizing Nation's
Current
(TECHNOCRAT, Apr 81) 114
~ Successful Test of Air-Lift Collector or Manganese Nndules
(TE(~IIJOCRAT, Apr 81) 115
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Seawater Desalination Pilot Plant Based on Refrigeration Using ING's
I.ow Heat
(TE(~JOCRAT, Apr 81) 116
New MAFF Research Themea Detailed
(TEQiNOCRAT, Apr Sl) 117
Development of New Method To Prevent Fall-Off of Incorporated
Genes
(TEC~iNOCRAT, Apr 81) 119
Experimental Multipurpose HTGR Practically on Target for 1988
Cri ti cali ty
(TE(~Il~10CRAT, Apr 81) 121
Joint Efforta With U.S. in RTNS Pro~ect
(TEQiNOCRAT, Apr 81) 122
Superhigln Head Pucnp-Up Power Generation
(TEC~iNOCRAT, Apr 81) 123
Synthesis of lhermally Stable Oils by Benzylation of Biphenyl
With Benzyl (hloride Catalyzed by Imn (III) Oxide
(TE(~iOCRAT, Apr 81) 125
Briefs
50-Day LPG Stockpile 128
Cementing Coal Ash 128
Crude Solidification Stockpile 128
Practical Wind Power Heating 129
- Silicon Solar Battery Efficiency 129
Marine Nuclear Pawer Plants Survey 129
System Dec~ntamination of Radioactivity 130
Operatorlesa Plant With Self-Control 130
En ame 1 Coat in g Rob ot 130
Range of Industrial Robots 131
Portable Seuwater Desalination System 131
1M-Bit Magnetic Bubble Memory 131
Ion Beam Equipment 1~2
Microcomputer Controlled Welding Machine 132
Main Shaft-Driven Generator 132
Optical Fiber Laser Oyrocompass ].33
7.hermal Printer Head for Thin Film 133
~ Asynchronous 128K Bit Mask RUM 133
Q~?aracter Panel Display 134
On-Line OCR, Facsimile Systemization 134
Automatic Qleck Equipment 134
Glass-Fiber Reinforced Plastic Composite Pipe 135
Semisubmerged Rig 135
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1~()It UH'1~1('IA1, lltiH: ()NI.Y
SCIENCE AND TECHNOLOGY
COMPLICATED PLATE ENDS SAID TO CAUSE COMPLICATED EARTHQlir1KES
~ Tokyo TECHNOCRAT in English Vol 14, No 4, Apr 81 pp 53-55
[Text] T'~~c prediction ~~I' nat~ral phenomena depends for its ac-
~ur~cv �n thc ~erlainty uf the 1~ >
m m
Buff~r eonv~yor SOKinp COnv~Yo~
Sortinp dwie~ II
Fig. 1. Equipment Comprising the System
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H'()R ()N'F'I('IA1, liti}~: t)NI.Y
not only for the better utilization of existing facilities and
to cope with increased installation of facilities to handle
increased production, but also beczuse of increased personnel
- expenses. These demands have been met by the central
control of existing automatic testing and inspection equip-
ment. By analyzing operations had points of control in each
process, these functions have been replaced by machines,
- and an automation system has been devised whereby euisting
equipment is put to the maximum use.
Conditions demanded of this system are as follows:
(a) Automation in planning operation.
(b) Effective utilization of existing testing and inspection
- equipment.
Labour saving through extensive adoption of automa-
tion equipment.
(d) Central control of various kinds of equipment and
instructions.
(e) Substantially enhanced process control.
(n Substantially enhanced reporting functions.
3. Outline of System
This system is composed of the equipment shown in Fig.l ,
and the specific features incorporating new techniques and
their automation are listed below:
(a) Application of an OCR automatic reading device
for the equipment.
(b) Adoption of group storage based on group technology
and development of software.
(c) Development of autohandlers I and II. _
With this system, all operations from entering a sample
to shipping, are all conducted by computer-controlled ma-
chinery. ln explaining this system's greatest feature, automation,
this article describes in detail the newly developed grouping
storage, and autohandlers I and II.
3-1. Grouping Storage
Grouping storage is a system in which in order to raise the
efficiency of a multiple number of automatic testing and
inspection machines, the same type of units, out of units stored
at random, are sorted for feeding, according to a schedule, to
each testing or inspection machine.
As shown in Photo 1, the grouping storage is composed of
a magazine, unit storage and unit take-out sections. The
magazine ser.,tion has a unit storage section provided with 540
slots. Each slot has its own r.umber, and selections involving
storage or taking-out of units are all performed by computer.
The driving mechanism employes a D.C. servo-motor drive
system. [n order to raise efficiency, it is designed so that it can
. ~
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F'OR ONFI('IAI. UtiE UNLY ,
Conn~ctor )oininq ectu~tor
Upp~r tNt hqd ~ :7-' / Conn~ctor ~xchanp~r (edapt~r)
fh(ft~r % ~ ~ti~ Ad~pt~r act~r
~ ~ i C``~~~ 1' ~ , } ~ ' Hotary holdv of
! : ~ ~ adapt~r
. ~ ' 1~1 ~ ~ ' ~
~ ~ . , ~ - ; '.'~`~71`,( ~ i ' ;
F..d ?oi' i.~"' 1-~`~` ` b P - I~ ~ 1 I
(PCB buffer) ~ .~,~4
1'41,~' E~~et roU~r
PC8 tr~rof~r bsr ~ ~t:,
I~ r II I.�. I. / Low~r tNt h~sd
~ �~..,~.f II onn~etors
'Low~r t~~t h~ad
Jo(nlny om
~
- Low~r tnt h~ad�eonn~ctor
~xch~np~raetu~tor
Fig. 2. PC Board Autohandler
rotate in both directions. It of course incorporates c~ntrol
mechanisms that speed up or slow down rotation at the start or
stop of the motor. The storage and take-out section has an
auto-hand instalfed on an elevator.
3-2. Autohundler
Attaching a unit or test-piece onto an automatic testing or
inspection machine or taking it off, requires about 15kg of
power since the connector terminals are numeious. Requiring
human hands to execute such work in large volume for long
hours entails difficulties. Therefore, automation has been
introduced into a series of jobs involving attachment and detach-
- ment of units, sorting of accepted products and rejected
products, stamping of seals certifying completion of tests etc.
- By shape, printed board units can be classified into single-
kind multiproduct and multikind multiproduct categories.
Therefore, after taking into account the capacity of an auto-
matic testing or inspecting machine, and the economics of a
handler, two types of rnachines were developed. The handler
comprises the attachment and detachment, stamping, sorting
of accepted and rejected products, and storage of rejected
components.
(i) Autohandler I
This is equipment designed exclusively for processing mass-
produced printed board units of the same shape. One feature is
that it operates by alternate actions of an attachment hand and
a detachment hand.
(ii) Autohandler Ii
This equipment is designed for processing various shapes of
printed board units. An external view of this equipment is
shown in Photo 2 and Fig.2.
(a) The shape of printed substrates - 6 kinds
(b) Back panel connectors - 3 kinds
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(c) Combination of front side connectors - 12 x 12 = 144
kinds
(d) Kinds capable of theory processing - 6 x 3 x 144 =
2.292 kinds
System in the msnufecturinp divicion Desipn eutomatfon fystem
R~que~t~ for ru~h
Files conteinfnp manufscturlnp Flle~ o~ ru~h
instructionsfor
~ products
aw~mblin~ I
Propram~ for FI1~~ on
pr~psrinp t~it ~nd t~tt
insp~ction planc plans To~t propram
Autometic
Enterinp Groupinp testinp end
~empl~s ~torepa in~pection Shipmsnt~
Printed boerd unit meehinss
Plls~ on FII~~ on troubl�
OK producc~ found by Filss on the ectuei
custom~rs r~cordc oi ~hipmentc
Files recordinp
ths numb~r oi
semple~ sntsrsd
Deily r~port on QC d~lly nport
productlon
R~pittretlon Erasion
Fll~f on ~ Flow oi pood�
Fils~ on th~ ~etual neord~ of cost~
r~celptt ~nd ~hipm~nt~ -i Flow of information
Flow of control~
Fig, 3. Outline of Information Processirig
As mechanisms giving it the capacity to cope with 6 kinds of
print substrates, the handler has an automatic selection of
positioning pins to width direction and an automatic adjust-
ment to the direction of height.
To the back panel side, 3 kinds of connectors are arranged in
a row for automatic selection. To the front side connector, an
arrangement of 12 kinds of connectors in a radial manner is
provided in duplicate, and automatic selection of their combi-
- nations is employed.
~ All of these orders are given by computer.
3-3. Composition of Software and Its Eunctions
An outline of information processing by this system is
shown in Fig.3. Composition of software and file composition
are shown in Figs.4 and 5.
Features of the software are as follows:
(a) Reliability has been enhanced by providing joint
processing with a thorough subroutine.
(b) System reliability has been enhanced by giving various
~ ~ . 27.'.
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Resltims cp~retinp
system
U-MOS�ARPS
UM05 ~y~tem
propram
- Procs~sinp Control SV~tem op~ration proprem
proqrem proyrams Sampl~ f~~d s~t~blithment proprem
Shipm~nt ntabli~hmsnt propram
Proprsmc for pr~psrinq inapsetion and t~~tinp plant
Equlpm~nt control propramt
Propr~m~ for th~ control~ of ~utomatic t~ttinp snd imp~ctfon mechfnss
Control proprams for pr~p~rinp delly r~port~ on produetion r~eords and quality
propnmt �
Inqulrinp proprsmt on th~ propr~t~ of proc~u work
_ Support proqrem for queiity npittratlon
proprems
Proprem for rspiftsrinp orderc for e start of e~amblinp work
T~~t proprem ~nd tample fs~d propram
Fil~ punchout proprsm
Fig. 4. Composition of Software Equipment
equipment functions to dispose of abnormal operations and
restore them to normal state, or by givin8 them functions to
prevent operational errors.
(c) Since unmanned operation has been introduced, a
system monitoring program has been prepared to prevent
various equipment and instruments from being in a state of
suspended operation for any great time.
(d) Elexibility has further been increased in system inter-
changeabrlity.
3~4. Features of the System
(a) Printed board units in numerous varieties can be input
piece by piece in any sequence.
(b) Automation is effected in the planning of a schedule,
_ and transportation and distribution, so that the automatic
testing and inspeciion machines can have ma~timum ef-
~ciency.
(c) By the adoption of authohandlers, system operation
has been made possible unattended.
(d) lnstructions can be given to a large number of auto-
matic testing and inspection machines by monitoring them
centrally.
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g
PANA FACOMa03dA ~
0
~
C
~ u g o "o
UM08
1 M-bYt~ UMOS ~ytt~m Proc~ainp ~ o ~ Fila u~inq
t~bl~ propr~m propmm v UMOS r o
o �u � -
_ ~ ? F 3 Q
L
d
10 K�byt~ 230 K�byt~ 360 K�byt~ T 200 K-byt~
a ~ ~ a c
Y Y Y Y Y
~~'1 N ~ I~O ~
~ ~
PANAFACOM 8038A
FIIN on ~etu~l o
r~cord~ N
o ~ (~ampl~ fNd fll~; c
6 M-byt~ w ~hlpm~nn fll~; Y FII~~ on ~u~mbllnp
(flxW) u ~ o tMt fll~; ~ ~ "~t~rY' ord~rt
y ~ cort~ fll~; � ~
a ~ ~ qu~llty ~ ~
control fil~) LL n
63 K�byt~ 196 K�byt~ 1100 K�byt~ 3000 K�byt~
6 M�byt~ TNt propram
Fig. 5. Composition of Files
(e) Being provided with collection of information on
operation, quality, and report functions, the system can use
such data for feedback purposes.
Process control is further enhanced by the adoption of
sample entering and shipment controls in the entire field of
the printed board testing and inspection process.
(g) Receiving and dispensing of various kinds of informa-
tion with other systems can be had by connecting this
system online with them.
4. Future Trends and Developments
With diversification in the kinds of products, and the
greater multifunctional capabilities of these products, auto-
mation in testing and inspection will become an ever more
important task in the future. Consequently, the important
problem will now be to cope with the production of
various kinds of products in small quantities. With the costs
of equipment bcing in the direction of getting even higher, an
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attitude is required of the users of such equipment to face
such developments in a systematic way, to include effective
utilization of existing equipment. This trend is expected to
increase in particular in the testing and inspection field of
electronic. and electrical instruments and devices. Consequently,
the need for development of automation equipment provided
with multifunctional versatility will further increase.
We shall be happy if the idea of incorporating into a central
control system the testing and inspection of printed boards as
in this paper, is of any service to readers.
COPYRIGHT: 1981 Fu~i Marketing Research Co., Ltd.
CSO: 4120/262
.
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NOR OFFI~'IAL US~ UNLY
SCI~NC~ AND TECHNOLOGY ,
COMPUTER MAKERS COMPETE OVER MARKET FOR OFFICE AUTOMATION EQUIPMENT
Tokyo CHUO KORON in Japanese Vol 20 No 3 Summer Issue 81 pp 148-158
- [Article by Yukio Shimura, a journalist focusing on technical sub~ects]
_ [Excerpts] I?mergence of Japanese Word Processors
' In the United States, English word processors have become widely used in the last
few years. However thE development of word processors has tended to be slow in
Japan due to the difficulties in handling the language.
As if to make up for the delay once and for all, more than 15 manufacturers are
planning to exhibit their word processors at the coming 56th Business Show. Among
the computer manufacturers, Shibaura Corp (Toshiba), Fu3itsu, Nippon Electric Co
and Oki Electric Industry Co, which make up the early starter group, along with
the newcomers, Hitachi, Ltd and Mitsubishi Electric Corp, will be the major par-
ticipants. Among the business machine manufacturers, the older contenders, Sharp,
Cannon and Pentel will be joined by late starter Ricoh, and early starter Matsu-
shita Communication Industrial Co and new participant Yokokawa Electric Works as
the major representatives of the communications and measuring instruments makers.
� Expectations are growing as rapidly as the number of manufacturers. One can hear
~ them talk about "large scale products appearing in the office automation (OA) mar-
ket after a long absence" and predictions that their 5 to 6-billion-yen business
of 1980 will be sure to expand into a 100-billion-yen market in the 1980's. Priceb
of their word processors vary from a little less than 2 million yen to close to
5 million yen, but the ma~ority of them fall within the 2 and one-half to 3-million-
yen range, which is lower than office computers.
Those new to the market are seeking an expansion in their business and all manu-
facturers are starting to vie aggressively k*ith one another for a larger market
share.
Toshiba, the oldest contender in this field, sold a total of 1,270 word processors,
between February 1979 and March 1981. This year, they plan to sell 2,100, twice
the number of last year. General rlanager of the Office Automation (OA) Department,
Koichi Kikuchi, showing his high motivation, says, "I want to nurture and strength-
en the word processors division as the fourth batter on our OA team."
Since Sharp entered the market after Toshiba at the end of 1979, they have sold
between 1,200 and 1~300 machines. Sharp's Executive Director Tobe does not
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hesitate to assert that they are the top manufacturer at present. They are deter- .
mined to attain the irrefutable position as top contender this year, with their
goal set at selling 200 units a month.
Fujitsu joined the market in the middle of 1980, setting their goal at selling
6,000 units in 3 years. They have had a good start. In the following 6 months,
from the middle of 1980 to the end of March, 1981, they sold 1,024 machines. At
the beginning of April of this year, at Fujitsu's Office Automacion Machines Sales
Promotion Headquarters located in their Onarimon Annex, Sales Promotion Manager
and Managing Director Yoshisaburo Nakanishi painted in the second eye of an one-
eyed Daruma doll in order to commemorate their success in selling over 1,000 u:~its.
Mr Nakanishi, very pleased, said, "We have been surprised at the big response we
have received since we put our products on the market. Word processors, no doubt,
will be our core product in the future."
Other makers, too, while looking askance at those major manufacturers, are devel-
oping an aggressive strategy to seek a bigger share of the market. Nippon Electric
raised their avera;~e monthly sales to over 100 units from the sixties level of last
October. Cannon, which started shipments this March, has already revised their
initial plan of 50 a month to 100. Hitachi, which joined the market as recently
as April, is planning to push hard to sell 1,000 during the second half of 1981
and 3,000 in 1982. Chief of Hitachi's OA Promotion Headquarters, Masanori Ozeki,
very confidently says, "This market is still very young. It is nonsense to say
that latecomers have disadvantages. Our products can satisfy well the functional
needs of users."
- This feverish contention surrounding the word processors seems to illustrate sy~
bolically the vitality and the future possibility of the still young OA market.
- Higher Efficiency Among Office Workers
It is indisputable that the goal of office automation is to assist people and
bring efficiency to office work. According to a survey conducted by Nippon Elec-
tric, moQ* nf rhe office workers apend 40 to 50 percent of their time in meetings
and making preliminary arrangements with other wor!cers. When ~_�f~ce and celephone
- conversations are added to this, time spent on irregular forms of comanunication
amount to 80 percent of their time. Of course, not all of this is wasted time,
but since time is money, higher efficiency in communication is strongly hoped for.
Low rates of office productivity growth, compared to that of factories, are also
a problem. According to data collected by SRI (Stanford Research Institute), in
the past 10 years between 1968 and 1978, productivity in manufacturing has risen
90 percent while office productivity has risen only 4 percent. This wide gap is
a result of factories receiving priority investments and the slow development in
office automation equipment. My day to day experience assures me that this is
- also true in Japan. This being the case, it is an urgent task to attain high effi-
ciency by turning a present labor intensive office into a mechanized, automa.ted
one.
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The first phase of this office automation process will be supported by single,
mono-functional products, such as copy machines, facsimiles, microfilm machines,
office computers, personal computers and word processors. These will later be
connected to compound, multi-functional products (system) in the second phase and
be incorporated into a total system in the third phase. If the stand alone type
(independent type) of word processors in use today are connected by communica-
tions circuits and can output through a facsimile in a different location, we may
call that the second phase. Furthermore, if they can be hooked into a national
network and used as an electronic mail service, that will be the third phase.
- "The age of office automation is not something for the future. It has already
started and will continue," says Nippon Electric's Watanabe.
We cannot overlook the fact that the core technology which supports the system
technology has been nurtured under similar circumstances. The major representa-
tive of this core technology is semiconductors. As the integration process has
moved from IC (integrated circuit) to LSI (large scale integration) to Super LSI
(super large scale integration), logic and memory costs have been reduced 25 and
- 40 percent respectively each year. As Ozeki of Hitachi points out, since "present
office machines are nothing but a mass of semiconductors except for their skin,"
there is no doubt semiconductors will have a great impact on the process of min-
iaturization and price reduction.
Unsettling Office Automation Equipment Industry in Chaos
As I surveyed the OA industry, the first impression I received was that it is in a
- state of chaos with a big goal ahead of them. By this "chaos," I of course do not
mean a kind of panic that rises when the end is near. Rather it seems to be a
reflection of a movement toward creation and the pain of giving birth.
In regards to OA equipment manufacturers or the OA industry, we still do not have
a specific maker which we can refer to as "the" OA equipment manufacturer, since
the industry maintains a strong, independent and divergent tendency at the present
stage. As a matter of fact, many of the office computer and word processor manu-
facturers were originally computEr manufacturers and they still are. Facsimiles,
so far, have been nroduced by communications equipment makers and will probably
remain so in the future. Copy machines belonged to the territory of business
_ equipment manufacturers. Outsiders will call them either "copy machine manufac-
turer" or "business mactiine manufacturer." One of the reasons for this, I believe,
is that the present stage of office automation is still geared towards single,
separate units and has not reached a compound, systematized level.
I have an interesting example of the "divergent tendency" which I mentioned earlier.
I asked Nippon Electric, which adopted the slogan "C & C Office," to list all the
departments that are related to OA equipment. They came up with almost 10. They
were: Domestic Machines Dept and Private Communications Dept which handle tele-
phone systems; Facsimile Dept which handles facsimiles; Information Processing
Systems llept which handles computers; Personal Computers Dept which handles per-
sonal c~mputers; Terminal Equipment Dept which handles word processors; Transmis-
sion Communications Dept which handles modems; Mobile Communications Dept which
handles pocket bells; and Picture Broadcasting Dept which handles television
monitors for stores. Surprised at this fact, Watanabe mentioned, "I intentionally
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did not include large computers and mini computers, but most machines manufactur-
ing departments seems to be related to office automation."
This divergence is found at Hitachi also. At Hitachi, to list a few, the Computer
Operations Dept handles affice computers; Communications Equipment Dept handles
- facsimile; Product Operations Dept handles word processors; and the Domestic Elec-
tric Equipment Operations Dept handles personal computers. The fact that the
Product Department, originally in charge of pumps and motors, now handles word
processors seems to be stretching it too far.
OA-related manufacturers are preparing for the advent of a full scale OA trend.
Armed with strategies that involve all departments of their operations, they are
trying to revise a present "vertical" stage of independent, diversif ied units by
totally and organically combining them in an integrated fashion. These efforts
have been manifested in the establishment of OA Promotion Divisions among major
manufacturers in the last couple of years.
Ozeki, who is in charge of the OA Promotion Division at Hitachi (Established in
August 1980) says, "Each one of our factories is technically strong. Our role
towards achieving total office automation is to develop a solid integrated rela-
tion among them while enhancing each one of their strengths." Toshiba also estab-
lished an OA Operations Control Division in November of 1980 and has so far played
the role of a scout in market devAlopment. The ob~ective of their plan is Goal A
(Automated Office). Their strategy is to approach it from three different direc-
tions, B(Business Machine), C(Communications System) and D(Data Processing
System). (See Figure 1)
~ t;~tx~,~
A
Key:
A. Automated Office 3 "+~r-f'-;
/ siit~(o�ihi~T
B. Business Machines ~ I ~ ~�41y
C. Communications System \ ~ /
, , , , 5 ~~~-~s;.~t~
D. Data Processing System sa~c>rrx~~%
1. Facsimile Multiple Address Equipment " %-'7�=~"
~ ~6 a~ y~~;
2. Multi-Work Station Office Computer ~ cs1A'J-f'>ot
3. Office Automation Pilot System ti.,/~~z.,,~~,1,,,
, ~-~,;~i
- 4. Voice Typing ~'Y~ ~
5. Of f ice Computer equipped with OCR r~vT:~~%�
(Optical Character Reader) 1 ~ ~a;~:�;=~:�a~
i i ,
6. Office Computer equipped with word ~~~~='~~K~ 12~�~3ocR
~ ~
processing function 2~,~t~-~~ % � SG'? GOCR
7lt-i!i PP~;~ib1Et~
7. Japanese Word Processor x~~%
8. Picture Information File ~
9. Facsimile
10. Store Online System ~I ~
- 11. Office Computer. Mini Computer. C B 1
Terminal Equipment
12. Hiragana OCR ,~~i;~f~ ~ s'~*
13. S00 Characters per Second OCR ~
14. PPC (Plain Paper Copier) g_~~~
:xta
Figure 1. OA Structure
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Mitsubishi Electric also opened an OA Project Room in Novembe_r af 1980. Chief
Ki otake Sakaki sa s, "Our present responsibility is to map out operations strate-
Y Y
gies and to engage in marketing activities." In their operations, Mitsubishi is
planning to construct a total OA system by organically combining technologies of
three different fields referred to as "3 D," Document Processing, Distributed Net-
_ work and Data Processing.
Many manufacturers have gone beyond just forming strategies. They have started
incorporating sales in their plans, thus unifying their OA promotion programs.
One example is seen at Fujitsu. Nakanishi, in charge of the OA Equipment Sales
Promotion Division (established in June 1980) says, "We will take the role of con-
trolling the OA Equipment Manufacturing Divisions (Electronics and Communications
Equipment Divisions). At the same time, we will go beyond into direct sales pro-
motion." He also added that they have already been successful in the sales of
building management systems centered around private branch exchanges.
Oki Electric, for the last 3 years, has been working on what they call a"Strategy
for Many and Unspecified Market Products" simultaneous with sales of large systems
for big corporations. GA equipment has played a central role in this strategy.
Also as a part of it, the Information Processing Department within the OA Systems
Division was established. Hopeful Matsuda, Chief of the new division says, "A1-
though we will keep on emphasizing the sales of single units, we would also like
to direct ourselves towards the sales of systems that cross over and incorporate
hoth electronic communications and information processing territories."
Although the OA market is based on existing equipment, for some reason, it is fill-
ed with the spirit of new life. I suspect it is partly due to the fact that at
this moment, manufacturers have finished developing their concepts and have com-
pleted forming their strategy and re-organization.
Inter-Industrial Trend
While manufacturers are re-organizing their departments to achieve an integrated
structure for dealing with office automation, they are also moving into other
product territories making OA industry more complex and intricate. This has been
- arioCher noticeable phenomena in the development of office automation. Business
machine manufacturers launching into computer fields and, the reverse of this,
computer and communications equipment makers moving into the copy machine field
demonstrate this inter-industrial tendency, ~rhich the expanding OA market and the
development of its system will fuel further in the future.
As another indicatian of this trend, I can point out that many joint ventures are
being formed among manufacturers of different prc~:3ucts. Ricoh, essentially a
business machine manufacturer, will be provided, by computer equipment ma.nufac-
turer Nichiden, with an OEM facsimile multiple address system (Equipment which
transmits stored information to more than one destination in a single operation).
To reciprocate, they will provide their own DG wheel for impact printers (as
against IBM's golf ball shaped printer, their's comes in disc form) to Nippon
Electric and other major manufacturers. Ricoh's managing dire~tor, Hamada says,
~"We have communications technology iae acquired through having developed facsimiles
but we do not make communications equipment nor switchboards. It makes sense to
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1
take advantage of each other's strengths to achieve a higher quality/price ratio
in one`s product."
Among the Matsushita Group, Matsushita Electric Industrial Co copiers and com-
puters, Matsushita Communication Industrial Co makes word processors and Ma.tsu-
shita Graphic Communication Systems facsimiles. This indicates more a divergent
type of development. However, the online OCR facsimile, which Matsushita Graphic
Communication Systems disclosed recently, is, as Yuzuru Tanaka (Director and Chief
of Facsimile Kenkyujo--Research Institute) describes it, like a"composite product
made by different divisions within the group." Basic technology for this OCR for
handwritten material was developed by Matsushita Electric Chuo Kenkyujo, while
Matsushita Communication Industrial Co handled the part of engineering the appa-
ratus. This system, by the way, is an epochmaking one where one can put hand-
written OCR data such as books and other forms with figures directly into a com-
puter using the normal transmission through facsimiles in branch offices and
operations centers.
I have so far mentioned that OA equipment manufacturers are becoming domestically
divergent and at the same time are shifting towards inter-industrialization. While
these trends suggest that the OA-related market will follow a basic principle of
expansion, they make one's assessment of it very difficul~. This is because, as
I have mentioned earlier, "OA equipment" incorporates various machines and systems
and overlaps with already existing industries. Figure 2 indicates the positions
of major pieces of equipment which are so called "forerunners of OA." Except for
copy machines, production of all equipment takes place near the border of each
industrial territory.
Of all the equipment included in Figure 2, copy machines represent the largest
production followed by office computers and facsimiles. The total production of
those three items is 600 billion yen and is used as a barometer to measure the
size of OA industry. Personal computers and word processors have not been on the
market long, therefore the figure is small. Interestingly, in the United States,
contrary to Japan, word processors make up the largest market but they sell few
facsimiles. Sakaki of Mitsubishi points out "it is because of the functional dif-
ference between a'typing race' based on alphabets and 'handwriting race' based
on Kana and Chinese Characters."
I quoted earlier that OA equipment production to be 600 billion. However, if all
OA-related equipment were included, the amount would easily exceed 1,000 billion
yen. As a matter of fact, one ma~or computer manufacturer has figured out that
the production of OA-related equipment from various departments totaled 130 bil-
lion in 1980.
If this is true, it means OA equipment has established a large market equivalent
to that of computers and is something that cannot be ignored.
30
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~
i.i1 ~ es : �ss~tawl 980
t a~ r o: Mai.eo~cawe 0
3 cm~+i eaxi+t-eez
~~z~~ b
( ~z~: n = � ~164L
a 1 Ci~S#3 � ELf:.~~= ~ lII.:4t
4 : t-Sit . ~1t.'E= KDD
� I!ilL~C',[
� f~1fi8�tR!!
9 ~!h ~ 3000 .
i ~ ~::v
� ti ,~a
;~i F ~ ~
~..~~~:e~-~ ~
Z�OCF, OM~ I�~*?~*f-
3'COM ~f71~ 3'NC~: J
�!Y7~ ~
4� POS ~iC'a-9 '~.._r,�i~ p
S� '(i't'1 ixihi7~i
, .~_.,,w I ,~.a
toso n ; ~ r.�,
H :eco
~c d
~h~SFR~F (t~7-C'x
.N i!A IR ~1F
Figure 2. Development and Output of OA-Related Industries in Japan
Key:
1. Figure: 1980 production (100 million) '
2. 0: Major OA products at present
3. Source: Partly revised material
obtained from Hitachi
A. Communications Equipment Industry 9800 B. Computer Industry 13000
1. Switchboard 1. Mainframe computer
2. Telephone 2. OCR, OMR
3. Telephone application equipment 3. COM
4. Telephone & telegraph equipment 4. POS
5. Carrier equipment 5. Intelligent terminal
6. Wireless communications equipment 2050 (estimate)
C. Office Business Machine Industry 7300 D. Domestic Electric Appliance
1. Typewriter Industry
2. Light printing E. Facsimile Industry 740
3. Microfilm F. Word Processor Industry 50
4. Cabinet G. Office Computer Industry
5. Office layout H. Personal Computer Industry
I. Copy Machine Industry 2860
a) Mass Communications b) Nippon Telephone & Telegraph Co
Research Firms Kokusai Denshin Denwa (International
~ Seminar Companies Telephone & Telegraph)
- ,c) ~Semi-Conductor Industry d) Maintenance Service
Supplier Induatry
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J~ipan Becoming a Strong Contender
Takuma Yamamoto of Fujitsu, at a press conference in late March, announcing his
nomination to be the new president, talked about Iiis future expectations. "Up to
now, we only had to follow the mentor IBM. From now we have to develop our own
path in terms of business and tecfinology." For that purpose, we will make the
development and sales of OA-related equipment a top priority, so that in the future
it will follow the patterns of computers and communications equipment departments
and become another pillar of the industrq."
This comment by Yamamoto shows Fujitsu's strong determination and convincingly
predicts the arrival of the OA era. His coBUnent also shows a great deal of con-
fidence on Fujitsu's part that it will not yield to IBM. As a matter of fact,
Fujitsu surpassed IBM in sales of computers in Japan. Now that the first hurdle
has been crossed over, they are ready to compete with IBM in the new OA market.
Fujitsu has an advantage over IBM in cominunications technology, which is a key to
this new market. They also have an edge over IBM in the field of small and super
small computers. In developing their marketing strategies, Fujitsu is planning
to take full advantage of the big competitor's weaknesses.
At the same time in the United States, Japanese products have an excellent reputa-
- tion, as industrial analyst B. Rosen points out, "When compared within the same
price category, Japanese personal computers are of better quality than U.S. prod-
ucts." Additionally, the conclusion of a recent survey conducted by University
of Southern California warns that the personal computer industry, too, like auto,
- steel and the television industries, will face fierce competition from abroad.
It might be a reflection of this upcoming strength that I heard so many top execu-
tives mention that "Japan is strong" during interviews for this report.
The point most frequently raised was the superior quality of Japanese products.
Hamada of Rocoh, a reputable copy machine manuf acturer, maintains, "In the high
speed machine field, we still cannot match Xerox, but in more popular models we
have the biggest ahare in the world market. It is because our machines are reli-
able and therefore need few repaira." Kazuya Watanabe, Chief of Personal Computer
Department at Nippon Electric, emphaeizing the high quality of Japanese products,
says, "Eighty percent of the demand for peraonal computers today is in business.
Japanese products definitely need fewer repairs therefore keeping the maintenance
cost down." It goea without saying that this superiority in quality is achieved
through production techniques, including mass production, and the uniquely Japa-
nese Total Quality Control (TQC) that involves all departments of the company.
We must also remember that Japanese Kana and Chinese Characters are contributing
to the development of this unique technology. As is ofcen pointed out, Japanese
do not use a phonetic alphabet, but use ideographic Chinese Character which come
in much larger numbers than the 26 letters of alphabets. Japanese language also
has many cases of the same sounds with different meanings, making computer input
and communication difficult. As a result of this, facsimiles, copy machines and
picture information files, where characters are treated as patterns or pictures,
have developed a great deal. Tanaka of Matsushita Graphic Communication, the
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foremost facsimile maker, confidently says, "Maybe not for the communications use
yet, but Japanese production of facsimiles for business use have reached the level
of the United States. These days, ther�~ are more cases of Americans importing
technologically advanced macfiines from Japan."
Japanese word processors, which are rapidly gaining popularity no~r, also deserve
mention as a product of technological advancement that conquered the difficulties
of handling a language whicfi uses many ideographic characters. At present there
are the following types of Japanese word processors on the market.
1. Tablet method systen where Chinese Characters are fed directly from the key-
boar3.--Sharp and Nippon Electric manufacture this type.
2. Kana and Chinese Characters transforming system where Kana is typed in and some
of them are automatically changed into Kanji. (Chinese Characters)--Toshiba and
Fujitsu make this type.
3. !~lphabet input type where romanized Japanese is typed in and are automa.tically
changed to part Kanji.---Cannon manufactures this type.
4. Association method type where each Kanji fed in is given two different read-
ings.
This active and diversified development is a result of the efforts on the part of
the manufacturers that made the technology to handle the unique Japanese language.
Naozo Yamamoto, Chief of OA Operations Cor~trol Division at Toshiba, with high ex-
pectations for Japanese word processors, says, "It took the United States 40 to 50
years to realize the use of word processors. In Japan it is starting to bloom all
at once now that the basic technology has been achieved.
Another characteristically Japanese approach is that the manufacturers are quick
to respond to many different needs of the users. Let us take the case of office
computers. There are many types of computers developed specifically to meet the
different needs of, for example, accounting, medical and legal offices, agricul-
tural co-ops and beauty shops. There are Kanji office computers, and system com-
ponent compurers which make additions and parts change possible by separating
memory, display, keyboard and printer parts. Ricoh makes this type. This un-
doubtedly is "the product development that scratches where it itches" as Sakaki
of Mitsubishi points out.
Now when total systemitization of office automation equipment is sought for, it
will become one of the strengths that major Japanese manufacturers are equipped
with different technologies that incorporate the fields of computers, communica-
tions equipment and semi-conductors. Watanabe Yasushi of Nippon Electric boasts,
"Every one of our OA-related equipment is at the world's top level. What supports
it is *_he world's highest technology in IC and fiber optics." Ricoh and Cannon,
which have been hasically business machine manufacturers have embarked on the
trimming of ICs. This can be noted as an indication of their policy to strengthen
their line of OA equipment. But for those makers to operate at full capacity,
"Completely free and open communications network as in the United States will be
~ a prerequisite," says Ozeki of Hitachi.
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Professor H. L. Morgan of University of Pennsylvania said, "Japan is about 5 years
behind the United States in office automation." As we look at the situation, this
comment, although it might have some truth in it, seems like an illusion.
I have to say that Japan is posing a challenge in the new stage called "Office
Automation."
COPYRIGHT: Chuo Koronsha 1981
- 9782
CSO: 4105/173
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i
i
~ SCIENC~ AND TECHNOLOCY
i
i
~
~
~
~
~
~
~ ON-LINE MEASUREMENT INSPECTION CENTERED ON AUTOMATIC SORTING SYSTEM
; Tokyo TECHNOC1tAT in English Vol 14, No 4, Apr 81 pp 22-25
~
[Article by Masahiko rukazawa, Meiji University professor]
I
~ [Text] 1. Inspection and Measurement
i
i ~
Inspection involves the process of ascertaining whether a lot
of works are within the designated tolerances and determining
' whether they are to be accepted (OK) or rejected (NG).
I Measurement, on the other hand, is the process of showing the
measurernents of a work in numerical values, or recording
~
~ the shape or the surface roughness of a work on a recording
medium.
Tolerances for a work are established to permit inter-
I changeability of like parts. Limit gauges are an example of
I a device to inspect mass produced works, and a micrometer is
often used for small-lot production. Determining whether a
work is within tolerance is therefore a combination of ineasure-
ment and inspection.
These are only general concepts, however, and there is no
j clear boundary between inspection and measurement. Some
~ people refer to inspection and measurement as only measure-
~ ment, while other geople lump the two functions under inspec-
I tion. Targets of inspection include raw materials, purchased
parts, and final products, but this article is centered mainly on
individual works.
j 2. AutomatedMeasurement
~
i
Automated measuring is required in the following cases.
(a) Where increased automation of manufacturing systems
, require a more advanced automated measuring system.
I (b) Where automated measuring is required for very high
speed operations.
' (c) Where automated measuring is needed because of the
f
i nature of the process (such as requiring remote control), or
i a because of the shape or measurements of the objects to be
~ measured (for example, very small objects).
I
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_ (d) Where reduced energy use overhead, and margins of
error caused by operator fatigue are sought.
When talking about automating a~ measuring process, auto-
mation alone does not mean much unless it is accompanied by
- automation in associated areas, such as obtaining quality control
information, and establishing prescribed processes for different
quality levels of works. Eeeding, loading, and removal of objects
- to be measured must also be automated.
Depending on the situation, complete automation may
cause more problems than it solves, therefore semi-automation
in measuring processes using some manual work~ may be a
required step of full automation processes in the future.
Automation in measuring contains part or all of the following
~ elements.
(a) Measurement
~ . (b) ludgment (OK or NG)
(c) Conveyance ( feeding to and removal from measuirng
device, rotation dividing, etc.)
(d) Controls (by judgment signals, control of processing
machines, and sorting of works)
3. Stages of Automation in the Measuring Process
An automatic measuring process generally goes through the
following stages in the order given.
(a) Automatic inspection
Measurements are taken automatically, and the results of the
measurement are displayed (signals or buzzers) and recorded on .
other media.
(b) Automatic rejection and separation
Based on automatic measureTnents, rejection and separation
" (OK + and OK - ) are performed.
(c) Automatic sorting
Based on automatic measurements, automatic sorting (separa-
tion into a majority class, + and is performed. ~
(d) Automatic measurements are made while the work is
being processed (in-prucess gauge).
By automatically measuring constantly changing sizes of a
wurk being processed, nacessary instructions (speed, position
and change in direction) can be given to the processing machine.
' (e) Automatic measurements made using a feedback system
(post process gauge)
Based on automatic measurement of the dimensions of a
work immediately after its processing, necessary instructions
(corrective actions) are given to the processing machine.
Of the above stages, (a) through (c) are classed under auto-
matic sorting and (d) and (e) are considered automatic measure-
ment. However, whatever forms they take, all of the stages are
based on automatic measurement, none of them have in-
- dependent on-line systzms, and each of them exists in most
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cases as an atiachment to or is linked to another machine.
This trend is expected to continue in the future.
In summing up, there are two concepts for ways to meet
the demanded functions: One is the automatic sorting method
in which finished works are further classified by their measured
tolerances; and the other is the automatic measurement method
in which the precision of the measuring apparatus is used to
determine the precision of finished products since present
precision measuring apparatuses can maintain high precision
more economically than available processing machine.
4. The Future of the Automated Measurement and
lnspection, and Automatic Sorting System as LCA
Te meet the demands of high precision, high speed, and
high productivity, the demand for automated and systematized
production processes is expected to increase in the future. To
- achieve this, measurement devices and controls are required
elements and consequently the demand for automated and
~ systematized measurement is expected to increase. As this
increases, the role of ineasurement and inspection on the
production line and the method of performing them may
change.
In other words, the development trend will show a gradual
change in the measurement and inspection functions of processes
on production lines as these functions come to be more and
more absorbed hy automatic machines, and they will b: in-
creasingly systematized so that only within�tolerance works are
- forw~rded to the next process.
With this in mind, the :~utomatic sorting system and the
automatic measurement system mentioned previously are con-
sidered two of~ the best systems to meet this.
It has generally been considered that automatic sorting and
i; easurement are technically difficult to achieve and incur high
costs. Thanks to the rapid development of various kinds of
measuring app~ratuses and control machinery in recent years,
I~owever, obtaining the right kind of ineasuring or control
mac}iinery is no longer a problem, and consequently, has
- simplified the design and manufacture of automatic assembly
machines. This includes both software and hardware, and
feeding, conveying, and sorting of works. This trend is es-
pecially noticeable in automatic sorting systems.
That is, the stage has been reached where these systems that
were once considered by small-and medium-sized businesses as
too difficult to achieve technically and also too expensive,
have came to be viewed as a target for LCA that is now within
reach.
Of coursc the scope of LCA depends on its purpose, and the
scopc is dctermined by the person setting up the system. De�
velc~pment, however, has now reached the stage where con-
a
~J7
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sideration is given to "an LCA system reaching a medium-scale
improvement" instead of "an LCA system not exceeding the
scope of a small-scale impro~~~ment".
An assembly process generally involves a lot of insert-
spindle-in-hole operations or similar operations. These opera-
tion involve accurate fitting and are difficult to perform even
by human hands. Man per''orms such operations by taking
advantage of h~s vision and the delicate senses of his fingers
but even then he requires some skill. Insertion generaUy takes a
good deal of time, and the amount of time required to perform
a task varies depending on the persons involved.
Consequently, a method to increase the speed of aligning
and inserting a spindle in a hole was developed by raising the
processing accuracy of parts and ~thus lessening variation in
dimensions among parts. This method requires high precision
machinery.
Recently, a new method for highly accurate fitting has been
studies. In this method the machine is given a sensing system
and flexibility that closely mimics that of a human operator.
This method is stiU in the experimental stage and is also ex-
pensive.
- If the tolerance of parts is set to a value several times that
actually required, processing will be completed faster, much
less equipment will be needed, and no sub-quality parts will be
produced. Or if a system is established in which finished parts
are automatically judged and classified into pre-determined lots,
and the classi~ed parts are fitted with each other, the end
result will be same as if the processing accuracy of parts had
been increased. Herein lies the meaning of automatic sorting as
a prerequisite to this selective combination system.
5. Feedback Control System and Feed Forward Con-
trol System
Automatic sizing devices, such as an in�process gauge that
measureswork being processed and controls the speed of cutting
as the dimensions change, and a post-process gauge that is widely
used in centerless grinders that measure work immediately
after it is processed and controls, based on the results of the
measurement, the processing of the next work to be processed,
are all typical examples of feedback control.
Contrary to this, under feed-forward control, disturbances
are detected in advance and the target for control is controlled
sa that the disturbance will not adversely affect output. For
accommodation controls in machine tools, disturbances such
as cutting resistance, vibration and temperature are measured
and the cutting conditions are controlled so that the evaluation
function produces the largest value. This is only one example.
1f' selective combination in an assembly process is to be the
target for control, the entire process including the selection
work constitutes a feed-forward control system. Here, the
sa. ~
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quantity that needs to be controlled is the clearance after
assembly is complete, and to maintain it at a fixed level, a
control - by checking the variation in the dimensions of works
(disturbance) and classifying them accordingly, and to pair
works of the same class - is added to the assembly process.
The automatic inspection machine, automatic rejection and
separation machine, and automatic sorting machine are all part
of the feed-forward system in that the information on quality
obtained as a result of their operations, such as the recognition
of works that meet the standards, is used in the subsequent
processes. On the other hand, they may be considered as part
of a feedback system if rejected items, for example, are sent
back and evaluated to improve the preceeding process.
6. Automatic Sorting
The following is an outline of automatic sorting as LCA.
Automatic sorting machines are generally devices that repeat
the following cyclical operations.
(a) Eeeding of objects to be measured (automatic supply)
(b) Eixing into position an object to be measured (fixing
into position at the measuring position)
(c) Automatic measurement
(d) Display or recording of the results of ineasurement
(e) Removing an object after it's measured (automatic
removal)
Automatic sorting and automatic making �
Depending on which of these operations is used and which
is automated, the extent of LCA is determined.
6-l. ~vtomatic Feeding Device apd Automatic Removal Device
Various methods are used depending on the characteristics of
the work, such as shape, measurements, material, place of
measuring, and method of ineasuring, but in any case, parts
feedin~ and conveying devices in assembly machines work as
references.
6-2. Automatic Measuring
Currently used automatic measuring machines for automatic
sorting can be ciassitied into a) mechanism type, b) air type,
c) electrical type, and d) optical type but the most widely used
are air micrometer (back pressure type), air~electric micrometer,
and electric micrometer. Air micrometers with a contact have
an accuracy of up to O.S�m but the accuracy can be increased
up to 0.2�m by using an electric micrometer of the dif-
ferential transformer type.
~
39
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Sortinp puid~ ~ Sortinp puide Sortinp quids
�
/
~ / o
f~
o
` o ~
Sortinp ehut� I Sortlnq ehuta Combinstlon cyllnd~r SortinQ chut~ ~
I
Fig. 1. Divider System Fig. 2. Switch�over System Fig. 3. Trap System.
Plunp~r Too amsll
_ Sortinp chut~ Vyork�pu~h
cyllnd~r Sortinp cylind~r A
Aec~ptsd
_ - Sortinp puld~ � B
_ _ ~ ~
e.~~. T00
Sortlnp tsbl~ ~erp~
_ Conwyor
Det~ction s~ction
Sortinp chut~
Sorti~p eylind~r
Fig. 4. Plunger System Fig. 5. Conveyor System Fig. 6. Automatic Sorting System
That Drops Works to the
Right and Left
6-3. Automatic Sorting Method
When sorting works by measuring signals generated in auto�
matic measuring, there are two types of automatic sorting: One
involves only the sorting of works into an OK group and a NG
group; the other proceeds as far as sorting of works and their
fitting. There are the following methods of sorting.
(a) Divider method (see Fig.l )
With this system, works� proceed through a sorting chute
. when the guide board is up. On receiving a sorting signal, the
cylinder operates and lowers the guide board to drop the
work into the designated chute.
(b) Switch-over method (see Fig.2)
In this sorting method, sorting is made by switching an
electromagnetic valve by sorting signals and by shifting a sorting
guide to a predetermined position by a combination of cylinder
strokes.
(c) Trap method (see Fig.3)
This system is based on the same principle as the divider
systenn in (a). On receiving a sorting signal, the sorting guide
(trap) opens, and works are sorted into fixed sortin~ chutes.
The sorting guide can be operated either by an electromagnetic
vatve or a direct solenoid.
(d) Plunger method (see Fig.4)
With this system, when a work is forwarded to a sorting
table after it has been measured, the sorting cylinder operates
after receiving a sorting signal, and the work is forwarded to a
tixed chute. Next, the work-forwarding cylinder operates and
the plunger proceeds forward and sorts the work into fixed
sorting chutes. At this time, since the sorting cylinder must
; 40.
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Ace~pt~d
~b
Too finell Too larpe ] C
U
. ~
A
B
~ D E
Gunpowd~r
1
Fig. 7. Classifying System That Blows Fig. 8. System That Shoves Works off Fig. 9. Sorting System by Revnlving
Works to the Right or Left at Measuring Heads Cylinder
always be aligned with the front of the fixed sorting chute
when it stops, an oil pneumatic cylinder, or a combination
cylinder for air pneumatic, is used.
(e) Conveyor system (see Fig.S)
With this system works are pushed down the slope of a
sorting guide at the fixed position after a sorting signal is
received, and works that are brought by a conveyor are sorted
by the sorting guide.
In a similar way, a method is used in which sub-standard
works are dropped to the left and right sides. For example, when
works are too small, the sorting guide shifts to drop them to
the left side. When works are too large, the sorting guide shifts
to drop them to the right side, and all works that meet the
standards proceed straight ahead on the centra] passage (see
Fig.6). Again, in classifying products by weight into "accepted",
"too light", and "too heary" categories, one method used is to
blow them into the proper bins by a btast of air. Inferior pro-
ducts are blown into either the left or right bin.
When the products weigh less than the standard weig}?t, a
- blast of air blows them to the left side. When the products
are above the standard weight, they are blown to the right
(see Fig.7).
(f) A method of arranging more than one measuring
element in a series (see Fig.8)
This system consists of ineasuring heads arranged in order
of tallest to shortest, and works are shoved off from the side by
either pneumatic or electric cylinder, for classification into
categories. This system is highly reliable but also has the
drawback of having numerous measuring elements requiring
complex mechanism.
(g) Revolving cylinder system ( see Fig.9)
This mechanism is simple and easy to operate, and this system
can sort works into several classes with high reliability. On
receiving a sorting signal, the rotating shaft causes the cylinder
to change position and drop works into a storage box.
0
~ 41�
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The revolving cylinder can be rotated either continuously
by changing the back pressure, or intermittently by using an
electrical contact system.
(h) Labelling and stamping method
This system is used when works need not be classified
into different sorting lines during the process. Sorting is made
by marking with a punch or stamp. Sometimes colors or etching
are used. This system comes in the following types.
* Punch: Numbers, letters, shape
* Ink stamp: Numbers, letters, shape, colors
* Paint: Colors, shape
COPYRIGHT: 1981 Fuji Marketing Research Co., Ltd.
CSO: 4120/262
, ~2..
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- ~oR oFFic~ni, t~~H; ~Ni.v
SCIENCE AND TECHNOLOGY
AUTOMATIC INSPECTION USING MICROCOMPUTERS
Tokyo TECHNOCRAT in English Vol 14, No 4, Apr 81 pp 31-34
[Article by Oharu Suda, NEIS Co., Ltd.J
[Text] At a meeting in 1970 of the CIKP (Conference of Inter-
national Repraduction and Processing) held in London there
evolved the "Integrated Manufacturing System" (IMS) (Fig.l
which was defined as a system with "needs" and "concepts"
being inputs and with "inspected products" being output.
It is unnecessary to give further consideration to the meaning
of "integrated". However, if this system can be divided into the
upper stream, midstream and downstream along a flow, these
divisions in general terms correspond to design, manufacture and
inspection. Use of computers in the respective stages may be
called Computer Aided Design (CAD), Computer Aided Manu-
facturing (CAM) and Computer Aided Inspection (CAI).
The greatest change in production systems over the past 10
years has been the extended use of computers. Among them,
CAI made a quick start. When IBM Inc. started sales of System-
7, called the Sensor Base System, it was reported that its use
would be mostly for inspection and test systems. It was con-
sidered that the remainder would be occupied by the monitoring
of production lines and that there would be a very little demand
for direct control of production lines (CAM in a narrow sense).
Since then, the passage of time has required the change of
System-7 to Series/1. It may be said, however, that the chief
use of computers �in production lines is in inspection systems.
The most significant in current computer use are the extra-
- large computers and micro-computers, which have been achceved
tl~rou~t~ the technical progress of LSI (large scale integrated
circuit). Although extra�large computers have nothing tp do
witli production techniques, microcamputers have already well
established themselves in factories.
The recent boom in personal computers, "micons", is stared '
in wonder. Magazines specializing in "micon" have been publish-
ed one after another and "micon" shows are flourishing. Every
visit to Akihabara, the electrical wholesale area in Tokyo, finds
tliat another new "micon" shop has opened. "Invader Games",
the computerized game machines which won great success as a
kind of "micon" product, now seem to have become rather out
of vogue. However development competition is severe to market
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a"post-invader" to follow on. Someone has called the situation
"an outbreak of microcomputers". "Outbreak" is used here
in the ecological sense, meaning that, as with insects, etc.,
Mieon Mleon Mieon
CAD CAM CAl
NNd~ \
\ I nfp~cud
~ products
~ IMS
Cone~pt
Fig. 1. Concept of IMS and Relationship Among
= CAD, CAM and CAI
microcomputers have suddenly begun to increase at an abnormal
pace. Simultaneously, it seems that it is likely to suffer sudden
extermination, and it has a slightly derogatory feeling. However,
"outbreak" expresses increasing speed.
tncidentally, such a micon boom does not adapf itself to
smell, like half-rotten cutting fluid in machine shops and is
seemingly puzzled at the door. Let us review the reason why ~
"micon" is not suited for use in machine shops, and let me
introduce GPS-8 of this company, which is adapted for use
in machine shops.
l . Microcomputers and "Micons"
Microcomputers and "micons" are deliberately used in a
separate manner, in which "micons" indicate products priced at
- about ~Z00,000 to be sold mainly for hobbyists. Three types
are produced by TRS, APPLE and PET in the USA, while they
are produced by Nippon Electric, Hitachi, Sharp, etc.,in Japan.
"Mican" is also a kind of computer consisting of an arithmetic
and control unit, an internal memory, in extended external
memory (cassette magnetic tape unit), a function part (key-
board) and a display unit (CRT display).
A large sized computer made 30 years ago was a i machine
of punched cards and a line printer, and a minicomputer 20
years ago was a machine of a teletype and paper tape, while
a micro-computer made 10 years ago is characterized by a key-
board and a CRT display.
Applicable Celds of computers are divided roughly into
(1) of~ce calculation, (2) technical calculation, (3) control, and
, ;qt~. ,
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(4) communication. However, most "micons" have, for con-
structional reasons, no interface that can be used for control or
communication, and both the input of data and output of
results cause bottlenecks in large volume office computation.
As to the rer~aining technical.calculation,function calculators
for technical computation are far less expensive, more speedy,
more accurate, and more handy.
Accordingly, the way computers are most generally used by
hobbyists whose interests are in the pursuance of the computer
itself, are to play on programs of games. Software is also sold
chiefly for games.
2. Machine Shops and Microcomputers
Use of computers in machine shops is of course not directed
to technical calculation ~r office computation, but concerns
management and control of machines. Management and control
are both included in control but what is closer to a machine is
called control while what is a step away from it is called
management. Control of machines includes (1) sequence control,
(2) control of location, courses, speeds, etc., and (3) manage-
ment of products and its feedback, etc. Management includes
(1) production control such as inventory, rate of operation, and
progress, (2) quality control, and (3) equipment control.
Quality control consists of an offline system for data
processing with inspected goods being intervened and an online
system connected directly with a line and synchronized with
tact time. The online system is divided into an in-process
system wherein data is measured during processing or assembl-
Table 1. Standarct Substrate for GPS�S CPU Card
CPS-8 Standerd cerd
CPU e~rd 280CPU I nt~rruptfon 8 pi~e~~, n~l tim~ elock
~ ROM 8k, RAM 2k
Ext~nd~d HAM RAM 78k
USART full dupl~x fin~ry eircult
S~rl~l Int~ri~c� 120BPS-192009PS EIA RS232C or 20mA
eurrmt loop
Input c~rd PHOTO ISOLATED 32 pl~c~s
Output c~rd PHOTO ISOLATED 3Z piac~f
An~lop Input 4 rnultlpl~x~r input~, 12 bit dipitsl ~Ipnsl
An~lop output 12 blt DA convnt~r bfnsry clrcuit
Pul~~ Input count~r Bl~~ry clrcuit 18 bit count~r, wlth o?ipinal
pulN d~t~ctlon
Pul~~ motor ph~~~ Ooubl~ on~ or two ph~~~ control, binary clrcuit
control
D.C. motor control O-A conv~nlon, voltep~ curnnt conv~nion
bin~ry clrcult
� 4.~
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ing, and into a post-process system wherein it is measured after
processing or assembling.
For example, in the field of assembly, control of screwing
torque is representative of in-process, and check of defective
products is representative of post-process. In the field of inetal-
working, many in-processes are used for grinding machines and
sensors of post-process are used fcr cutting tools such as fine
boring.
For the application of micro-computers to these fields,
interface and applicable software become decisive factors
rather than the computer itself.
In a system like a desk calculator operated by electric cells
and having only a keyboard and liquid crystal display, care
must be taken only of static electricity acting as a noise from
outside. When a computer is connected to machines, however,
the cable providing the electric source, and input and outgut
lines, all function like antennas and bring in noise from outside
into the comr~~ter, causing unexpected functioning.
The difference between noise (N) and signal (S) is that S is
what is predicted and expected, while N is what is unexpected.
Although unexpected functioning caused by an unexpected
input is called a"noise error", this statement is made without
considering the standpoint of the computer. The computer
might say that S and N are both the same electrical signal and
cannot be discriminated unless a way for discrimination is
programmeJ beForehand by man, and accordingly, that it
should not be blamed for such an error.
When a micon, not just being used on a desk, is connected to
, a machine, it is placed in a very poor electrical environment
because machines are all operated by electric motors, except
the case where an air compressor is far away from a machine.
_ Power voltage may be reduced by as much as 30% at the start of
a neighboring heavy machine, and an input line may run in the
same duct along with a welding cable of a large capacity.
As a recent example, specifications of a micon for machine
control, made by a certain system house, describe nonchalantly
that there should not be any source of electrical noise within
200m around. Computer makers do not know machines and
machine makers have a prejudice against computers. Neverthe-
less, the tendency is to use micons. As a result, such an absurd
system is produced. Not only the control board is solid state ~
(transistorized) but also machines themselves become solid
state and are covered with dust. Know�how as to how to use
electronic devices in such circumstances should developed from
electronic instruments coming first to machine shops, such as
NC equipment, measurement equipment, and sequence con-
trailers.
Not only the electrical environment, but such conditions as
temperature, atmosphere and vibration are severe to micons
made t'or I~obbyists. The first deadlock reached by engineers
whc~ intend tc~ introduce microcomputers into machine shops
_ ridin~ cm the micon boom, is environmental conditions, inter-
lace design :~nd software design.
~ 46
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r - -Sp~t~ - -1
I
Output card ~
Inputeard ~
r-~
CPU csrd
,
~
a
Jeck ~ Moth~r boardi A ~
. . , , . o
Pow~r eontrol AC]OOV
Fig. 2. Fundamental Construction of GPS-8
3. Required High-Level Language and Problem-Oriented
Language
This company is an engineering group in steel. automobiles,
etc., having much experience overcoming such deadlocks, and
is dealing with larger�scale systems of computer-aided inspection
and pattern recognition as a computer system house. It has
developed a general use control system GPS-8 (Genera) Purpose
System�ti) as a law end product. The main frame is the Z�80 of
Zailog Inc., whic;h is regarded as the best 8-bit micro�processor
at present. Stress is put on sequence control and positioning
control which are two major fields applicable in mechanical
autc~mation. It intends ta provide interface and software to be
instantly available (refer to Fig.2 and Table 1).
Micons uriented tu hobbyists (the writer being one of them)
I~ave defects in that tl~e language is fixed to BAS1C, interface
cannot be added or they do not withstend environmental
~c~nditiuns. At the next stage, what attracts one's attention is
so�called SBC, which is sold as a board unit. It may be said that
SBC of a board unit is sold entirely naked, as compared with
micons which are well finished systems.
Accurdingiy, "sup~ort systems for development" or "house
machines" are required fc~r it to be programmed. Although
micans are se~ld at '#200,000 to ~300,000, the house machine
is prired at several million yen, which is a peripheral instrument
nc~t so different from the former. Furthermore, itdoes not permit
high Ievel language to be used as in micons, and it is required to
master Ic~wer level (elc~se ro machines) language. Investment in
ihe "hc~use machine" tmavoidably requires the same or more
: ;47.
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ESC 1' 2 3~' 4 S' S . 6\. 7.. 8 g ~ p ~ ~ FEED DEL ~ T ~
~ ~ . 1 , ~ ,
CTR W F. ~ k T 1' U ~ U I' RETUR\ ~
a -'r { - F - . .
+ n s u H� c; ~i ~ h t. ~ ~ - 1.
. t- ~ ~ ~ ~ -
SHI FT 2 X C H ~ ~1 1' f- t LI ST
~ ~ ~ ~ � ~
(tF:l'T H~~~ +
Fig. 3. Arrangement of Keyboard
amount to be invested in labor cost for engineers who take
care uf tliis machine.
- Many persans are likely to consider that to master a language
closer t~ machines means advanced utilization of micons. Slow
execution speed of high level language inevitably leads to such
misunderstanding. However, a computer is a mere tool and it
is important that a simpler explanation will enabie everybody
to use it properly. Each person is not required to repeat the -
development history of computers.
In general, standards for appraisal of software are the follow-
ing 5 items:
(1) Satisfactory function
- (2) Short execution time
(3) Sr~all memory area requireu
(4) Short program steps
(5) Understandable
If they contradict, we are perplexed as to what should be
taken. For example, when the same programs described at two
places are prepared in the form of subroutines, items (3), (4)
and (S ) are satisfactory but item (2~ becomes unacceptable.
Here, let us rewrite item (1) as foilows: "Satisfactory func-
- tion attained during the whole life of a system". No system has
a fixed function. In the course of development, funetions
chanRe kaleidoscopically. Required functionscontinue to change
even after the completion of development. If it does not cope
with this requirement, ~t will become a"system which satisfied
the function tomorrow".
High class language and problem oriented language are
by all means required by software which can cope with functions
changing for the whole life of a system.
4. Language of GPS-8
Problem oriented language for sequence control of GPS-8 is
a relay and ladder language called Cross�[n-Sequence (CIS).
- 48
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~ H ~ ~I
ve4 ~
x~ r
vaS xee
''a' I-i''a~/-i ~e� i
/'~1-1 I----l,~xl-/ve'I ee
~ ~ ri
~ r~~~ ~ ~1~
r~i
ve~ H'~ h-/'oa~/..
~--a xe~ ~
Fig. 4. Relay and Ladder Drawing (Video Plotter
Output)
CPS-8 automatically depicts a relay and ladder ~gure of Fig.4
~ with an input from a keyboard shown in Fig.3, and at the same
time atuomatically translates into mechanical words, so as to
program with only the relay and ladder language.
A difference from general relays is that signals are made to
_ flow only from the upper to the lower and from left to right, in
order to avoid turning around.
This has already been realized in programmable togic control
(PLC) dedicated to sequence control with the aid of hardware.
However, the greatest characteristic of GPS-8 is that a combina-
tion of instruction words of Z-80 CPU allows a maximum of
256 input and output sequence controls to be dealt with
simultaneously with the task, described with computer language,
such as motor control and treatment of ineasurement data.
Sequence circuit on a picture plane is translated into the
instruction of Z-80 each time one line disappears from the
picture plane, and reversely a sequence circuit is formed from
the instruction of Z-80 each time it appears on the picture
plane. These processings are carried out not when a machine
operates but when it communicates with a man so as to make a
program - with suf6cient time.
Standard substrate for GPS-8 has a 12�bit AD (analogue -
digital) converter introducing to 4 multiplexers. Inspection of
it into a spare slot shown in Fig.2 enables a sequence controller
alone to serve also as a measurement unit. Discrimination of
OK-NG also functions as input for sequence control or output
for display.
Increase in slots enables measurement data to be recorded
on cassette tapes and to be output on printers. If input and
output are not so frequent and CPU time is sufficient, a simple
statistical calculation can be performed. Of course, it is possible
to connect on online to upper computers (with USART sub-
strate).
COPYRIGHT: 1981 Fu~i Marketing Research Co., Ltd.
49�
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SCIENCE AND TECHNOL.OGY
LARGE-SCALE INDIVIDUAL CREDIT INFORMATION SYSTEM BEGINS OPERATIONS
Tokyo TECHNOCRAT in English Vol 14, No 4, Apr 81 p 73
[TeXt] . The large-scale individual credit informution kind of center. However all centers except that
system, into which the individual credit infor- in Tokyo employ the manual data check sys-
mation center functions of each bank asso- tem with small quantities of collected data.On
ciation in Tokyo, Osaka, and Nagoya are top of that, the information of each center
untiied, started its operations in February could hardly be used mutually so they have
1981 suffered the problem that a blackdisted con-
'Phis system has accumulated in it data of sumer who had some accident in Tokyo could
so-called individual loans such as, housing loans, easily get credit in another district such as
various consumer loans, current uansactions, psaka or Nagoya. The newly developed system
or ccedit card utility. Such a kind of system is is a wide�area on-line individual credit informa-
deemed indispensable to the prohibition of tion system, introduced first in Japan and
credit accidents. Since the Tokyo Bank Asso- aiming at coping with such a problem and at
ciation inaugurated the individual credit infoc- the same time provide speedy credit checks and ~
mation center in 1973, 14 bank associations accurate operation by means of data intensifi-
all over Japan have so far estabUshed the same cation.
ra..u..e...w~~.nn~i~m..n~.i..,.ro~ ow...e..ouau~anina~.~a~.i
o~e~~ m
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COPYRIGHT: 1981 Fu~i Marketing Research Co., Ltd.
CSO: 4120/262
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SCIENCE AND TECHNOLOGY
ALL-TIME RECORD FOR PLASTICS MACHINE INDUSTRY
Tokyo BUSINESS JAPAN in English Vol 26, No 6, Jun 81 p 57
[Article by Katashi Aoki, president, Japan Plastics Machine Industry Association]
[Text] APAN'S plastic manufacturing ma- wall are two of the rypical methods
J chine industry recorded an all-time employed in extruders to increase
high turnover in 1980, up 22% from extruding power by which to reduce
the previous peak achieved in 1979, the amount of energy needed for
although the output of plastic ma- operation. With injection molding
. terials and plastic products declined by machines, energy consumption is re-
4% and 5.2%a, respectively. This . good duced through the use of a new
record for plastics machines was a mechanism designed to supply power
result of brisk demands from auto- only when it is required instead of
makers, electronics manufacturers and providing a constant power supply as
other industrial users of plastic pro- with the conventional type. A new
ducts. In line with the progress in their type of polystyrene foam molding
production streamlining program, an machine adopts sepazate molds, each
increasing number of manufacturers devoted exclusively to the process of
has started to manufacture plastic heating or cooling in order to elimi-
parts for their own use instead of nate loss of energy. (In the conven-
seeking supplies only from outside tional type, the mold must be heated
sources. [n 1980, injection molding or cooled alternately to complete the
machines ranked top on the list of operadon.) Another example of
plastics machinery installed for in- energy-saving is a molding machine
factory production of plastic parts by with a vent-equipped barrel. This
these users. eliminates the process of drying the
Active repiacement demands from material before it is fed to the
the plastic product proassing ir~dustry machine.
also has contributed to the increased
_ turnover of the machines in 1980. Resources-Saving Molding
Plastic product m~kers found it neces- The manufacture of pro~ucts which
sury to instull new machines offering do not meet the standazds not only
a variety uf technical improvements wastes the material but also results in
and innuvations, all reflecting the ihe useless consumption of energy.
many achievements in the field of The plastics machine industry has
~ pl:utic processing. completed a system to eliminate mold-
Major areas of technological im- ing such products. Most of the systems
provements are outlined as follows: developed for this purpose utilize a
micro-computer which memorizes
Energy-Seving Molciing optimum operating conditions. With
A large number of molding this system, the machine automatically
mnchines featuring a 40-60% cut in adjusts to the most efficient operation,
electricity consumption than their making corrections to accommodate,
conventional counterparts have been for example, environmental charges.
put on the market.
Adoption of special screws and use Super-Precision Molding
uf a barrel with specially-treated inner The super-precision process achiev-
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ed in injection molding has led to a pevelopment of New Processing
rapid increase in demand for plastic Technologies
products for precision engineering. [n- ~e recent introduction of stretch- '
jection molding machines with this blow molding of PET, PVC, PC and PS
particular feature have been widely ~terials has brought about a substan-
adopted by makers who had to raly tial change in packa~ng used for food,
previously on non-plastic products for cosmetic and pharmaceutical products.
their needs because 0.02-0.03mm was In addition, the RIM system has been
_ the maximum precision level for mold� expanding its applications from
ed plastic. In most cases, some were automobile pacts manufacturing to
made to a O.Olmm precision ievel, roduction of computer housings and
while others to 0.03mm. This lack of P
_ uniformity in measurements was many other areas within the electron-
another reason the manufacturers re- ics industry. The LIM system, too, is
frained from using plastic products. finding a wider range of applications.
The latest molding machines not only With the ever greater progress in plas-
boast a precision level as high as tic processing techniques now bemg
O.OOImm but also allow complete built into processing machinery, plas-
uniformity in measurements for all tic products are expected to fulfill an
products manufactured through the ever widening area of utilization. D
use of a micro-computer.
COPYRIGHT: 1981 The Nihon Kogyo Shimbun
CSO: 4120/263
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SCIENCE AND TECHNOLOGY
BRISK DEMt1ND CONTINUES FOR PLASTIC PROCESSING MACHINES
Tokyo BUSINESS JAPAN in English Vol 26, No 6, Jun 81 pp 61,63,67-69
[Article by Atsushi Iida, secretary general, Japan Plastics Machine Industry
Association]
[Text] ,~FTER a continuing downward replacement demand for new machine
~ trend since 1973, Japan's pro- models featuring innovative techno-
duction of machines for plastic pro- logies for plastic processing. Machines
cessing turned upwazd in 1976 and specially designed for reducing the
reached a level which exceeded the consumption of resources and energy,
previous peak record. The 1980 record machines that assure molding to uni-
was even better, breaking the form measurements, high-cycle mold-
100,000 million for the first time in ing machines, totally automated pro-
the history of plastics processing ma- cessing machines and machines featur-
chine manufacturing in Japan. ing automatic changes of materials,
As shown in Table 1, production in coloring and molds to increase opera-
1980 increased by 6.3% in quantity tional efficiency are major types of
and 21.6% in value from the 1979 injection molders newly introduced to
level. Percentage by types of machines the market during 1980.
against the fotal is shown as follows:
Extruders: The 1980 turnover showed
R~iore than 90% of the 1980 pro- a slight decline in the number of units,
duction was occupied by injection but scored an increase of 17.5% in
molding machines and extruders. [t is value from the 1979 level. Further
noted that the active demand for sophistication in overall machine quali-
injection molders was the major reason ry, which has pushed up the value
for the uverall growth of plastics per unit, explains the reason for the in-
machine production in 1980. crease in value despite the quantitative
decline. Just as with injection molding
Types of Machines machines, a variety of new processing
Injection Molding Machines: Al- technologies have been incorporated
though exports remained almost on into extruders - newly designed
the same level as in 1979, a rapid screws adopted to attain a substantial
increase in domestic requirements, increase in extruding capacity, a tem-
particularly from automobile, elec- perature control system featuring
tronics and precision machinery manu- accurate adjustment of incidental
facturers, was attributable to the ac- environmental changes to raise
tive performance of injection molder standards of product quality, and com-
production in 1980. This was because puterized control of molding opera-
makers in these specific sectors have tion are some of the examples of tech-
begun to switch some of the plastic nical improvements.
parts production to their own facto- It is also noted that an integrated
ries. Also supporting a marked increase system for blown film manufacture
in machine production was a growing has been increasingly adopted. Here,
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Table 1. Japan's Production of Plastics Processing Machinery
(in ~ million)
19'l9 1980 1980/1979
Compression molding ~ Q'ty 84 75 89.3
machines ~ Valuc 498 ! 1,140 ~ 228.9
(njection molding ~Q~ty 7,669 8,391 ~ 109.4
machines i Value 67,812 i 82,700 i 122.0
Q'ry 2,416 ~ 2,359 ; 97.6
Extruders ~ Value 19,216 ~ 22,583 ~ 117.5
~
Blow molding muchlnes Q~~Y 290 I 266 91.7
Value 3,639 4,860 133.6
Calenders, vacuum ur Q~~y 274 309 112.8
pressure forming machinea, Value 3,856 4,267 110.7
~nd fnaming machines
Total Q~ty 10,733 11,400 106.2
Vnlue 95,021 115,550 121.6
1979 1980 decline in quantity because large
models occupied a greater part of the
Injection molding 71.4�rG 71.6% output.
machines One of the notable trends in 1980
Extruders 20.29'0 19.5~ was a wide range of industrial appli-
Blow molding machines 3.8%'0 4.2�~a cations of extrusion blow molding
Calenders, vacuum or machines whose utilization previously
- pressure forming 4.1~ 3.~qo was dominated by the manufacture of
machines, and foaming bottles for cosmetics, detergents,
machine~ pharmaceuticals and food. The new
Compression molding o.59~ 1.0�6 areas of application include molding of
machines automobile ducts, and heat collectors
everything from tublar film produc- and hot water tanks for solar systems.
tion and film printing through the It is expected that the introduction of
final stage of making bags is processed blow molding machines e~i clRlue vep1E
on one integrated production line. designed for super high p Y
With the introduction of this system, will rapidly increase demands for
production capacity for PE and PP blow-molded products from many in-
bags has expanded to a great extent. dustrial sectocs.
Among other recent developments Stretch blow molding machines
is a tubular film-making machine, now have been widely used for making
in the experimental stage, that uses bottles with PET. These bottles are
LLDPE which is expected to become increasingly adopted for use as cosme-
the mainstay in the tleld of PE materi- tic, detergent and food contaiers be-
als. Many industries will benefit from cause of their transparency, toughness .
the wide applications of this machine and gas-resistance capacity. Not only
when it is tinally commercialized. have they begun to take the share
Blow Molding Machines: The out- which used to be occupied by PVC
put in 1980 increased by 34% over the and PE products, but they are also
1979 flgure, but it represented an 8% gaining wider markets through new
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Table 2. Production and Export of Plastics Processing
Machinery by Type
(in number of units)
Production Export
Year
I Injection Extruder Injection Extruder
I 1967 3,646 2,409 225 163
1968 4,325 ~ 2,890 347 i 198
1969 I 6,555 I 3,319 668 ~ 209
1970 6,583 I 4,740 747 I 272
19'll ~ 4,469 4,069 I 725 317
1972 7,158 I 2,310 898 I 239
1973 8,971 i 3,061 1,169 356
- t974 3,979 ~ 2,645 961 360
1975 2,637 1,680 799 387
1976 6,1X>8 1,700 1,415 318'
1977 5,992 t,562 2,189 526
1978 6,409 2,156 2,391 492
1979 7,669 2,416 ?,342 637
1980 8,391 2,359 2,361 439
ways of utilization. with injection molded ones.
Latest technical achievements in Compression Molding Machines:
blow molding also include development Full-scale automation is the latest
of a stretch blow process using PC, PS, development in the category of com-
or PVC, although this process was pression molding machines. A number
' previously consideted the most diffi� of models on the market today are
cult to accomplish. With this process, equipped with sophisticated automatic _
bottles of heat-resistant PS are manu� facilities for measuring materials, feed-
factured at less cost, even though they ~g them to the mold, forming them
are superior in transparency and into the desired shape, and removing
shock-resistant capacity. A sizable the products from the machine. Addi-
demand for bottles of this type is tion of such sophisticated features to
expected from food manufacturers the machine has pushed up the overall
who utilize a high-temperature filling value of the 1980 output 2.3 times
formula for their food packaging. over the 1979 level, despite the approx-
Vacuum or Pressure Forming Ma- imately 10% decline noted in terms
chines: Some of the vacuum/pressure- of uantit In 1980, the turnover of
formed plastic containers for retailing transfer moldin machines designed
food such as ice cream and mar- g
gerine gave way to injection molded for IC and other precision electronics
ones when improvements in injection parts manufacturing showed a marked
molding technology made it possible ~owth.
to manufacture extra-thin containers.
Today, new vacuum/pressure forming Exporu
machines allow an integrated pro- Exports of injection molding
duction, completing all ~tages of pro� machines have remained almost on the
uesses in une continuous operation - same level since 1977 as shown in
from sheet forming by extruders, Table 2. Shipments in 1980 totaled
vacuum/pressure forming and 2,361 units, representing a slight in-
trimming, up to grinding the trimmed crease over the 1979 data, but failed
- waste with which to re-feed the ex- to reach the level of the previous.
truder. Now that such technological Performance in 1980 as indicated in
improvements have enabled mass- Table 3 was characterized by declining
manufacturing by the vacuum/pressure shipments to two major markets,
forming process, containers made by South Korea and Thailand, but the
. this process have become competitive decline was nearly offset by growing
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Tabie 3. Exports
(in number of units)
Typ~ lnjection Exttuder
CountrY Year 1979 1980 1979 1980
Republlc of Kurea 258 124 i 73 15 .
244 252 51 47
Taiwan 15 34
HongKong ~ 458 S27 11
'fhailand 150 105 31
I 339 264 I 83 47
Singapore 14 32
I Malaysia 78 6~
154 ~ 83 124 44
Philippines ~
I Indonesia ' 46 I 202 30 16
~ ~ ~ 6g ' 3
Iran ~ I q g I 8
I ~~aq ~ l3
Unitrd Kingdom ~ 52 56 5 Z
Italy I 0 3 3 ~
39 19 0 2
Canada l4
United States 323 35~ 25 '
Suuth Africa 55 108 0 3
Australia lS 43 ~ 6
New Zealand 3S 19 1 4
Others 80 126 99 151
Total 2.342 2.361 637 439
exports to Indonesia, South Africa and Table 4. Imports
Australia. Although the U.S. has con- (in number of units;
tinued to be the largest market for ~~jection
Japan's injection molding machines in
terms of value, an overwhelming quan� Year 1979 1980 '
dty has been shipped to countries in Councry
Southeast Asia wher~ molding ma- ~nited Kingdom I 2 4
chines made in Hong Kong and Taiwan France 9 20
have been expanding their shace of the ~ederal Republic ~
market. Because of strong sales offen� of cermany I 189 03
sives launched by these two countries, Canada 39 g
Japanese manufacturers have found it uniced Scaces 21 t3
hard even to maintain previously es- Ochers 16 51
tablished markets. Tot~ 2~6 'gg
To cope with changing conditions,
_ Japanese injection molding machine
manufacturers are trying `o~ ~e Exuudcr
~ African market, as well as placing
hopes on the U.K. and Scandinavian Y�~` 1979 1980
markets. Country ~
~ Table 3 shows exports of extruders I~
T~Wan 3 3~
which sharply dropped from 637 units ~ 0 6 I
in 1979 to 439 un~s in 1980. Ship- I sweeen ~ i
United Kingdom I 16 ~
ments to lran experienced the heaviest Federal Republic I
decline from the 1979 record of 68 ofcermany i 15 ~ zl
units to unly 3 units in 1980 due to gwiczerland I 13 I ~
the Iraniun potitical situation. Also ~t~Y p I 2
marking a drastic decrease were ex� ,~uscriu 3
purts to Suuth Korea which suffered uniced Scates ~ 9~ 30
from a fureign exchange shortage. Sln- ochers 0 0 .
gnpore, the PhiGppines and Indonesia Tocu1 59 ~S
were other areas to which Japan ship-
ped fewer machines in 1980 than in
5 8~
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1979. In these markecs, Japanese ex- mainly supplying high-speed injection
uuders showed a rather poor sales molders for light-weight containers,
performance because of the price in- recorded a sharp drop. [t seems sales
creases due to the rising cost of pro- of machines of this specific type in
duction materials. Slowing sales of Japan have already run their course.
Japanese machines were also at- [n the category of extruders, ship-
tributable to the tough competition ments from West Germany leveled off,
from Hong Kong and Taiwan ma- while a sizable decrease was noted in
chines, among which many were imports from the U.K., in sharp con-
blown-film extruders. trast to an exceptional increase in
Imports machines shipped from the U.S.
A slight increase was noted in Imports of plastics processing ma-
Japan's imports of injection molding chines, whether they are injection
machines in l980 as compared with ,~gla ste dy growthsfor thelast everal
the 1979 data.
As seen in Table 4, West Germany years. The imported models are limit-
- continued to occupy the position of ed to those designed for a specit`ic type
the major supplier oF injection mold- of molding which are not being mass-
ing machines to Japan, while Erance ~a~eu enou JaPo mau~eufacture 1 su h
achieved a sharp increase in stupments models loca~ ~
of this type. Canada, which had been y�
COPYRIGHT: 1981 The Nihon ICogyo Shimbun
CSO: 4120/263
I
I
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I~()R ()N'I~1('IA1. Iltii~: ()NI.Y
SCIENCE AND TECHNOLOGY
BIOMASS AS AN ENERGY SOURCE
Tokyo TECHNOCRAT in ~nglish Vol 14, No 4, Apr 81 pp 35-45
['fext] 1. lntroduction
The trend towards utilizing biomass as an energy source and
for chemical raw materials has been prompted by the uncertain
prospects t'or oil supply as well as rising oil prices.
Oil is pumped up from underground. Coal is also dug out
from the ground. Since both of these are subterranean resources,
they have characteristics common to all such resources; that is,
their reserves are limited and unevenly distributed. This cauted
a serious problem of the supply of energy and chemical raw
materials. (Table 1) (Fig.l ) The supply capability of fossil
resources is shown in Fig.2. In about the year 2000, produc-
tion will hit its peak and decline thereafter. Even coal, where
reserves are very large, will also become a problem, due to a
~oo% ~oox, ioo%
Communi~t 16 16
bloc
W~st Europ� 1 q 3~
North
35 3 ~
10
17
C~ntral end
South ~q , 8
Am~rice
A~ia & 10
Ocaeni~ 6 7
Africs
Middle Eest
25 20
340 bil./bls 680 bll./bls 1,000 bil./bl~
' Accumu~st~d prov~d Undiicovered
produetion r~~~rve~ re~~rv~s (~~timats)
~ ~
v
1,000 bil./bl~
Di~cowrsd r~qrvn ~
2,000 bll./blt
Ultimste n~~rvat
Sourc~: Apency of Nstur~l R~tourc~t end En~rpy, "Nerpy
D~ta".
Fig, 1, Distribution of Petroleum in the World
60~
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shortage in supply around 2300. Countermeasu~es against the
exhaustion of fossff fuels are thus expected to be urgently
prepared.
As suggested by the fact that petroleum and coal are called
fossil fuels, they are made from the fossilized remains of bio-
lo~cal entities. By this fact, they differ greatly from other
subterranean resources. Since biological entities are direct or
indirect products of photosynthesis, which makes use of solar
energy, it also means that the fossilized remains of biological
entities have been transformed by solar energy. On the other
hand, the total solar energy which impinges yearly on the earth
is very large, 1/72 of which is estimated to be equal to the
total of all the uil and coal deposits, and 1/10,000 of which is
estimated to be equal to the present annual comsumption of
S~De I ' 2 I - ~~I
Neturol
pes
80
Patro-
leum
60
40
Wetarpower, wind, Nuclser power
firswood end and
eprieulturel weete non-fonil fu~l
Coel ensrpy
20
0
1800 1900 2000 2100
Source: Bohn, T. ~ Rath-Nepel, St. "Erdoel und Kohls"
1976, 26, 347
- Fig. 2. Long�Term Change in the Utilization of
Fossii Fuel Resources & Energy
energy by mankind. (Table 2).
Thus it is thought that we should utilize solar energy direct-
, ly or indirectly instead of transformed solar energy as in the
past, i.e., oil and coal. If technology is developed for efficiently
utilizing even a small portion of the earth's solar energy as a
new energy source, we will no longer have to worry about the
supply of energy.
Needless to say, our technology is, as yet, by no means ad-
vanced enuugh to supply our energy needs from a solar source.
Utilization uf solar energy is categorized as follows:
: 1) Use of solar heat energy 2)Photovoltaic conversion, and
a 3) Biamass.
61
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Table 1. Worid Reserve of Energy Resource
Petrol~um Natural pss Cosl(rieh coal) ~il sand Uranium
Oil shsis
Ultimet~ rti~rvet 2000 bil./bls 142,000 -r 170,000 7,700 bil.t Oil sand _
FrNworld 1,500 bil.m3 1,600bi1/bls
Communist 500 Oil shsls
5,500 bil/bls
Provsd rsrerves 641.6 bil/bls (1979) 73,000 bil/m3f1979) 490 bil. t - 2.59 mil.t (1979)
Free world 551.6 Fra~ world 46,000 Free world 290
. Comr.iuni~t 90.0 Communi~t 27,000 Communist 200
North Am~riea 5.296 10.9% 24.9% 74.0% 36.496
C~ntrsl snd South 8.8 5.6 ~�a 2~�~ 4�2
Americe
Europ� 3.7 5.3 14.5 17.3
Middls Eo~2 66.4 28.8 - (Others~.2
A~fa, Oc~anis 3.0 S.0 11.2 4.9 12.0
Afriea 8.9 8�2 8�9 29'9
Communi~t bloc 14.0 38.3 41�~
22.9 bll/blt (1979) 1,819.Bbil. m3 (7979) 2.81 bil.t (1978) N~pllpibl~ 33.900t (1978)
An~u~l produetlon Fn~ world 177 Fr~~ world 10,648 Fn~ world 12.0
Communl~r 52 Communl~t 6,548 Communl~tt4.1
World 28 World 4B Wo~ld 78B ~onq t~rm 7g
R~~~rv~s productlon Fr~~ world 31 FrN world 43 Fr~~ world 24Z
(Y~~rl
In t~rm o~ D~trol~um 880 716 3,430 - -
(100 mil.t)
Soure~: Oil & Ga~ Journal, Intsrnstionel Coel T?ed�
OECO/IAEA (D~c. 1974)
Table 2. Comparison of Energies with Solar
Energy (In cal/year)
Totel ~ol~r ~n~rpy cominp to ~arth 7.2 x 10~
Estim~t~d d~po~lt~ of oil and coal 7.0 x 10n
Worldwid~ Y~arly ~n~rpy con~umption 7.2 x 1019
Aequlsitlo~ of ~olar ~n~rpy by photosynthMl� 7.2 x 10~
- Y~~rly food eon~umptlon 3.6 x 1018
Sourc~: In~titut~ of Phy~ical ~nd Ch~mieal Ra~areh,
��Soln En~rpy" (1978)
Among these, the utilization of bioma~ plays a very important
role. This is because the annual absorption of solar energy by
~ pliotosynthesis is ten times the annual world energy consump-
ticm in volume, while only 1/200 part of all photosynthesis is
used as food. There is theoretically a good probability of
~ utilizing biomass as an energy source. At this moment, the use
of biomass is not regarded as economically feasible but research
into its development continues.
!n Japan, biomass is classified under tt~e category of new
fuel oil production (Fig.3,4), and the supply of new fuel oil is
limited in the government plan of energy supply for 1990.
(Table 3)
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svncnecie o
_-~yasoline, Wu
Neturel yas Synthetic gec kerosene
SYnthesis and gas oil p~`
N
Cae~ V ~
~E
i Msthanol ~ E
~ N
~ SynthNi~ M(xture with
~ Fu~l contai- Ilyht residual
ninp oxyQ~n
i ~
Cellulow ~
~ Fsrmentetlon
~
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c
m
E
~
OII ~snd ~
mc
R~forminp snd rsfininp E ~
�
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m
OI I liqu~faet~d ~'o
from coel ~ >
N ~
Ow~lopm~nt Convsntionsl y~
i~ n~c~aary tschniqus~
Soures: AQency oi Naturol Re~ourcee and Energy,
"Nwv FuN OII" (1980)
Fig. 3. New Fuel Oil Supply System
N~[urN Aieonoli:~UOn Llpht o~l Biomsu
~ Hytlrou~bon 1~~ePOn
o~l
CoH
P~trolwm
M~tlwm
Co~l liqu~t~euon a'~
lraction Oil und
O~~ ~h~l~
r"---"-~ H~~vY oil
~ Nuclur ~ Ir~ct~on r"" "i
~ Solu f'-"--......z: ~ Wind '
~G~oth~rm~l~ Ww� ~
� ~
L_~_____J ~ ~LC.i
L~~~~.~J
Liph~ o~l
Inchon Oldm, ~tc.
M~tlwm oil p~~~~ ~how ~ub~tltut~~ by e~w tu~l Oil
1nn~on
Sourc~: Ap~ncy of Netural R~~oure~~ and Enerpy
"N~w Fu~l Oil" (19801.
Fig. 4. Conceptual Diagram of Utilization of
New Fuel Oil
63
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However, cecent developments in the technology for using
biomass are encouraging. Indeed, there is now a greater change
of utilizing biomass than ever before.
2. Advantage of Biomass
Biomass has the following 5 advantages over the other energy
sources:
l. It is a renewable energy source.
Biomass is produced by plants t`ixing carbon dioxide from air
while obtaining solar energy. Carbon dioxide exists in air at
0.03% and is continuously produced so long as life exists. On
the other hand, photosynthesis is continuously carried out by
_ making use of carbon dioxide and solar energy. Thus, carbon
~ dioxide in air is kept at a consistent level. Biological entities
~ are producing organic substances by fixing this free carbon
dioxide. Biomass consists of one aspect of the circulation of
carbon dioxide in air. Thus, it is produced endlessly and will not
be exhausted.
2. [t is enormous in quantity.
Worldwide demand for energy (mostly fossil fuel) in 1970
amounted to a leve! corresponding to 1/10,000 of the solar
energy which reached the eacth. On the assumption that food
consumption is 2,000 cal per person per day, the total food
consumption of mankind (4 billion people) amounts to about
1/20 of the demand for energy. On the other hand, the capacity
of the earth for producing biomass corresponds to 10 times the
total demand~ for energy. Thus, the total amount of biomass, is
enormous.
3. From the environmental point of view, it is a clean energy.
Biomass is a product made by life fixing carbon dioxide
from air. [n other 4:~rds, biomass is produced by fixing carbon
dioxide, a gas harmful to life, and discharging oxygen, which is
necessary to life for respiration. When it is dissolved, it uttimate-
ly results in carbon dioxide and water, emitting nothing harmful.
In the intermediate stages, it emits a small quantity of harmfu 1
substances and technically there are ways to remove them. The
table shows a comparison between exhaust gases from vehicles
with biumass-fuelled engines and with petroleum (gasoline or
- kerosene)-fuelled engines. If alcohol is used, measures have to
be taken for NOx, HC and aldehyde. Compared with oil fuel,
improvements are needed in respect of aldehyde but no
- measures are necessary for SOx.
- 4. lt is a self-supporting fuel.
Where there is land, sunlight, warmth and water, b'romass can
be produced anywhere on earth. It is not unevenly distributed
as are fossil fuels.
5. [t is highly sortable.
As will be described later, biomass is stored primarily in the
form of alcohol. Alcohol is a liquid fuel, easy to transport and
easy to store. This greatly differs from gaseous and solid fuels.
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In t~rm of
shininq houri
Solar ~nsryy to the wrth ~7.2x1020kca1/Y ? N
o ~
~ O N
N L m
- Subnrran~sn r~tourcn ~1.03x1019keal ui ao ~
ap c
Photo~Ynth~sisbyyr~~n~ '7�2x10~~kcal/Y ~ M
O ~
pl~nt (orpaniG matt~r 2x10~~t) ~
O
~ ~
D~mandf for en~rpy (1970) ~7.2x1016kcal/y o
FoOd (for 4x109 p~rsont) ~0.36x1016kcel/y
Fig. 5. Photosynthesis in the World Energy Demands ,
~ 3. R&D Programs in Various Countries
3-1. Japan
[n 1980, the Ministry of International Trade and Industry
established a"Joint Research Group for New Fuel Oil Deve-
lopment" for implementation via a 7-year program. This group
is composed of three subgroups: 1) a group for synthetic oil from
synthetic gas, 2) a group for extraction of oil from oil sand or
oil shale 3) a group for oil converted from biomass.
In the third sub�group, the major subject is the conversion
of cellulose to alcohol which is highly important as a bio-
mass resource, becauses it exists in very large amounts in un-
used resources which are also not needed as food. The Science
and Technology Agency has launched several projects on bio-
mass, which are joined this year by another project: "Com-
prehensive R&D of the utilization of biomass as an energy
source". This new project includes methane fermentation, utili-
zation of Eucalyptus, and conversion of hemicellulose and
lignin. The Ministry of Agriculture, Forestry and Fisheries has
also launched a new "Biomass Project" which included an
assessment of living resources, introduction of new resources,
recycling of resources, primary processing of raw materials, and
conversion processes.
3-2. The United States '
President Carter announced a"New Energy Policy" in Julyi
1979 which aimed at decreasing the import of oil to 4,500,000
bls a day (abuut half of that in 1979) by 1990, and to promote
R&D on alternative fuels. The funds for all this amounted to
$140 billion raised by a petroleum industry surcharge. R&D on
biomass has been carried out since 1975, through the "Federal
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Fuels from Biomass Program" which the Department of Energy,
the Environment Protection Agency and the Department of
Agriculture have promoted. Its budget in respect to alcohol is
shown in Table 4.
On the other hand, a grass-roots movement in favor of using
an alcohol-gasoline mixture (gasohol) has spread since 1978.
_ In January 1978, a gas station in Springfield, Illinois began to
sell gasohol (gasoline with 10% alcohol). By May 1979, 800 gas
stations were reportedly selling gasohol.
3-3. Brazil
In 1975, the Brazilian government launched a national pro-
ject "PRO ALCOHOL". In this project, the government made
the use of gasohul compulsory, and provided various subsidies as
incentives fur companies to base their activities on biomass
utilization.
ln 1980/81 Brazil's estimated production of alcohol, through
the government's measures, has increased to 2 million k! from
sugar cane, 1 million kl from cassava, and 1 million kl from
- bagasse. For this purpase, 3 million hectares of land are being
used (=0.35~% of total land area), 120ha of which have to be
reclaimed, it is reported. Over the period 1977-1986, with
these measures, Brazil is expected to save 3 billion in imports
against an investments of ~600 million for reclamation and
$1100 million for the alcohol plants. Moreover, the whole
program is expected to create more than 130,000 new jobs.
3-4. EC Countries
ln 1975, the EC countries launched the first 4-year plan for
solar energy utilization, which includes a biomass project. Each
member country is studying some aspect of the project. For
example, in Britain, the Energy Technology Support unit and
its collaborators have carried out a feasibility study on organic
waste, or green plants which are to be used as energy sources.
The budget for the four-year plan was ~.1? million, 1.2 million
of which was assigned for the biomass project.
ln Sweden, the Energy Forestry Project is the important one.
it includes R&D on the subjects af redesign of auto engines,
and conversion of forestry resources into methanol. Sweden
regards f'orestry biomass as its most valuable and abundant
source of raw material supply in the longterm.
3-5. Canada
Canada is in the same position as Sweden. ln addition to the
conversion of timber resources to methanol, however, raw
material for biomass in Canada includes agricultural and urban .
wastc. It I~as a five-year plan wl~icl~ began in 1978 with a budget
amounting to 380 million Canada dollars.
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3-6. New Zealand
~ New Zealand aims to produce ethanol from agricultural
biomass, e.g. beets and corn, and from timber resources. It is
also planning to produce methanol and synthetic oil from wood.
In addition, there is an interesting plan to produce ethanol from
Fodder beet which can produce 15k1 of ethanol per ha.
3-7. Southeast Asia
Thailand, Philippines, Indonesia and Malaysia all have an
interest in biomass utilization. ]apan also has begun to co-
operate with them.
4. Biomass Resources
Biomass resources include the following
1) agricultural products
2) agricultural waste
3) industrial waste
- 4) urban waste
5) stockbreeding waste
6) forestry resources
7) marine resources
8) microbe resources.
In addition, one method of acquiring solar eneigy rrraking use
of life, is producing hydrogen and oxygen by decomposing water
by adding light or energy to microbes. At present, technQlogy
for utilizing microbes to produce hydrogen is at the stage
~of basic studies and is for the time being excluded from present
discussions of practical energy.
41. Agricultural Products
Nearly all agricultural products can be foods in tt~e form of
biornass. Also, they can be lurned into energy sources. They
include rice, wi~eat, sweet potatoes, sugar cane, cassava,
rapeseed, sc~y hean, sunflower, etc. If special seeds which grow
in lceland will be cultivated, they will be included in agricultural
products.
Agricultural products will be one of the major resources for
biomass. From this view point, effective products are needed.
A measure by which a product is assessed is the yield per ha,
and the conversion rate of it to alcohol. Table 5 shows the yield
of agricultural products cultivated in Asia.
As production using an alcohol fermentation method is an
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Table 4. Federal Budget for Alcohol Fuel Development
(Unit mlllion dollsrs)
1979 FY 1980 FY
Biort~efs 72�9 ~9�9
Ethanol 2.8 5.0
Production sy~tem (raw mecerlel ~ ~ ~ 2
for athanol)
Cellulo~e decomposition 3.5 4.5
Ga~ification (msthanol production) 3.6 7.0
Substitution of raw meteriel 2.0 2.2
Dsv~lopmsnt of elcohol fuel utilizetion 3.5 4.0
Methsnol from coal 3.0 0.5
Bs~ic rss~srch 0.1 0.5
Table 5. Yield of Agricultural Products and Alchol Alcohol
from It
~ Betic unit Annual yield
~Tropicel ] Yi~ld (t/he. y~sr) (t/kl ~thanol) �t Ethenol
k
Superc~n� 50 ~ 60 15.1 3.3 4
Ca~~eve 10 ~ 25 5.3 1.9 -r 4.7
Sw~et poteto 60 100 5.3 17.3 18�9
(3 tim~/Y~~~l
Supsrcorn S~~d 5~t6) 3.0 1.7 1
(Brezll) ( (2 tfm~/Y~sr) ~ 5.2
~Temp~ret~~ ~ 62.6' 15.2 3.5
Sw~~t potsco
(Southern Kyushu, 23.6 6.3 4�4
Jspen)
Foddsr b~~t (N~w 90 g ~ ~ 15
Zseland
Bsat (Hokkeido, 52 ~ 4.7
Japan)
equipment�based industry, the capacity utilization rate is a big
factor in production costs. Therefore, a continuous supply of
raw materials is essential to keep costs down. In tropical areas
it is possible to harvest throughout the year cassava and sweet
potato, and besides tliis it ;s possible to dry-store them at the
farm. This solves the problem of continuous supply. Though
cassava and sugar cane ;~re said to be the most promising
products, cassava has some disadvantage due to its one crop
per year. Sugar cane has two crops a year, but it has the dis-
aJvantage of not being able to be stored as dry matter.
At this moment, the sweet potato is considered to be the
most ~~rumising raw material for the following reasons:
l) Yearly yizld per ~anit area is largest because crops are 2-4
times per year.
2) Continuous supply is pussii�;a.
3) lt is resilient against pests.
4) It does not begin to decay for 7 days, while cassava lasts only
for 2 days.
n
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The cultivation techniques are most advanced in lapan and
in the U.S.A., but especially Japan has a long experience of
improving the yield of sweet potatoes. Mr. J.Kobayashi of the
Kyushu Agricultural Experimentation Station is responsible for
this matter. The average yield of sweet potato is 30t~ha a year,
while an especially good crop can yield SOt/ha.ConsiderinR its
good yield, the reasons why the sweet potato has not attracted
wide attention as cassava are thought to be: (1) sweet potato is
not suitable as a staple food due to its sweetness, (2) it cannot
be cultivated by extensive farming techniques as is the case with
cassava, (3) it is less resilient against severe drought and (4) it is
less resistant to pests than cassava.
Recently the Philippines has developed a farming technique
to prevent pests by flooding every 10 or 20 days. Development
of agricultural technology may further change this situation on
yield. Mr. L.A.Wilson's ~nal target for improved yields is
estimated as follows: sweet potato 200t/ha~y, cassava 140t/ha/
y, rice 80t/ha/y and corn SOt/ha/y. However, Japanese specialists
thir.k annual yield should be over 400t/h for competing with
gasoline when conventional conversion process is applied.
Mr. Hayashida of the Okura & Co. reported there is a good
prospect that the co-farming of cassava and sweet potato will
yield more than 300t/ha/y in the very near future in Malaysia,
providing enough fertilizers and good farming. [n fact some
Malaysian farmers are growing sweet potatoes between the rows
of cassava for preventing weeds. They are cropping 200t/ha/y.
,
~ ~ ~
, !
Fig. 6. Cassava
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Alternatively, new varieties of plants are being developed.
- For instance, Beetato Product Ltd. of Columbus in New
England, U.S.A. has cultivated a new plant, the "Beetato",
which is created by crossbreeding a beet and a potato. In the
test period 1976-1979, this plant showed a yield of 180t/y/ha
helped by irrigation.
These facts suggest that new cultivation techniques may
create suitable new plants in the near future. Along with these
plants, which are expected to be raw materials for ethanol, there
are some plants which are expected to be raw materials for the
chemical industry. The following are some of them which. are
not directly used for foodstuff or feedstuff.
Milkweed (Asclepias Syrica) was chosen by the U.S. agri-
- cultural department as a new resource for elastomer.It is
expected to be easy to increase the productivity of milkweed
over that of Hevia brasiliensis. Guayule which has a longer
history of development than milkweed was widely cultivated
during World War [I. The Firestone Corp. has disclosed its
tentative cost estimate for making rubber from guayule. Ac-
cording to tl~e company, the cost could fall to US$0.43 per
pound by 1985 to make it competitive with natural rubber.
Euphorbia genera, which includes the well-known Euphorbia
tathyris, is a promising hydrocarbon plant. According to Prof.
M. Calvin, dry matter of Euphorbia lathyris contains 5'~0 (in
weight) of butane-soluble matter, which has a calories count of
~ 17,800BTU/pound, and 30% of inethanol-soluble matter with
- 7,300BTU/pound. Euphorbia tircalli which is attracting Japanese
attention contains 9�l~~ oil (0.4~/~~ of benzene-soluble and 8.5%
of acetone-soluble matter). By rough estimation, the cost of oil
from E. tircalli is reportedly nearly the same as that of petro-
leum at $40/61.
Leucaena leucocephala is a tropical root nodule plant which
grows in symbiosis with nitrogen fixation bacteria. It can be used
as a hydrocarbon plant, while it is also raw material for pulp.
_ Jojoba (Simmondsia california) is the focus of attention as
an oil and fats plant. Its seeds contain about 50% glicerid~ oil
in weight, whose major component is erucic acid. Crambe aby-
seinica also prc~duces erucic acid. As is well known, erucic acid
can be induced to nylon 1313 via brucine acid. Iron weed
(Veronia Authelmentical and Alchornea Cordifolia can produce
epoxide fatty acid.
Note: Zcolite catalyst ZSM-5 06 Mobil Oil is known to be a
catalyst which can convert methanol to gasoline. Mobil Oil
announced recently that tliis catalyst also easily reconstitutes
jojc?ba oil, a~rn oil, etc. into hydrocarhon oil.
4-2. Agricultur~l Waste
Chat'f, ricc and wheat straw, and other remains of agri-
cultural food products after edible portions are extracted, a-
mountinb to I~ugc quantity, are wasted without being utilized.
These are usable resuurces.
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4-3. lndustrial Waste
When forestry resources are processed into lumber, large
quantities of unusable branches, bark, etc. are wasted. When
lumber is used industrially in woodworking, large quantities of
chips, sawdust, shavings, etc. are produced. When factory
drainage is biologically treated, sludge heavily containing
microbes is produced. These are all usable as biomass resources.
4.q. Urban Waste
Some of urban waste also can be used as biomass resources.
4-5. Stock-Breeding Waste
ln most cases, excrement of livestock is wasted, although it is
used as fuel in some countries. This can also be used as a bio-
mass resc~urce.
The quantity uf waste is very large. Table 6 shows the es-
timated unexpluited wastc biomass in ]apan, which can supply
enougl~ alcolu~l to drivc all tlie autumobiles in Japan, if con-
verted to alcohul.
4-6. Forestry Resources
Fallen or withered trees in forestry areas can be used as
unexploited biomass. Some special plants of the pulse family
such as ipil-ipil can be used~as energy sources by cultivation.
Note that ipil-ipil is used as quality charcoal.
4-7. Macine Resources
Giant kelp, for example, which is now experimentally
cultivated in the sea, is considered to be a hopeful biomass re-
source, as its crop per unit area is large.
4-8. Microbe Resources
Production of microbes is a typical method of utilization.
This kind of resource, however, is biomass as food and feed
ratl~cr than an energy resource.
5. Types of Biomass Utilization
5-1. Supply System of Alcohol Fuel
Biomass is mostly fuund as solids composed of 1) starch
2) cellulose 3) hemicellulose, and 4) lignin, though sometimes
it is found in the form of protein or fat. These are used as
1) an energy source 2) raw materials for the chemical industry,
when food and feed stuffs are excluded.
In its utilizati~n as an energy source, biomass is in some
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Table 6. Waste and Unexpior Biomass in Japan
Quantity Estimet~d orpsnic
Itsm psnsrated (dry metcsr, 10,OOOt/y)
Un~xploited wood 20,000,OOOm3 (400kp/m3) 8,000
Fors~try wstts 9,000,OOOm3 ( " 1 3,600
Lumb~rinp we~te 28,000,OOOm3 ( " 1 11,200
- Ut~d lamber 2^30,000,OOOm3
Aprieultursl weste 12,000,OOOt 12,000
(Ory mstter)
U?ben waste 33,000,OOOt (3096) 10,000
Livs~toek wefte 62,780,OOOt 6,280
Psper induttry we~ts 570,OOOt 610
(Ory matt~r)
Indu~trfal wa~t~w~t~r sludp~ 1,680,OOOt 1,760
(Dry m~tt~r)
Food proc~uinp Indu~try ZZ~
w~~t�
Humen w~st� 42,300,OOOmj 1,200
S~w~rp~ w~~t~ 89,100,OOOm3 (196) 690
(9996 Mol~tur~)
Totel 54,760
Source: Netionel Chemicel Leboratory, "Toko~hi N~w~" 13-6, 1978
Table 7. Composition of Wood & Rice Straw
Cellulo~e HsmicNlulo~~ Lipnin
Wood 60 20 25
Ffe~ ~traw 4~ 33 6
utilize in the form of such solfds if it ~is to be used as an
alternative fuel to oil.
Thus, it is necessary to use biomass ef~ciently as fuel by
changing it into liquid or gaseous fuels.
The supply system of alcohol fuel is shown Fig. 8.
Part of biomass is gasified to synthesize methanol, while a
Iarger part is converted into ethanol.
5.2, Liquid Alcohol
As it is well known, starch, cellulose and hemicellulose are
made of a collection of glucose. Lignin contains benzene nuclei.
The chemical structural formula of starch is relatively
simple. It consists of a simple chain of glucose. Starch can be
relatively easily decomposed by enzymes into glucose, which
is converted to ethanol. This is carried out by the process
shown in Fig.12.
Woody plants are largety composed of cellulose. Like starch,
cellulose is also composed of glucose, but unlike starch, it has
each link of its glucose chain reversed. Thus, enzymes which
decompose starch are not able to decompose cellulose into
glucose. In addition, ~ellulose is solid and hard. So, it has to
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be loosened before enzymes can be applicd to it. In order to
loosen it by present techniques, cellulose has to be pulverized
or cooked in a weak a7kali. This requires a great deal of energy
and cost. Amylase which dissolves starch is not applicable but
an enzyme called cellulase has to be used to break up cellulose.
At this moment, the cellulose decomposition process which
is best known is the Gulf Oil Co. SSF process (Simultaneous
Ethanol
Natural q~t N~w tynthethie mathod Methanol
Oil ~and (Sapami Chuken Procesil Mix
Oil ~hal� o
CO~I
~ c
'X ~ CO, HZ
' a ~ynth~tle y~~
A g M~thanol fynth~~l~ M~thsnol ~
~ N ~
WOOd �
a c7 t
Wood timb~r ~ o
Aprieultunl � ~
c~ Q
wa~t� o 0
u�~
O
LL~
Sterch plent HydrolY~i� ~ Absolute
S~Ilulo~~ m~tter ,o ~ ~ Ethanol
(Urban w~st~ ~a o 0
aQrfcultursl west~) c" ~
HydrolYf(f by ~ 4 ~
hydrolas~ E 'N
LLGO
Supar plant
Fig. 8. Alcohol Fuel Supply System
CHZOH CH2OH CH2OH CHZOH CHZOH
H H H OH HH H H H H HH H
H OH H O
~OHH,~" O OHH p�--O HH O�--�O OHH OH
H~n r"'? H OH H OH
H OH H OH H OH
Fig. 9-1. Structure of Amylose
H COH
H2COH H~ HZCOH Hp 2
HO~OjyO~~l~l~l-HO 0 o Oa ~HO OQ
H
/ ~H HO a~~H~ H
C~OH HO
HZCOH HZ OH 2
Fig. 9-2. Structure of Cellulose
Saccharitication & Fermentation Process). Eig.13 shows its
, conceptual tlow chart, and Fig.14 shows the plan of a pilot
plant uf the SSF process. This pilot plant has shuwn an operating
capacity oF it/day since 1976. It is characterized by the fact
th:?t it handles pre�treated cellulose with sacchari~cation at the
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EsDartopra~s .....4X1-4xl-4Xl-qXl-4X1.....
Whset~traw .....qXl-4xt-4X1-4X1-4X1.....
3 2
~ ~
1 1
q MeG
A
1
~
3
Whestalbum~n ,,,,,qX~-qX~-qX~
(solubla)
Be~t SA~-3A1-SA~ SoYb~en qGsll-4C? 31-4Gal~
3 ~
~ ~
_ ~ A
A
X: D-Xylopyrsnos~ A: l.�Arebinoturano~e
MsG: 4M~~hylplucopY~anouronic aeid
Gal: O�Gsl~ctopyrenos~
Fig. 10. Structure of Hemicellulose
same time as fermentation. This process avoids the inhibiting
reaction of glucose feedback by connecting the fermentation
with the saccharification process to lessen the total reaction
speed. The develupment of this process has been followed by
the University of Ancarson. Fig.15 shows a comparative study
of costs of the SSF process.
Woody resources heavily contain hemicellulose in addition to
cellulose. They cannot be effectively utilized unless hemi-
cellulose is utilized in addition to cellulose. Hemicellulose is
composed of chains of a type of sugar different from glucose
and these chains are hard to break. [n order to sever them, an
- enzyme called hemicell~ ~se has to be used. Although cellulase
and I~emicellulase are sufficiently popular enzymes to be com-
mercially available, they do not have very high dissolving
power an~d are not suitable enzymes for the purpose of de-
compusing cellul~~se an~ hemicellulose industrially. If it is
desireS tc~ utilizr ~rlluluse an~ hemiceUuluse industrially, power-
f'ul rnzymes h~ve tu I~c Jevelupe~l. 13esides this, there is anotlier
pr~~ress by which hemiceiluluse is Jecumposed into xylose. Of
~uurse it is possible to gain xylic, easily from xylose; however,
therr is anuther process uf xylose xylulose ethanol. The
lat~cr prucess is ~alled the SIF prucess (Simultaneous Isomeri-
~.~tiun & Fermentatiun), whuse concept is shown in Fig.16.
Tl~is prucess is hopeful fc~r utilizing I~emicellulose.
5-3. Gasi~cation of Biomass
The cunventional process is basically good enough for the
_ gasification ~~t biumass. Fig.17 shows the concept of the gasifi-
c~tiun process uf biomass.
tluwevcr, an industrial process which can supply alcohol
~umpetitivc with uther processes ur with ttasoline has not vet
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~ CM=OM
~ I
I
~~r ~
O ~ GHSO3M
- CHj O J\
- CH2OH (CH0)
I H
CIN C1H~OM ~CHSOyH
OM ~%M SO3H CM-CH
~ ~ I CH OM CMSO9M \CH2OH
Y I 4-II O CHZOM
CMSO~M ~ CH2OH 11 ~H OCM ~
~ ~ CM CH=OH--~~ --CMSO H 3 CH
CM ~T 3 OM ~ OCHj
I ~
CH~OH CHS03M ~ CH O
/ CH2OH O ~ CN~OM
O CH CH~O CH II O OCHj
~ ~ I II
CH2O CH MS03F~ ~T~ OH
~ CH~OM I I
Cj~OH O I~I O
Ci OCH~~jC OCH3 .
CHSO~H - MSO~H OH
OH
O
O O O CM3
C~~~H OCH; CM~O ~M
CH ~ p
CH
C~ ~ H 1I C�lO
I CH~OH � O OCH~
CHS03H
CH ~
- CM~OH � O CH~
/
/
CHSO~M ~ iH10M
CH - CH
CM=ON i CHSO~M
\
Fig. 11. Structure of a Lignin Sulfonic Acid
been developed. liowever, much development work is currently
_ being undertakeri. For example the Purex process of Union
Carbide, the proc;esses uf Muure-Canada (Richmond), of Battle
_ (Pacific Northwest Laboratories), of Pullman-Kelloy, of Alberta
Industrial Development, of Dekab Ag Research, of. Sagami
Central Ir.stitute etc. are al] included in this category.
5-4. Others
The remaining portions of woody plants consist largely of
lignin. Compared even with hemicellulose, lignin has a very
complicated structure and is still harder to be decomposed.
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~ TrNtm~nt ~ntl brm~nt~iVOn Ot r~w meNn~li
V ~Itt ~ntl
uech~nfip~tio~ Di~tillatio~
s�`
~ ~ntym~~ top-pntl~ ~ICOho~ M~tA~n01
h~ o
C
Clunmp
I Br~w~np Roup~ly I ~
Puwur~- Suam t.^k d~~~~~l~tl I ' ImDUra
t0i~o~ bO~~~r i ICOhO I I Y~ ~ ~ICOh01
Stnm I I ~ E E _
I ~ vo > > ~ 'o
Ju~[� I A~r I I o ~ u � O
Ammonmm CO; ~ ~ I v i c ~
I ~ntl ~Ulf~i~, ~1C. p N
~ i Fu~~i oli 5a ~ _
mol~u~t ~ a O , _ c FuNI oll
. St~nhnuon I ~ ~2 KZ ~ ~ ~Q~ ~ c
I x W V �u E�u
I Fs~ment~t~on I o 0 0
i I [snk i c ~ 1
Mo4pn ~ e
I
LJ �
---J Ho, w.t.,
~ow.,
Source: Data et Alcohol Industry Divition of the Ministry of
Internetlonel Trsds end induttry
Fig. 12. Current Alcohol Fermentation
Enzyme
menufacture
Ethanol
Cellulosa Saceherification
and fermentation
Y ea at
menufacture Solid waste
Source: G. Emart, 2nd Chemicel Conqre~i of the North Americen
Continent (1980)
Fig. 13. Conceptual Flowchart of SSF
Wl~en Jecoil~posed, it contains benzene nuclei. Thus, it can be
utilized as bci~zene. However, studies on its decomposition
have not yet produced sufficient results.
As c~utlined above, when the four components of biomass
are dcc;omposcd into sugar, they can be utilized in the following
I~c~rms: methane gas, alcohol, hydrogen and bacteria.
Of these, hydrogen can be obtained by the following process.
A c.~crtain type of microbe is cultured in a sugar solution as a
nutriment source, and the microbes are exposed to light to
c~~nvcrt water into hydrogen and oxygen. Studies on this
pn~cess are at an experimental stage and far from practical use
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- Llquid culturo Csllulow ~
c
' T.reesei yeast m
~
c ~
E �
~ U
' > u
~ ~
EnzYme Fermen� � ~
tation d _
manu� ~F ~iquid -
~ feeture storage A ~
m9
Steem
Ethanol
Source: G. Emert, 2nd Chamicel Dlttillation ttorepe
Congra~s af the North American reeidue~
Contin~nt(1980)
Fig. 14. SSF Process for Cellulose Biomass
co~ ce~te~~na
Fixed microbe 95%ETOH
(Ex. 25�~ (572 pel/hrl
F. Oxysporum)
35'C 90�C
r--'-'-----
Biomes~ ~ o Dittilletion
~ Acid i 0.80% Xylose 25 C
column
Acid ; Hydro~ysic ~ 0.19�~6 Glucote (34,100 gel/hr 100 C 1
Circuletinp ~ ~ COy Centering 0.5%
weter ETOH
2.196
i Fixed yeast ETOH
lEx. F. 25�C
Oxysporum)
25'C 35~C 90~C
Circuleting water
4.35% Glucose t12,500 pal/hr.) 100�C
Note: 1 pel=0.003785m3
Source: O.C. Sitton et al.
CEP f 1 21 52 (1979) Fig. 15. Conceptual Diagram of SI F Process
- f^:� the time being. For utilization as bacteria, microbes can be
directly utilized as food and feed as a protein source because
they are more than 50% composed of protein. The technology
for this purpose has already been established. This leaves
~ methane and alcohol as the forms in which further develop-
ment is h~ peful for utilizing biomass as an energy source. Of
these two, methane can be obtained easily by fermentation.
Furthermore, a membrane which is permeable only to methane
has recently been developed, enabling methane to be easily
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i~()R ()H'N'1('IA1. IItiN: ()NI,Y
Hiph�temperature
~ gar Acid
~ Preheater for
Prsheeter for reactor Reactor
r~ector R~ector
Orier Wood chips Alkeli
Wood chipt
Grinder p ~
Hydrolysis bath
Circuletiny oil Blend~r Light oil
and water
Msdium oil
Light oil CO, H2 Oil Off-gass CO, H~
~ Off-yes
Besic catelyst Recycling /Flash tank
Redueed-presfure Flsfh tank Aeduced-pres~ure ~ /
distilletion column distillation column
do
Air cool~r
Re~iduum P~eheeter Reaiduum Preheeter Separator Air cooler
(1 ) BOM Proc~~~ (2) LBL Process
Source: O.C. Elllott, 2nd Chemical Gonpraff of the North Americen
Contin~nt (1989)
Fig. 16. BOM Process (Left) and LBL Process (Right)
Biomen Ge~ification Gescleeniny
heex
Oxygen of biomeu collection
Sulfur collection Sulfur
- COZ
Rsmovel of H2S� Shift reaction
COZ
Purge
Methanolfor
Compre- Synths~is Refininp induttrial use
i~ion of inethenol of inethenol end es fuel
Fig. 17. Conceptural Chart of Biomass Gasification
Processes - For Synthesis of Methanol -
obtained at nearly a 100~1o concentration. Since methane, even
when unretined and at around 50-60% concentration, has a
calorific valuc of 5000 cal., it can be used satisfactorily as a
fuel. However, the utilization of inethane involves difficulties
in two years. For one thing, methane is a gaseous fuel and is
}iard to store and transport. This is its main obstacle to large-
scale utilization. In addition, although methane can be
_ generated easily, it is technically very hard to obtain in large
quantities continuously and stably. At present, therefore, it is
recognized that the most practical way of utilizing biomass as
an energy source is by changing starch, one of its components,
into alcol~ol.
COPYRIGHT: 1981 Fuji Marketing Research Co., Ltd.
CSO: 4120/262
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SCIENCE AND TECHNOLOGY
REORGANIZATION OF CAUSTIC SODA INDUSTRY SUGGESTED
Tokyo BUSINESS JAPAN in English Vol 26, No 6, Jun 81 pp 75-82
[Article by Masa~i Yamamoto, director, Basic Chemical Products Division, Basic
Industries Bureau, Ministry of International Trade & Industry]
[ Text ] HE caustic soda industry is en- between Japan and the United States
T gaged in the production of caus- in the production costs of ethylene,
tic soda and chlorine through salt one of the basic materials of PVC. The
water electrolysis. import of ethylene in the form of
Caustic soda is used extensively in ethylene dichloride (EDC), a semi-
the manufacture uf chemical fibers, fuushed product, from abroad is on
paper and pulp, alumina and chemical the increase, creating a problem for
seasonings, for dyeing and processing the caustic soda industry.
textiles, for the treatment of waste In the meantime, it was decided in
acids and for pollution prevention 1973 to abolish gradually the mercury
_ including the removal of NOX and SOX pracess in existing caustic soda plants
from exhaust gas. so as to prevent environmental pollu-
Chlorine, obtained as a by-product tion. About two-thirds of all plant
of the caustic soda industry, is indis- equipment was converted from the
~ pensable as a basic and auxiliary raw mercury process fo the asbestos dia-
material for polyvinyl chloride, chlo- phragm process in the fust�stage con-
rinated solvents, polyurethane, other version program started in 1973 and
chemical products and chemical costing about ~230 billion. The con-
seasonings in the form of chlorine gas, version of the remaining one-third is
hydrochloric acid and sodium hypo- progressing in the second-stage pro-
chlorite. [n addition, chlorine is used gram at present, mainly to the ion
to purify city water and sewage. exchange diaphragm process. The
The demand for caustic soda and makers should endeavor to rationalize
chlorine has been stagnating in the their managements in view of the huge
protracted recession following the costs needed for the change-over.
first oil crisis. The problem of surplus
_ equipment has surfaced. Although de- Demand and Supply
mand picked up temporarily in 1979, The output of caustic soda is slow�
it dropped again ~fter 1980, reflecting ing down following a peak in produc-
a downward trend in general business. tion reached in .1973. The operating
A further decline in consumption ratio for equipment stayed at a low
seems inevitable nuw that the produc� level of about 60% in 1976 when the
tion of paper, pulp and PVC, which conversion to the diaphragm process
had Qrogressed to a considerable ex-
consumes the greatest quantities of tent, and have been operating at a low
caustic soda and chlorine, is slowing ratio ever since.
down. The domestic demand for caustic
Furthermore, there is a wide Rap soda in 1979 stood at 3,085,000 tons,
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Table 1. Demand Trend of Caustic Soda
(Unit: 1,000 tons)
~ ! Supply j Demand i Term- I Operat- I;
I Year ; ing ratio j
; Output ; Imports i Total ~ aemand I Exports ' Total ~ en ory I
, i
~ 1973 ! 3,214 I 66 - ~ 3.196 98 ! 3.294 ~ ;1 ' 82 ~
, 1974 ' 3.067 ?3 - ~ 2.913 184 3.097 65 ~ 77
i 1975 ; 3,007 ~ - ; - ~ 2.791 ; 125 ;?,916 i l56 69
1976 ' 2,841 3 - i 3.781 ~ 128 ''_.909 ~ 9l 6l ,
i 1977 ;'.882 ' 28 - ! 2.842 ~ 62 , 2.904 ' 97 62
I 1978 i?.723 ; 26 - 2.684 j 8& 3.772 74 ~ ~3
~ 1979 ~ 3,'_13 26 , - 3.085 j l34 3.219 ~ 95 , i0 '
1980 ~ 3,03~ ~ 37 - ~ 2.900 i 195 3,095 ~ 71 64 ~
~ (est.l ~ ~ _ ~ ~ i ~ i
~
Table 2. Breakdown of Demand for Caustic Soda
(Unit: 1,000 tons)
I 1980 ~
~ [tem 1978 ! 1979 , ~~st.) I
Chemical fibers 234.4 ~ 244.7 ~ 228 i
~ Paper and pulp ' 319.2 ~ 360.2 ~ 346 j
~ Cellophane 39.4 ~ 45.1 ~ 35
j Alumina 145.1 ~ 194.0 ; 206 !
i DYeing 58.8 ! 62.5 ; 60 ;
i Detergents 61.6 i 65.4 ' 62 ;
~ Dyestutfs and intermediates ~4�~ ' SS�~ ~ R~ I
'?.~i Inorganicchemicals 583.7 ~ 584.7 ~ 538 i
N I Flectrolytic soda ' 69.0 i 77.7 73
i Organic chemicals and petrochemicals I l79 130.6 l 18 ~
~~.5' Others 54R.7 708.0 ~ 72a ~
Total 1,455.6 1653.1 1593 '
i Seasonings 80.8 ' 87.5 j 79 '
~ Oil rctinery 33.6 I 34.6 ~ 32 ~
~ Others 317.3 ~ 396.8 'i 321
1'otal 2.684.1 ~ 3.078.5 2,900 !
climbing 14.9% uver a year earlier. The situation deteriorated in 1980.
This growth was ascribed to a brisk 'I'(1e deepening recession brought
demand in the consuming industries - about declining demand in the chemi-
alumina, inorganic chemicals, paper cal, chemical fiber and cellophane
and pulp, and chemical fibers - and to industries. The annual demand
the preemptive demand in anticipation dropped to 2,900,000 tons, which
- uf' soaring custs uf raw materials and represented a decrease of 6% from a
f'uel, including the hike in electric year earlier.
p~~wer rates al'ter April 1980. Exports However, exports in 1980 with
witf~ t34,000 tons recorded a substan- 195,000 tons recorded a considerable
_ tial growth of 5'_.3;"~ uver a year gain of 45.5% over the preceding year,
earlier, thanks to the buoming demand favored by the woridwide shortage of
abroad. caustic soda and the formation of an
As a result, the uutput of ~austic Australian export cartel.
soda in 1979 stood at 3,213,000 tons, lmports in 1980 grew 42,3�'o to
up 18'7o uver 1978 and approaching 37,000 tons, mainly due to the open-
the peak year of 1973. lmpurts with ing of the new Korean Dow plant.
2G,000 tons stayed on roughly the (mports, however, accounted for only
same level as in 1978. 1.2~10 of overall supply.
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Table 3. Breakdown of Demand for Chlorine
(Unit: 1,000 tons)
I 1980
ltem 1978 1979 (est.)
Paperand pulp 238.1 266.2 249
P V C 824.1 ~ 970.3 868
Seasonings 66.8 I 68.9 63

1~ Chlorinated products ?69.6 I 280�2 300
Chloromethane 90.4 I 118.1 122
P 0 132.7 161.7 149
T D 1& M D I 80.6 95.2 91
Dyestuffs and intermediates 86.7 103.7 111
270.7 301.9 287
Inorganic chemicals I 812.5 795
Others 657.5
Total 2.717.2 3.178.7 3.035
368.9 419.3 426
Recovered chlorine
Balance ~ 2.348.3 3,759.4 2,609
- Caustic soda equivalent 2;724.6 3,209.6 3.034 ~
Tab~e 4. Imports of Chlorine Products
(Units: 1,000 tons, �k)
- 1980
Item 1977 1978 1979 (est.)
lmports 54.1 288.0 344.9 185.2
FDC ~mport ratio 3.l 13.4 I 15.5 9.6
- Imparts 5.7 I 1?.4 21.9 30.0
Carb~>n tetrachloride Import ratio 11.0 ~ 23.3 I 33�7 42.3
lmports 1.4 5.1 I 15.3 10.0
Perchlorethylene ~m~rt ratio 2.4 I 9.6 25.5 14.4
Imports 0 ~ 1 ~
Trichlorethylene ~m~rt ratio ~ ~ 0'1 ~
[mports 0 2.4 2.4 0.1
~ I lmport ratio 0 1.2 ( 1.1 0.1
' Import~ 10.0 9.5 16.4 16.0
pPG [mpott ratio 6.7 5.5 8.8 9.1
(mports 3.8 i 9.3 10.5 10.0
PG (mport ratio 8.7 20.2 19.2 ~ 23.8
The demand for chlorine in 1979 duction of paper and pulp, PO (a raw
grew 17% to 3,179,000 tons (including material for urethane) and inorganic
recovered chlorine). The growth was chemicals.
The international competitive
accounted for by brisk demand in the wrer of chlorine made in Japan is
PVC, paper and pulp, chlorinated sol- P�
vents, inorganic chemicals and ure- being gradually undermined. Soaring
thane industries as well as premptive prices of naphtha in Japan after the oil
purchases in anticipation of future crisis have resulted in a sharp rise in
price increases. olefin prices, whereas price rises in the
The demand for chlurine dropped United States and Canada are not so
by 4.5% to 3,035,000 tons in 1980. great. This has created a big price gap
Main factors causing this decline were between Japan and these countries.
the stagnation in the P'VC industry Moreover, rising electric power
which accounts for some 30�Io of the rates in our country are pushing up the -
demand, and a slowdown in the pro� manufacturinR costs of chlorine prod-
82 �
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ucts and weakening Japan's competi- products made in Japan are losing
tive power. their international competitive power,
As a result, imports of chlorine and some chlorine products are being
products are annually growing as imported in increasing quantities. The
shown in Table 4. Although the industry is studying production and
growth of imports slackened a little in reimport of chlorine-related chemicals
1980 owing to the domestic recession, from countries where olefin is availa-
imports of ethylene dichloride (EDC), ble at low cost or caustic soda is in
the basic material for PVC, still stood demand. But an abrupt import in-
at 200,000 tons and accounted for crease in chlorine piocio~cts could dis-
about 10% of domestic consumption. turb the supply and demand situation
Imported carbon tetrachloride, basic in the domestic market, lower the
material for freon, made up 40%, operating ratio of plants and affect the
polypropylene glycol (PPG), basic production of caustic soda adversely.
material for urethane, made up l0~yo Further rising of production costs
and perchlorethylene, used as a solvent for caustic soda and deterioration of
and dry cleaning agent, made up 14% Japan's international competitive pow-
of tl~e domestic dert~and. Thus the er are conceivable if the operatmg
- percentagc uf unported ~hlorine prod� ratio goes down and various tixed costs
ucts u~ overall ~fomestic cunsumption go up. In addition, there is the con-
is rising gradually. siderable gap in costs of electric power
and raw salt in Japan and abroad.
Future Responsibilities These conditions are certain to make
There are several prublems facing Japan's position dif~cult in the seeable
the industry. First is the demand and future.
supply balance between caustic soda Japan's cau:tic soda industry is
and chlorine, and the import problem carrying out a conversion program for
of chlorine products. its manufacturing process as explained
Causric soda and chlorine are pro- below. Rationalization of the industry
duced simultaneously in the caustic is essential for its survival and expan-
soda industry, but it is difficult to sion. We must cut production costs
maintain always the ideal consumption whenever possible, ensure orderly im-
balance between caustic soda and chlo- ports of chlorine products, maintain
rine because the tields of demand are the balance between overseas and
different for these chemicals. This . domestic production and adjust the
sometimes creates a difficult situation supply-demand balance between chlo-
regarding chlorine, a gas of high tox- rine and caustic soda in a comprehen-
icity thai is difftcult to handle. sive way.
- In Japan the demand is always The second-stage conversion pro-
greater for chlorine. Surplus caustic gram for the manufacturing process is
suda has been expu~ted. (Table 5) The also a problem. The third "Conference
imbalance of demand between chlo� for Promoting Countermeasures
rine and caustic soda is yearly gowing. Against Pollution by Mercury, etc."
_ As mentioned earlier, chlorine (hereafter abbreviated to "confer-
Table 5. Demand-Supply 8alance of Caustic Soda and Chloi~ine
(Unit: 1,000 tons)
ltem 1977 ~ 1978 ~ 1979 1980
~ (est.) ~
~C~ustic soda ICS) domestic demand (A) ~?.842 j 2 684 3,084 ~ 2 900
(Imports thereot) (28) I (25) (26) i (37) I
Chlorine demand IB) 2 955 ~ 3,020 ~ 3,593 ~ 3.302
I Imports thereot) (73) ;(297) ~(380) ~(268) ~
- ~ Chlorinn demand yurplus (C) 68 i 64 I 155 171 ;
~ CS supply surplus? ;
CS exports (D) 62 ~ 88 I 134 ~ 195 ~
I Increment of CS inventory (C _ p) 6 ! - 24 2l ~ - 24 ~
~ CS output 2,882 I 2,723 i 3,213 i 3,034 I
~CS plants oper~ting ratio 62~a I 58% 70�Io j 64%
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Table 6. Caustic Soda Manufacturi~g Process Conversion Program
(Units: 1,000 tons/year, "o)
I No. of ~ Scheduled ~onversion
Conversion starting , conversion , ratio
enterprises capacity
Jan. 1980 - Dec. 1982 ~ 7 448 ~ 508 ?7�3 28�6
~ ~p 950 ~ 1.026 57.9 - 57.7
Jan. 1983 - Dec. 1983 ~
7 243 14.8 ~ 13.7
i Jan. 1984 - Dec. 1984 ~ i 100.0
Total I '-4 1,641 ~ 1,777
(Note) I. Some enterprises are entered twice in the list.
2. Schedyled conversion capacity includes the mercury process equipment
that can be dismantled or put out of action.
3. The table includes enterprises With limited fund r~ising ability and
management structure requiring improvemen[s.
ence") resulved in November 1973 to harsh environmental and economic
convert caustic soda manufacture to factors surrounding the caustic soda
processes causing less pollution of industry, including price tluctuations,
water systems. the recession in interrelated industries,
The original plan called for conver- and the steep increase in the import of
sion from the mercury process to the chlorine products might affect the
asbestos diaphragm process in two� pace of conversion.
thirds of the plants by September Estimated investments of ~�130 bil-
1975, and in all remaining plants by maz~ng plantse o t he~newt p ocess.
the end of 1977.
However, the fourth conference T~emendous efforts will be required o f
held in May 1977 abandoned the ~austic soda enterprises, whose man-
original program on the grounds that agements have been weakened by the
caustic soda manufactured through the tust-stage conversion program and the
asbestos diaphragm process is of rela- subsequent recession, to carry out
tively low quality and cannot be used such huge investments for the second-
in some fields of application. stage convecsion program. The struc-
Cunsequently, thc convecsion of ture of the industry itself will have to
plants, which had nut yet adopted the be overhauled.
asbestos diaphragm process, was halted On the other hand, the ion ex-
while the ion exchange diapiua8m change diaphragm process has some
process, a newly developed manufac- advantageous features compared with
turing method, is being judged to see if previous processes, including smaller
its use is industrially feasible. consumption of electric power and
[n the meantime, the Committee ~~er concentration of caustic soda
for Promoting the Cunversion of Caus- ~yith less residual salt content. It will
tic Soda Manufacturing Processes in benefit the industry in the long run,
June 1979 judged that the ion ex� and should be promoted actively.
change diaphragm process was indus-
trially feasible and the fifth Confer� Conclusion
ence in September 1979 resolved that The caustic soda industry is suffer-
the remaining soda plants should be ~g under ever-worsening conditions
converted to the new process by the including soaring costs of raw mate-
end uf 1984. The sixth conforence rials and fuel, deteriorating profits and
announced the cuncrete conversion competitive power, and sur~ng im-
program as shown in Table 6. por4s of chlorine products. Never-
The plants which have not yet theless, it must implement the conver-
carried out conversion (27 plunts of 20 S~an of equipment within the next
cumpanies with an aggregate produc- ~}uee years.
tion capacity of 1,575,OOU tons per ~'}ie government on its part con-
year) are required to adopt the new sulted the [ndustrial Structure Cuuncil
~ process by the end of 1984. However, ~ April 1981 concerning the organiza-
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tion of the petrochemical industries
and the implementation of basic poli-
cies during the 1980s. In response, the
Chemical [ndus!ry Committee of the
council decided to organize a subcom-
mittee for studying ways to strengthen
the PVC and soda industries which are
closely related to the petrochemical
industries.
[t would be desirable for the coun-
cil to make a serious study of Japan's
caustic soda industry and present a
definite policy which would enable the
consolidation of international compe-
titive power and the smooth execution
uf the second-stage conversion pro-
gram. 'This would assure that the caus-
. tic soda industry will play a vital role
as a key chemical industry in the'80s.
COPYRIGHT: 1981 The Nihon Kogyo Shimbun
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1~OR OH'FI('IAI, 11~N: ONI.Y
SCIENCE AND TECHNOLOGY
MArIiJAL ON FACTORY NOISE ASSESSMENT COMPILED
Tokyo TECHNOCRAT in English Vol 14, No 4, Apr 81 pp 49-51
[Text] Tlie establishment of nuise assessment techniques is in
demand as a means of noise pollution control. ln response to
this demand, the Ministry of International Trade and Industry
has prescribed and compiled into a manual assessment tech-
niques aimed at controlling factory noise. The following is
summary ot' this manual.
1. Current Noise-Preventing Techniques and Assessment
The techniques of preventing factory noise have been general-
ly established, except for special cases. Efforts are now being
made to find techniques that are more economical.
From the economic point of view, it is best to plan and
execute noise countermeasures at the time of factory construc-
tion. Countermeasures initiated after the onset of a problem are
often under many restrictions and thus cannot be sufficiently
effective. It is thus necessary to formulate correct counter-
measures in an assessment conducted prior to construction of
the industrial plant. An assessment does not merely serve to
prevent noise but is, indeed, helpful for avoiding double invest-
ment.
Closely related to noise control techniques are measuirng
techniques and assessment. With respect to assessment in
particular, in Japan the dB (A) scale is almost always used; it
is used even for environmental standards and regulating stand-
ards, except for aircraft noise, and the present Japanese regula-
tiuns do nc~t incorporate the conception of noise duration, as
at the assessed noise level proposed by the ISO (lnternational
Organization for Standardization). Though there are many
instances where the use of assessed noise level is considered
'advisable from the realities of factory noise, the actual appli-
cation of this level seems to have some problems.
2. Present Methods of Assessment, and Problems
The methods of assessment are not yet sufficiently es-
tablished as a step toward noise control. ln the case of air and
86
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water pollution, data and experience from more than 10 years
of preliminary research are available for effective use but,in
the case of noise, such experience is scarce and necessary data
O~Urm~n~tion O~ th~ tp~t~ t0 b~ uwd
~t brp~t ot oss~um~nt
Grountl ~u~l~u antl _ Sound ~our~� Outdoor pr~s~nt non~ dete
~ m~no~alopiui tl~u d~t� Indoor
~ I UVOUt d~u
i
i
i
~ Env~ronmmtd
i noisa data
_ i CompuLnon fo~ eOnv~nion
~ or a.i. on ~ouna ,ourc.. ~n
~ int~rlor 01 bw~tlinp ( ~
I
i
I
I
I
MoO~llnp of ~MUU d~moinp D~cnion of fou~d wurc~f antl ~
t~rp~t~ of comDut~tion i
i
~ I '
i ModNlnp of I~v~l�computinp i
i ~ formul� I ' .
I
I '
I ~
Mod~l tut, fi~ld t~st, ~tc. (Futun) ~
I
I Pr~Nnt nois~ camPut~tion ~
i
I
~
I
I
No ~
Conformity I
i
V i
i
I
I
Futur~ noiu computeUOn ~
i
I
I
� ~
Rpuletlnq ftendard ~
No B
s~ a vslu~ 1or ~it~ I
~ ~ bound~ry lin� ~
~ I
v I
i ~
' ~
~ ~ I
_ _ _ _ _ _ _
I f- ~ _ -1 ~
~ I ~ I I
~ ~ I
I I ` f~~~~~~~~~~~~~~~~~~ I I
I t ~ ~ I
~ ' No ~ B Environm~nnl ~ i ~
~
L--- ~ � ~Q ftendud ~
'f---�---
i '
i ' ~
~ Y~~ ~
L______________ _____'______________J
Entl
Fig. 1. Flow Chart of Noise Assessment
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must be provided hereafter through measurement and othe:
activities in accordance with the purposes of assessment.
The first problem at the present stage is prediction of the
noise power levels of noise sources. Related measuring methods
have been set by the ISO, the JIS (Japanese Industrial Stand-
ards), etc. for some instruments, but these are all for small
instruments, and measurement by large instruments is not, as a
standardizing of ineasurement of noise�source power levels
according to types of machines. This will create a major bottle-
neck in the conduct of assessment.
The second problem is the shortage of data concerning
excess damping, which directly bears on the improvement of
accuracy of assessment and the economy of control measures.
whole, sufficiently accurate. Even in the case of small instru-
ments uf certain types,machines of the same type manufactured
by the same company sometimes show different readings,
depending un the conditiuns ~f operation and maintenance.
This situation of the prediction uf nosei power levels, which is
basic to assessment, poses a problem with respect to the
accuracy uf assessment. Further, the trend is toward future
Though there are some data on absorption damping by air and
by the conditions of the ground surface, data must be acquired
and accumulated in the future for excess damping, including
that by air and ground surface.
Data on meteorologic3l conditions are so inadequate that,
for the present, prediction must be limited to standard meteoro-
logical conditions (windless and rainless weather).
As for methods of assessment, it is necessary to predict by
computation and, if prediction by computation is difficult, to
supplement with reduced-scale acoustic model testing or field
measurement .
At the present technical level of model testing, testing for an
entire factory is difficult and must be limited to only a small
section of it. The limit to scale reduction is 1~40 to 1~50.
Under special circumstances, model testing at reduced scales of
1~ 100 to 1/200 may be possible if ineasurements can be made
at a representative frequency.
' Since model testing involves these problems, there must be
field measurcment and field testing. It is important that field
testin~ include the ab~~ve�mentioned problem of excess damping.
3. Methods of Assessment
Assessment should be conducted according to the flow chart
J in Fig.l .
First, the s~ace to be used as the target of noise assessment
must be determined. It must not be limited to the site
hc~undaries of the factc:ry concerned. but should also include
any adjoining residential areas thet may be affected. Next,
assessment is made in the case of expansion, and in the case
of new construction, as fallows:
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( I ) Case of Expansion
a. Study of Conformity Under Present Conditions
First. a simulation model is prepared for the existing
facilities, and the accuracy of the model is ascertained by
data on the present conditions.
(i) Determination is made of the sound source to be the
target of computation by collecting existing sound data
and laVout date.
(ii) A model is prepared for excess damping due to screens,
ground surface and meteorological conditions. In this case,
modelinb fur compiex excess damping must be made by
mudel testing, field testing. etc.
(iii) The formula for compliting the overall noise level is
modeled by means of the distance damping model cor-
responding to the above-mentioned computation target
sound se~urce and the excess damping model.
(iv) The present noise level is computed by this mociel and
study is made of the conformit~� ~etween the results of this
computation and the results of analysis of the present noise
level.
If the required accuracy cannot be obtained from this study,
the modeling of sound source data, layout data and excess
damping must be reconsidered, and work in (i)~(iv) repeated.
b. Predictive Cumputation
Future noise as of the time of expansion must be computed,
using a model incorporating the change, etc. of sound source
data and layout data for the expansion, after preparing this
model from the model on present conditions.
(i) Sound sources forming the targets of com~iutation are
- determind based on the sound source data and layout data
for the existing facilities and the expansion.
(ii) In this case, a sound source in the interioi of a building
is substituted by a building sound source.
(iii) Tl~ose computation target sound sources which may
involve excess damping must be madeled similarly to a�ii.
(iv) The level computing formula must be modeled similar-
ly tc~ a-(iii).
(v) Future-predicting computation must be conducted and
study made as to wl~ether the results of this computation
are witliin limits of regulating standard values for the site
b~~undaries. !f the regulating standards are exceeded, the
nc,isc rountermeasures must bc recansidered; thus, com-
putatiun is madc, using sound source data and layout data
that havc hccn newly prepared.
(vi) If necessary, future noise sliould be computed for the
vicinity and study made of the conformity with environ=
mental standard values.
(2) Case af New Construction
A procedure similar to "b" under "Case of Expansion" is
uscd, but ttic existing plant, layout, etc. should be checked to
confirm the accuracy of the model.
+ COPYRTGHT: 1981 Fu~i Marketing Research Co., Ltd.
CSO: 4120/262
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h'OR OF'NI('IAI. UtiN: ON1.Y
SCIENCE AND TECHNOLOGY
HIGHLY EFFICIENT AUTOMATIC SCREW GAUGE METER
Tokyo TECHNOCRAT in English Vol 14, No 4, Apr 81 p 65
[Text] The National RecrewChauae~metery(On-Line~ControlledXMeasuring1Ma hine
factured an automatic s $ g
for Inspecting API Reference Master Gauges) which is capabl3 dimensionalcmeters.
surement in 1/10 of the time needed by conventional large,
The meter automatically measures the screw elements of API master taper screw
gauges (such as the effective diamat~srss ecifiediinethesstandardsnofttherAmer-
external threads and internal th ) P
ican Petroleum Institute (API).
The automatic screw gauge meter experimentally made consists of the components
shown in Fig. 1. In contrast to the structure of large 3-dimensional meters,s~t~,
uses a cy lindrical coordinate system consisting of a diameter diS~em)~nand also ~
a height direction (Z-system) and a revolutional direction (Q-sY ~
uses features of,plain, ball and ball and roller bearings combined to increase
measuring efficiency and measuring accuracy. Reportedly, this reduces the con-
ventional measuring time, 10 hours required for a set of oi3iuho rntWhileeachiev-
a large 3-dimensional meter used in inspection, to 1/10,
ing higher accuracy.
The meter has tlic following main functiona:
(1) Measurable range--600mm in dia ereesdinerotationa~l directional direction),
200mm in height direction and 360 g � measurin force:
g
(2) Diameter and height direction two-axial sensors-- ~�2~~
aUout 100g
Msin unit
R�sV~tem R.Z Z.axial detector
2�system
O�iystem
Date proce~sor Ditplay
Typewriter
Control datk
rig. 1. Components of Measuring Machine
COPYRIGHT: 1981 Fuji Marketing Research Co., Ltd.
CSO: 4120/262
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SCIENCE AND TECHNOLOGY
MEASURING INSTRUMENTS RELATED TO LIGHT LASER
Tokyo TECHNOCRAT in English Vol 14, No 4, Apr 81 p 73
[Text] Ando Electric Co has developed four kinds (six models) of ineasuring
instruments for light and laser, including an optical fiber analyzer.
1. The 11g}it power meter AQ-1111 is a compact, light-weight, general purpose
power meter that measures the power of light and laser. It comprises a main
body and a sensor. The sensor is a silicon photodiode for short wavelengths,
or a germanium photodiode for long wavelengths. There are three display modes
available: w, dBm, and dB. The measuring range of the power level is -70 to
+lOdBm/O.1nW to lOmW for the Si sensor, and -50 to +SdBm/lOnW to 3mW for the
Ge sensor.
- 2. The optical fiber analqzer AQ-1902 iacorporates a function to detect the
Fresnel reflection from the broken end of an optical fiber cable by the opti-
cal pulse method. The trouble can thus be located, regardless of the broken
condition. Another function detects back-scattered light and measures both
light and connection losses. The loss condition of the optical fiu::r cable can
be displayed on a CRT, and the loss between any two desired locations, in addi-
tion to the total loss of the fiber, can be measured remotely from one end of
the fiber.
3. The ligtit wavelength type AQ1601 is a digital-display wavelength type light
region consisting of two units, one for short wavelengths and the other for long
- wavelengths, with me~suring wavelength regions of 0.78 to 0.9um and 1.2 5 to
.1.4~im, respectively. Accuracy is �O.Snm.
4. The light spectrum analyzer AQ-1404 is a spectrum analyzer of the wave-
length region to display the spectro-characteristics of laser diodes or light
emitting diodes directly on a CRT by using a sweep spectroscope according to
wavelength selection. The wavelength range for the spectro-unit is 0.7 to
l.lum for short wavelengths, and 1.1 to 1.6um for long wavelengths.
COPYRIGHT: 1981 Fu~i Marketing Research Co., Ltd.
CSO: 4120/262 r
~
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SCIENCE AND TECHNOLOGY
20 KW LASER MACHINING SYSTEM ADOPTED
Tokyo TECHNOCRAT in English Vol 14, No 4, Apr 81 p 66
[Text] ~ T;;e Agency of Industrial Science of T'ech- tion of the laser beam and gas tlow are per-
nology, M[TI, has ndopted a three-nxis orthotro- pendicular). The running performances of the
pic system ~s the 20kW COz gus laser mnchin- two SkW machines have been evaluated and
ing ~ystem which was the most important de- examined, with the conclusion that Mitsubishi's
velopment problem for their syperhigh per- three axis system machine is superior to
formance laser applied Compound Production Toshiba's.
Sysiem. 'fhus, in the second step, a 20kW machine
Becausa of the 20kW COz gas laser ma- with a three axis system will be developed. Con-
chining system is the nucleus of this large sequently, Mitsubishi Electric Co. will be the
project, until now, two developme~~ts were main contracter and Toshiba will Cooperate for
set forwazd in paraltel by Mitsubishi Elec;ric Co. the excitation portion. Both companies will
(three axis orthouopic system) and To~shiba complete the 20kW l~ser machine by Septem-
Corp. (two axis orthotropic system). This big ber 1983.
development project plans by March 1983, The first lazgest laser machining system
completion of an automatic production system mazketed in the world is that of Abuko Co.
for complex small batch production of machine (U.S.A.) a 15kW machine but this machine was
pazts which account for 70 percent of machine designed for laboratory use and has not yet
production. In the production system, the been used in a production line. Behind the
20kW COz 6~ ~g~r machine is used for Abuko, the United Technology Research Co. is
driiling, cutting, heat trenting and so on. developing a 20kW machine in the U.S.A. It is
At the first stnge of research, two types of expected that 5-20kW machines will form the
SkW machines were developed: one Mitsubishi's � main stream of laser machining in the near
threa axis octhotropic system (d'aection of the Future.
laser beam, gas tlow and disch~rge are per-
pendicuLu to euch uthar); and the other
'toshibu's two axis orthottopic system (direc-
COPYRIGHT: 1981 Fu~i Marketing Research Co., Ltd.
CSO: 4120/262
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1~(1R (11~1~1('IAI. Iltil~: ()N1.1'
SCIENCE AND TECHNOLOGY
AUTOMATIC MEASURING CONTROL SYSTIIrI-FOR LARGE MACHINE TOOLS
Tokyo TECHNOCRAT in English Vol 14, No 4, Apr 81 p 67
[Text] Mitsubishi Heavy Industries has recently developed an automatic measur-
ing control system for large machine tools.
If no large tables are available for measuring the machining accuracy of large
parts machined by large machine tools, larger measuring jigs are requirec~.
- However, jigs tend to introduce large measuring errors, caused by the difference
in the posture of secured ob~ects being machined, during cutting and during
measuring.
The newly developed automatic measuring control system uses a numerical control
unit, which is capa,ble of micron-level control of the distance of movement, to
automatically calculate machining accuracy from the movement of the machine and
the movement of the measuring head. Thus, it has succeeded in preventing large
measuring errors.
The system has the following features:
(1) Mounted on a large :nachine, it can precisely measure diameter, pitch, the
distance frcm reference surface, etc. of machined holes in large parts in the
setup for machining. Workpi~ca
~ ~r- ~
~2~ Zt can be connected t0 3 machines . M~nurinp M�~~urfnp hsad ~sesurlnp h~ad
C ' (A) h~~d ~ ~B) r~ C
A
achin M achins Meehin
(3) Its measuring heads are inter- t~A~ ~B~i t~~~
changeable with tools and can measure
from 3-dimensior.al directions.
Rspi~ter R~pist~r R~pistsr
(A) (8) (Cl
Exter~el tipnel
Minicomputer
(CPU)
COPYRIGHT: 1981 Fuji Marketing
Research Co Ltd. T~~~tYp~ Fig. 1. Structure of Automatic
(TTY1 Measuring Cr,ntrol
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I~UR OHNI('IA1, IItiH: ONI.Y
SCIENCE AND TECHNOLOGY
NC ROBOT FOR APPLYING SEALING AGENTS
Tokyo TECHNOCRAT in English Vol 14, No 4, Apr 81 p 67
[Text] With the cooperation of Toshiba Silicon, Taiyo Tekko Co. has lately
developed and begun marketing Seal Maker," an NC robot for applying sealing
agents, which is the first successful venture of its kind in Japan.
The development of "Seal Maker" is intended to easily automate assembly with
packings, for which automation has conventionally been difficult, by automatic-
ally coating silicon rubber (highly viscous and liquid).
With points on the track, which is desired to seal directly from work, memorized
in a control unit equipped with a microcomputer the robot can automatically
repeat the track. Because it uses a 3-axis (X,Y and Z) simultaneous driving
system, it ~can deal with automatic coating on ob~ects of any shape.
x
Other features of the robot include Po
the following: ~
\ :i Z v
(1) It is electro-pneumatic, starting ~
operation the instant it is electric- '!��xi* n"�
~P ~ ~
ally energized.
Lin~er Int~rpol~tion ~
(2) It easily pennits correction, can- b~~WN~ X snd Z ax~~ ~
cellation and addition of operations P~�~ P'.
P ` P ~o
X-Y ere interpoletion P
F, 1\`
at site. P" `
(3) It has interpolating functions, ~
has few instruction points and can be Pe
P ~Simulteneouc X�Y�2� ~ ,P:a
"taught" easily . p a P�~ li~~sr Int~rpol~tion i \
P~
(4) It can maintain a constant circum- -.Pe
~ P~e Pj7\P:.
ferential speed on any complicated con- P�~,
tinuous track. ~ P:.~Pxs
(5) It has sufficient output and P"'
P~:rj , P� p~~~.. P:~
rigidity to coat from 2 heads simul- . P�~
taneously. P ~�f P=�
P,. P~ei.~.'
(6) As a rectangular coordinate robot, Y Z~~~ i~t~rpolatlon ~~~P�
it provides high interpolating accu-
racy and allows suf f icient space for P" Fig. 1. Example of Teaching Points
seal coating.
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SCIENCE AND TECHNOLOGY
RECORDING TRAVELING LO~US OF AUTOMOBILES
- Tokyo TECHNOCRAT in English Val 14, No 4, Apr 81 p 68
- [TeXt] . The Machine T'echnology Laboratory hus 1.9m for a car of 2000cc class. rraveling
developed an autom�rtic recording method distance can be calculated by counting the
which permits mcasurcmants of the truveling number of pulse generations. Measurement of
lucus uF cars to be made with a simpl~ device the time between the pulses ennbles veloaty to
muunted un thc cars. be: obtained. Traveling ditection (posture angle)
The methud for automatically recording the can be obtained from the difference between �
traveling locus of a car, recentty developed by the left and right wheels.
the laboratory, is to measure precisely the However, this method has some error
speed of both the lefc and right wheels by factors within it. 'fhe greatest of which are
use of pulse generating devices mounted on the road surface and traveling conditions. Rough-
left and right rear wheels of a car. The locus is ness of the road causes a change in the number
then calculated from the resulting measurements of pulses. Curving causes lateral acceleration
obtained. Although the principle of this and aiters rolling distances. 'to solve these
measurement has been known for a long time, problems, two corrections are required. One of
improvements have been made in the method them is a correction by calibration points.
to obtain a precise locus. Calibrating points emiiting light or an electro-
The hardware consists of pulse generators magnetic Field are provided beforehand at
urving as car speed sensurs, and a data recorder. several points along the source, and they correct
[n addition, �rutomatic control requires a micro- errors. The other is a correction for lateral ac-
computer, which calculates absolute positions celeration. [n this case, a correction constant is
evc~y mument. The pulse generator uses a previousiy obtained and correction is made
bruke drum with 12U indntations cut on the when laterul accel~ration is caused as, for
penphery at cyual intervals, with a back plate example, traffic lanea are changed. 'Chese correc-
which uses ~ cumbinatiun of a light emitting tions enable errors to come within several
diode (LLU? and u phutu transistor. 1'his ~m�
~Ilowx thc pcriphury providcd with indent~tions [t is considered that this technique not
at cyu�rl intervals to be disposed between the unly serves to raise intelligence of "intellectual
Li:D �rnd the phuto tr�rnsistur, cars" (an unmanned cur permitting automatic
The rotution ul' the brake drum causes operation with artificial eyes and brains) but
pulxes to bc generatod photo electricully from also is applicable to the operation system of
the pulxe gonerutur, l2U pulses being generated cars such as an automatic caz position observa-
I'or oach rotatiun. One rotntion corresponds to tion system (AVL),
- COPYRIGHT: 1981 Fu~i Marketing Research Co., Ltd.
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H'Ult (N~N'1('IAI. U~N: ONLY
SCIENCE AND TECHNOLOGY
ON~ OF NATION'S LARGEST INDUSTRIAL AERODYNAMICS WIND TUNNELS COMPLETED
Tokyo TF.CHNOCRAT in Engllsh Vol 14, No 4, Apr 81 p 69
[ T~Xt ~ lshikuwujlmu�Horimu Heav~~ lndustrles Co. has rerently constructed ur
i?s re.seurch institurr u wlnd tunnef jur restinA expunslon ojatmospheric
uir rurbulcnce. Th~ wind runnef is the la?grst oj its kind in Jopan.
7'hr jarllltirs cun be used jw conducring varlous tests, including
rrrutrun uj geugraphical und environmental con,ditions similar to the
uctuul conditions at a site, by arranging inside the tunnel a scole model
oj the topography, investigation oj the phenomena oj atmospheric
expansion oj coaf �dust, the phenomenv oj atmospheric poilution by
exhaust gases jrom cooling towers, chimneys, aircrajt, and eutomobiJes,
and the injIuence oj wind on the naturai envtronment can 6e obtained.
Another use oj the jaci(ifies is jor tests involving resistance nnd sta6lllty
ugainst wind oj lar~e stnrctu~es such as bridges and high�rise buildings.
8y insralling the wind runne( in combinations with additional equip�
menr, such as a consrant�velociry adsorbing device jor the coflecNon oj
_ Jloating matter like coal dust, and a measuring device jor porticle
diameter distriburion, as well as coal dust collectors, .+vch as a wire�mesh
nei water spray device, coaf dust can be prevented jrom escaping into
rl~e utmosphere. Also, by adding u vertica! disrribution varia6le device,
rhe Jlc~x~ af wind near the surjace oJ ground can 6e reproduced, and
un addirion uj a gcnrruring devicr oj va?iable wind-velocity can creote
rhr su�ralfed "riutu?al breath oj wind� "
The ~�urnputrrs inrurpr~rated in thr equipment can perJorm a suc�
cessi~m uJ' dutu procrssing wnrk including tests, meusurements, and
pf~~ttinK un ~;ruphs nj thr re.n~lts, thusguarunleeing ejjiciency and hlgh ,
urc~nuri~ in wind tunnel expcnments.
Thr totuf length uj tl~c rquipmrnt. is RS meters und the measu?!ng
t~~nnrl .rrctiu~~ is Am uero.rs, 3m high und 24m long. !r can creaie a wind
sprcd wilh u muximum veloc'!ty vj 13m~s.
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SCIENCE AND TECHNOLOGY
BELTS FOR CARS REDUCE CAR BODY WEIGHT BY 15KG
Tokyo TECHNOCRAT in English Vol 14, No 4, Apr 81 p 69
[Text] Bundo Chrmic�u! /r~dustrirs, Ltd. Aus succeeded in manuJacturing a
belr jor uutomnbifes (brund name: Llbace/ that can !(ghten the werght
oju car b~~ somr lSk~.
Libnre rs u jlar kind of belt that t~ses neorene rubber as thr base
mutrriul und tetrnn as rord. ha.s grooves molded in severol lines fthe
numbrr oj li~irs run Ar Nianged depending upon the useJ on one side
which rs ~~srJ jor Me transmission of motive pnwer. Compared, with com
ventiunuf I' befts, tlir rrcentfy developed belt l~as u greatfy reduced width,
lengNi, urid weighr. TAe lighrer weighr nJ tqe bef? has nor onfy enabled it
to b~ srrapped in a zi~zaX Jashin, jor insrance jrom the engtne to jan, to
Krnerutur und !n purnp jor power sreering, but n(so conrributes ro
reducing puUey size reducing weight.
At present, three to jour belts are used drpending on use such as jor
the jan, rooler bclt, etc. Consequentfy, the crank�shajt needs to be
fonger tn take a larger puJley, but with the fibace, the length oj the
crankshujr con be shartened 309o since a single or 1.5 width ojlibace can
perform the junctions oj 4 conventiona! 6efts. This also, greatly con�
tributes to shorrenrng the jorward section of a car. According to pre�,
lrrninary caic:~lations, the adoption oj the firm's new belt brings a6out
6enejrts in the jorn~ oj lOkg in reduccd engine weight alone and an
overa!! weight reduction nj obout lSkg accruing jrom simplijied as�
semDli~ wnrk and reduced noise.
Altsrnstor Tensionsr Compnnor for
} t + el~ conditione~
Wstsr pump
& fan
+
Oil pump for
-t- + pow~r ctesrfnp
Air pump Crank
I~i~;. I. Layuut UsinK Polyvinyl (Scrpentinc), I~ord Mustang
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SCIENCE AND TECHNOLOGY
HIGH-SPEED ENCAPSULATION DEVI(E DEVELOPED
Tokyo TECHNOCRAT in English Vol 14, No 4, Apr 81 p 70
[Text] ~ Shikoku Chemicals Corp. has develcped a capsulatioR material is used.
"High,Speed Encapsulation Device" to en- The high-speed encapsulation device consists
capsulate semiconductor devices with liquid oF the material supply unit, metering discharge
resin at super low voltnge and at high epeed. [t unit, non-adhesive special plastic mold, holding
is their intention to entec the olectronics field tool for the mold, and mold feeder. A transport
together with "FC hard", a onedrop type of unit and hardening furnace is optional. The
epoxyresin encapsulatiom m~terial thut has mol~ set on the special tool is put on the feeder
already been launched. and encapsulation material is d'uectly poured
The newly developed drive has the follow- into the mold with connection to the air
ing features compared with conventional trans- extraction unit. Then it is moved to the
fer formation: ha:dening furnace in turn.
(1) Less breakage of bonding wire because The main specifications of the prototype
encapsulation is at super low voltage below aze as follows:
one-tenth of transfer formation. Production capacity per month:
(2) Separation matecial is not re,quired by 200,000 to 1,000,000 pieces
the special plastic material which has non- Pouring temperature:
adhesive properties, and which can ptoduce Normal temperature to 50�C
higher encapsulation effect, more reliable pro- Voltage~current: 100V, SA
ducts that ace both heatproof and shockproof. Compressor: lOkg/ema max.
(3) Preprocessing, such as pelleting of The price of the main unit is ~FS to ~F6
powder material or high f~equency preheating, m~llion.
is not required because a combined llquid en-
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1~()It 111~1~1('IA1. lltil~: ()NI.Y
SCIENCE AND TECHNOLOGY
LARGE APERTURE GAP SINGLE CRYST.~:L DEVELOPMENT COMPLETED
Tokyo TECHNOCRAT in English Vol 14, No 4, Apr 81 p 71
(Text] Tu,rhibu Cnrp. hus n~ccr~ded (n develupin~; i.ED's cry.stal pullinp dircc�tion (!00/ to become
un uutnmorir pufling ~ec�hnlqut under computer substrate marerial oj the yel(ow or orange LED's
c�untrul for gulfium phosphlde (CaPJ Jor Ilght thar prevlously was totally lmposstble is now
~ rmtrting drodes (LF,DJ. Dionenslons oj a CaP possiblt up ro 62mm dtameters and large scaJt
single crysraf is eniarged ro 62mm by this pvoduction oj crysrals can be realized in ac�
� method and at the same rime denslry oj cordance with present trends jor multi�color
subsrratr dejects becomes appraximately one� LED's. The reason that pulling oj this CaP
renth (J04/cm3 order/ oj thar by present single crystal is made under high a[mospheric
~ methods. For red LED, emitting ejjiciency is pressu?e oj 70 atms, is ro prevenr separation oj
enhanced 2 to 3 per cent more than at present Ga and p under high ternperarure.
avaiJable. Toshiba developed rhe large scale producti~n
This new pulling technique, is a method to technique jor GaF single crystals 52mm in
simultaneous(y measure data on many crysta( diameter, then the largest operrure, rn June,
growrh parometers ujjectrng manujacture, such 1980, but this time a 62mm diameter has been
as jurnace temperarure, weighr, length, rate oJ realized and jurther expansion in aperture to
pulf, and ~oration speed of growing crystal ar ?6mm !n diameter ts planned withln onr year.
the time oj crystol puJling, and to process it by Toshlba is plannin8 to expand the applica�
rhe computer. This method automates previous Non oj the automatlc pul? technique jor stngle
- manual wArk and visual checks to increase ~rystols under computer controi to the pro-
productivit}~. Large aprrtures wlth high quallty ductlon of S! and GnAs single crystois jor the
urc ach(evrd. super LSl.
/n udd/tion tn pulling dircction (lll/ crystuf,
to becume substra~e mote?ioi oj the red orgreen
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SCIENCE AND TECHNOLOGY
CAPITAL SPENDING IN ELECTRICAL INDUSTRY REPORTED
Tokyo TECHNOCRAT in English Vol 14, No 4, Apr 81 p 71
[Text]
Therc rs concern that wtth tht s?nwer poce of huslness, lnvest?nentln
plant and ~quipment wJll, generalfy, he morr conservattvt in 1981, bur
as jur us nc~ rlectrica! industry is concerned, investmenr (onconsrrvction
basisJ is p~edicrrd ro cuntinue ot u htgh level. Accordlru� to the source,
nj rhe Icadrng general elrcrrlc, home applianct, nnd p. ~!s ~upp!lers, tach
fs pfanning u rwo-digrr prrcentage increase !n tnvestment over the
prr~~ious year. Mosr noticeable, !s the investment jor home VTR's and
rcfared producrs, ond the rncrrosing demand jor parta ond semiconducto~s
has become a fuctor to puah up Investments jor p/ant antf equtpmtnt.
Table I. Capital Spending for 1980 and 1981 by Major Companies in
the Electric~l Industry
' 980 ~ 98 ~ G rowth rate
(%1
- Hitechi 720 800 10
_ To~h{be 495 Over 550 Ovsr11
Mit~ubi~hi 300 Just below 400 Jutt below 30
Mst~uehite 470 Ov~r 610 Over 30
Sony� 480 760 56
Sanyo 280 420 50
Sherp 307 400 30
Nippon Elsetric' 640 Ova~ 700 Over 10
Matiushite 200 400 100
Electric pert~
TDK Elsctronic~ 260 300 75
Not~: The 1980 fipure ~howe estimstion oi aetuel apandinp end the
1981 fiyur~ showt epproximet~ or provi~Ionel fipuret.
' Nlppon El~etrlc Co., ~nd Sony ~r~ be~sd on ~ eontolidetsd ba~s
bee~u~~ thNr productlon d~psrtm~ntt er~ op~rot~d by nl~t~d teperet~
comp~ni~~.
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N'()R UI~N'I('IAI. l1tiH: UNI.Y
~ SCIENCE AND TECHNOLOGY
ELONGATED IMAGE FIBER PERMITS DIRECT IMAGE TRANSMISSION
Tokyo TECHNOCRAT ir. English Vol 14, No 4, Apr 81 p 72
[Text] + Sumitumo Electric lndustries, Ltd. h�rs de� type. [t ulso features small diemeter and
veloped �rn elongated imagc fiber which em- greater flexibility. Furthermore, this type of
ploys optical fiber production technology to image Ciber is superior also in terms of the
permit direct transmission of images. transmission wave-length area and the wave-
This elongated image Ciber cunsi~ts of three length loss chazacteristics, producing a trans-
- parts: i) the image pick�up optical system mission loss of 0.01 to O.OSdB in the case of
(image pick-up part) which picks up the image visible rays, which is L/l00 of the conventional
of a subject, 2) the image fiber integral part, loss.
and, 3) the picture optical systen~ (picture 'fhe main uses of the new product are
pazt) which projects the received image. The (1) monitoring the internal surface of pipes or
image fiber integral pazt is made up of approx. tubes, (2) close monitoring, by means of
l5,000 quartz glxss fibers each with a core dia- images, of a 100�C (approx.) high-tempera-
meter of about LO micrometers. They are ture r.nvironment or, if equipped with a cooler,
bundled into a length of approx. 10 meters and about 1,0~0�C hot substances, (3) two-
each surface is protected by a spiral tube. dimensional measurements of temperature
'I'his company's internal production technology distribution (500 to 3,000�C) using its wide
has created about ~ 10-meter elongation as com� transmission wave-length area, and (4) use
pared with that uf ? to 3 meters which had in areas where its radioactivity resistant char-
previously been regacded as tha limit of an acteristics can be beneficially employed.
image fiber of the multicomponent glass t"iber
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SCIENCE AND TECHNOLOGY
HIGH-SPEED LSI LIGHT DATA LINK DEVELOPED
Tokyo TECHNOCRAT in English Vol 14, No 4, Apr 81 p 73
[Text] Fu~itsu has developed and launched into the market the super-small 32m
bits/sec.
The light data link is a bidirectional system that converts digital electronic
signals to light signals to transmit them via light fiber, and performs the re-
verse conversion at the receive side. The realization of a super-small size has
been made possible by integration of LSI's and light elenents.
The main features are as follows:
1. Small-scale (one-ninth the size of a conventional data link).
2. Transmission speed range up to 32M bits/sec.
3. The refresh pulse method includes an extensive AGC (Automatic Gain Control)
function that enables use of the data link without any ad~ustment for trans-
mission speed. This method regearsaconsecutivelyWiandnensurescdetectionuof the
when the same code (0 or 1) app
receiuing level.
4. The low-distortion encoder and decoder are built in, and synchronous data
transmission with high quality is thereby made available.
5. The mounting structure is a print mounting type that is equivalent to a
24-pin DIP. Its height is 7man.
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SCIENCE AND TECHNOLOGY
DEVELOPMENT OF ACADEMIC INFORMATION SYSTEM EARNESTLY PURSUED
Tokyo TECHNOCRAT in English Vol 14, No 4, Apr 81 p 74
~TeXt] � The Ministry of Education is earnestly
tackling the devetopment of ar~ "Academic
[nformation System" in fiscal 1481. This sys-
tem is supposed to connect the libraries or the
computer centecs of the national and private
universities all ovec ]apan to each otheT and at
the same time to supply their documents and
their numeric information by connecting to the
network the' pivot center, which is to be es-
tablished in Tokyo.
The contents consist of (1) organization of
the data bau or offer of the manuscripts, etc.
- concerning the list or the location of the
primary information, such as books or academic
magazines, (2) distribution of information
abou~ international reseazch results, and (3)
or�anization of the data base concerning
domestic research results and inputting of the
information into the international data base. In
t981 the Ministry is Cust starting the develop-
ment of the softwace of the ceuievalloffer
system which plaYs the most important rote in
the whole system. [c also Plans to discuss the
pivot center organization and how to manage
and operate it.
CoooM~iW~ uNO~ r~wrU U~O~ cemou~B c~nMr
(1. SMCUI e~b O~w wlvk~,
~pMCY (MbIN O~U bM~ j. QMM~I NICYI~IIOn. .
rrv~cd 0. fObul ~~rOww~ ~M
~p/tw~rH
?wot e~nnr
CoepN~tM oelnt Ilbr~rY 11. Cent~at Wlu~tT~nt.
I1 Can~cuon .na oH~r ot 7. M.nnma.
pr~mar ~n/orm~~wn. D~~~ e~ Mrvie~.
7. Ory~nu~aen ol � Rwre~ ~n0
IM~t10~ ~~~O~T~tlOn) tlN~lOp~~t, COmOYt~/ CMI~~ O~
6 fAUUnon ~n0 IWOr~to~r el ueO
tniNnpl unlrwutV. ~te.
LIbnIY OI ~K~ YI~IW/~IIY (ACC~M IIOT fMTln~l IO
(1 WIe1tlOW OI In10~T~llOn ~V/\Nn)
~ c^"~"enin0 pig, 1, Concept Figure for Academic
OII;M Of OIIT~IV ~OIT~l10~
orp~nun~en ei ~ea~uen ~ nformetion SYstem
~nlerm~t~an
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SCIENCE AND TECHNOLOGY
DEVELOPMENT OF BIOCELL DISCRIMINATION, SEPARATION EQUIPMENT
Tokyo TECHNOCRAT in English Vol 14, No 4, Apr 81 p 77
[Text] Showa Denku Co. has successjully develop- deniof reactions at time ojlivtr rransp/antatton.
ed 6iocel( dlscriminarion and separatlon equlp� !n the sysrem, a physiologica! saline solu-
ment (by the rrade name oj "Celi Sorter Shaw� tton, efc. is added to the biocell to jorm a
Medic CS�SU00'y. suspended so/urion. Then laser light ts applied
This equipmenr applies laser light to bioceils, to this solution to measure sccttered light or
and mea.tUres and discriminares the yropertfes !lghr intenstty. And those measvred values are
obrained from the nnturc oj rhe cel(, enabitng put inro a microcomputer jos analysts, dis�
the equipment to separate and txtract cerrain plaYing va?ious properties, the number, and the
ceUs as the occosion demands. A clintcc/ excmp~t haarrealised ufrra ht hr t ted measurementte ~
yas olready proved thot an experimenral niode! u to 5000 ceUs a second rn terms of disrrlmina-
oj ihis equipment can detect ai an early stage, non.
r...w,. Yov..n.. ~
S~p11~1 DrOCN~~np COnlr01 ~Y~1Mn OOt~C~I m~~Wr~nO ~Y~IMn vN~~ Af/ p~N~ul~
si�.n~
~
i
Gn tbw tv~um ~
~ Sb~. ~
~b h.
~ ^tw~� ~ ~nv~~ob0~c~~
t~.
~ ' ~ ~4.p~l,n a~~09V ~ Ylln~ W Wtlon
~ ~~~on~~ ~ C�u.uw�eew~~
~ q1Y~lOn ~
ONDI~Y/GP~~~1~0~ ~
I ~
1 I ~
I iluOl~KMI QN~II~IU~
' N~q~ L~N~ 11011\ MY~C~
?Iin1M~t ' \
LI/NI~COII~CII~O FIOW ~ -
~ I~n~ 110ft1~ �
LNnt co11,e1~n0 ~
1 IM~ C~11 YpN~llon ~V~~~
t ~ /
1 Mn~ . ~p~~_
0 i aun~rw ' ~ E'~1�emun~e oi.t.
~ l1 ~ l ~ 1~/PI M~Wi .
00 n U ~ ~
,
00 ~ �
' QGU nc�w..
5~~~~I prOt~~~p ~Onlrol ~
i~ig. i. Constituent Diagram for Biocetl Discrimination and Separation
L;yuipmcnt
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�
SCIENCE AND TECHNOLOGY
~ AUTOMATIC ANALYZING SY~TEM FOR LABORATORIES
Tokyo TECHNOCRAT in English Vol 14, No 4, Apr 81 p 77
[Text] Denki Kagaku Keiki Co. has announced plans to sell in May an automatic
analysing system for laboratories in which a f low in~ection analysing method
(FIA) is used for the first time in Japan.
7'he principle of FIA is such that a reagent solution is sent by a constant flow
~ump to a small tube of approximately 0.5mm in diameter, specimen solution is
poured into the reagent solution flow, the both solutions are mixed [as published]
by a reaction coil to give a reaction, and then extintion degree o� the thus-
- produced complex substance from the two solutions is automatically measured by
an extintion meter.
This equipment of this company is simple in design and structure. Moreover it
does high-speed analysis, analysing two or three substances per niinute. And
only a very small quantity is required as a specimen so that equipment is most
suitable for analysis of precious specimens.
Spsoimsn
R~apent
R~actlon
coil
Pump Inj~etion velv~ D~t~ctor
Fig. 1. Principlc Diagram for FIA Basic Flow Pass System
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SCIENCE AND TECHNOLOGY
DEVELOPMENT OF METHANOL CHEMISTRY
Tokyo TECHNOCRAT in English Vol 14, No 4, A.pr 81 p 78
[TeXt] �[Hitsui 'fuatsu Chemicals, [nc. proposed to methanol can be obtained.
Malaysia the joint construction of a big industry The amount of9 ok 3gas feam if thedgastr g
for methanol. 'Chere are�many plans to produce in Japan is Sx10 Nm a Y
methanol as fuel on a large scale by 1985 in converted into hydrogen, 6.3x107 tons can be
USSR. USA, Middle East, Canada, Mexico, obtained. If the hydrogen gas is cooverted to
New Zealand, South Africa and Malaysia. In ammonia oc methanol, the calculated values are
Japan, a national project is under construction 3x10a tons o~ 4x10a tons enpsteelefucnace~i
in Saudi Arabia by [Witsubishi Gas Chemical ~s~im t d to be616x105 t ns, then 6.6x105 tons
Co., a leader of the groups.
'fhe resources of coal, natural gas, tar sands, of inethanol can be obtained by using t e
and oil shell in Japan are very few oc none, cacbon monoxide and hydrogen from cooking
therefore, there aze two ideas to import such furnace. By effective use of gas from coking
fucnace, of gas fcom oxygen steel furnace and
resources either as caw material later converted e~ lant in a consolidated
into synthetic gas or as intermediate such as nitrogen from oxyg P
methanol. iron foundry, it seems possible to construct
It is said that the development of Ci super modern factories of ammonia and
chemicals in Japan will be realized earlier than methanol.
T'he use of the,multiple resources from all
expected in the Cields of oxalic acid. ethYlene over the world is required by Japan in ocdec to
gtycol and ethylene in addition tPo methanol and ge~ ~~d of the heavy dependence on naphtha
acetic acid. It is expected that olyacetal ftom
methanol and formalin will become cheaper obtained from crude oils of Middle East and
ol eth lene and be used as a~~ to convert to C~ chemistry, methanol
than high density p Y Y
a new common resin. Further, new usages of � chemistry.
methnnol as MTBE, improvement agent fo~ It seems important to remember that there
was a deep connection between iron and
octane value of gasoline, single cell pp tein and organic industcy 80 ye~cs ago, and to consider
synthetic naturul gas ate being develo ed in the
U.S.A. nnd Europe. The C~ chemistry in Japaa again a new combination based on ammonia
will spreud with great speed us a methanol industry, and new C~ chemical industcy.
chemistrY if s continuous ~upply of cheap
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SCIENCE AND TECHNOLOGY
CORROSION T~ST OF SUPER HARD CERAMIC WITH THERMAL RESISTANCE
'Co'~cyo TECHNOCRAT in English Vol 14, No 4, Apr 81 p 78
[Text] ~ The Govermental Industrial Research In-
stitute, Kyushu, has been researching a develop-
ment f'or "SIALON", super hard ceramic with
thermal resistance. ~nd the corrosion test to
examine the corrosion resistance against high
temperature gas has been started as a laboratory
fur it was consttucted. The research is con-
nected with the lapanese moonlight plan ce-
quiring "reseatch and development of high ef-
ficiency gas turbine" and is expected to develop
high quality ceramic materiais as part of a
turbine able to endure high temperature gas
such as 1,500�C. The research was stacted in
1978 and the prnctical use is expected by
1984.
SIALON, sintered matetial of silicon nitride
-alumina system, was developed as the result of
a special research done ftom 1974 to 1977, it
has a high strength and a good corrosion
resistance even undet high temperature. The
research tu develap a heat resistant super hard
matetial using SIALON fot turbine blend and
other component is going well. As a result, the
- manufacturing technology using a hot press and
a sintaring method reached a final stage. Thus
- it becomes important to check the corrosion
resixtance for the developed muterials under
high temperature likC 1,500�C. 'Che testing
apparatus were set up in a newly constructed ,
laburutory, 170m2 wide.
Continuous corrosion tests will be per-
formed and citY gas at 1500�C will be blowed
~gainst the samples for 20hr under high pres�
sure. According to the test results, further
improvement for thc materials will be ~dded.
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SCIENCE AND TECHNOLOGY
CONTROL SYSTEM OF POWER PROCESS BY COMPUTER
Tokyo TECHNOCRAT in English Vol 14, No 4, Apr 81 p 78
[ Text ] ' Oji Paper Co. has decided to introduce a
computerized control system of power process
at thc Tomakomai factory where more than
40Q,UOOkI of heavy oil a year are used and
whcrc the electric power system is very com-
plicated. At first the whole electric power used
in the factory, hydroelectricity, was supplied
from a private power plant, but at present a
steam power electric generator and also outside
electric power are used because of the increased
demands. Therefore, the factory has to use two
kinds of frequency, 60Hz from hydroelectricity
and steam power electric generator and SOHz
from outside eleCtric power. [n order to save
energy the company has then decided to
control the whole supply of the factory by
using a computer cf 1'oshibu Corp. [t is ex-
pected that the effective use of private power
plunt and outside electric power, and effective
usage of electric power corresponding to a
variety of operation will decrease largely the
onergy co~t by tha completion of the system.~
Deio Puper Co. is the only compuny a-
rnong puper und pulp industrics that uses a
computer on u~ large scale for electrification
plant.
Oji Paper Cu, is t'urther considerating to
cnntrol tho hydroclectricity in a fuctory
lucatcd fat Crom the plunt, and to introduce
the sume wystnm in tho uthor fuctories. In
f~ct, ratlonalizution uf xterm power electric
generation by introducing a computer system is
under wey at the Nichinan factory.
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SCIENCE AND TECHNOLOGY
~
~
, INDUSTRIAL PRODUCTION OF CARBON FIBER TO COMMENCE SOON
Tokyo TECHNOCRAT in English Vol 14, No 4, Apr Sl p 8G
[Text] + Tohu Rayoo Cu., une ol' the companies higher than normxl. Also, its exposuce to
developing carbon fiber business,has developed fl~e does not cause detcrioration of the
a refractory fiber "Pyromex" (trade name) and filaments, but merely a red-hot appearance.
activated carbon fiber, and will shortly com- Compared with usual refractory fiber, its
mence industrial production. According to the insulation performance deteriorates little at
company, the refractory fiber is expected to high temperature. For instance, it has excellent
be used for heat-protection suits or as an dimensional stability at high temperature. [t is
_ alteroative material t'or asbestos, and the durable against chemicals, e.g. organic solvents,
activated crrbon fiber will act as an adsorbent weak acids, and weak allcalis. Utilizing these
ol' urganic materials or odors. The company properties, the new refractory fiber is expected
has already started suppiy of an activated to find applications for fire-protection suits
' carbon fibec water filter to the market. 'fhey and gioves, Fue-proof curtains, etc.
plan to expand theu non-[extile business with 'I'}~e new activated cazbon fiber, which is
the new materials. made from acryl ~ber, contains a sign~cant
The new refractory fiber is produced by a amount of nitrogen as a constituent. Therefore,
process in which carbon fiber is made from it has particular adsorption properties, especial-
polyacrylonitrile. This fiber is provided with ly, it can adsocb mercapto compounds, one of
suFficient strength and elasticity for spinning the very odorous gas groups. Its speed of
' and weaving. As for its anti-fue performance, adsorption and adsorption quantity are greater
it does not burn even in an atmosphere in than usual activated carbon, and after repeti-
' which oxygen has been increased 20 percent tive adsorption and re-activation, deterioration
of performai~ce is less.
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SCIENCE AND TECHNOLOGY
ELECTRIC CONDUCTIVE FIBER BEGINS COMMERCIAL PRODUCTION
Tokyo TECHNOCRAT in English Vol 14, No 4, Apr 81 p 84
[TeXt] r Teijin Ltd. hus announced that they have tions. 'fhe:e has also been developed a con-
succeeded in development of a dyeable white ductive Piber blending method, but as it uses
electro-conductive fiber "T'-25", and will start metallic filaments or cacbon powder, uses of
commercial production in spring 198t. The the conductive fiber thus processed are limited
new conductive fih�~ is mam~factured by com- by reason of its dark colored appearance.
pounding polyester :'iber and a white metallic [n the manufacturing stage after spinning
material developed with the company's special "T�25", a white metal compound specially
technology. As it can be dyed, and its anti- selected is added to the outside ol' the yarn.
static electric performance does not deteriorate this method can be used for either the con-
nuticeably, it is being watched eagerly as the tinuous fiber or the staple. With the method,
new conductive fibei to take the place of the company has succeeded to provide the
current tlbers at present in use. fiber with conductivity and dyeability. The
A great problem with synthetic fibers is electric conductive metallic material does not
that clothes mxde fcom them adsorb dust or leave the yarn, and its addition does not affect
crackle due to staticclectricity generated by advessely the excellent properties of polyester
friction. Usually, the problem has been dealt fiber. The company has applied for patents
with by prevention methods, as a second proc- in Japan and overseas.
essing method, ur a"kneuding method" in which The price of "T-25" cloth, it is said, is 10
scafic~electric prevention materials are mixed percent higher than blended carbon conductive
into the fiber, but the~e are problems with fiber.
these methods under low temperature condi-
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FOR OFFI('IA1, l1tiH: ONI,Y
SCIENCE AND TECHNOLOGY
MODEL SYSTEM FOR RECYCLING INDUSTRIAL WASTE UNDER DEVELOPMENT "
Tokyo TECHNOCRAT in English Vol 14, No 4, Apr 81 p 86
[Text] � The Ministry' of International 'Crade aad recognize the reali.y of waste from smaller
Industry hus decided to start development of businesses and take effective measures. For
model systems Cor disposing of and recycling this purpose, the Ministry has decidEd to
industtial waste. 'fhe systems are intended for start development of model systems fot dis-
smaller enterprises und thc program starts next posing of and recycling industrial waste from
fiscal year. In the present situation, in purticular, smaller businesses as part of its policy for
in which smaller businesses find it difficult to effective use and recycling of waste.
acquire sites for disposing waste, the Ministry I'he report contains the following points:
will promote this development from the point (1) the responsibility of makers should be
of view of promoting appropriate disposal and clearly stated and retailers should cooperate in
effective utilization of waste and will cazry out joint collection. (2) For the method of collec-
surveys of emissions from smaller businesses for ' tion a makers joint association and the
individual prefectuces to determine optimal municipality should discuss together without
model systems for disposing of and recycling sticking to the deposit mettiod. (3) The re-
waste in individual areas. sponsibility of the mayor should be stated
[ncreases in the load of waste on environ- definitely and the methods of collection should
ment now represents an important problem in be stated in the general policies for measures
the preservation of the environment alang with for controlling scattered garbage and recycling.
atmosphericpollution and water contamination. (4) 'fhe responsibility of controllers and occu-
On the other hand, in lapan, which hay few pants in areas of bargage scattering for clearning
resources, there is an increasing need for re- should be stated clearly. (5) 'fhe installation of
cycling for building up the resources from the automatic can vending machines shoutd be
point of view uf stable development of an subject to report to the authorities. (6) Can
economic society. However, rrcent tightening scatterers should be find and for can makers
of environmental restrictions and campaigns breach of duty to join a can manufacturers
against the construction of ultimate disposal associntion, such measures should be taken
plants have muda it difficult for individual as the MaYor's guidance and advice, and
enterprises, above all smaller businesses, to ganctions in the form of publication of negli-
~ acquUe sites t'or waste disposul. [n addition, it is Bent companies.
estimated thnt about hall' ot' the total industrial A joint association will consist of beverage
wuste emissions is from smaller businesses and, makecs, container makers, automatic vending
thus, waste from smaller entecprises is ycarly machine makers, etc. and will be obliged to take
repre~nting nn even more serious problem. measures to prevent can scattering and establish
Under thrse circumstances, it is necessary to rules for recycling, while shuing expenses
appropriately with the Municipality of Kyoto.
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HOR ON'FIC'IAL USE ONI.Y
' SCIENCE AND TECHNOLOGY
EXPERIMENTS WITH DISSULVED AIR FLOTATION IN ACTIVATED SLUDGE
Tokyo TECHIvOCRAT in English Vol 14, No 4, Apr 81 p 87
[Text] ,~~�N,ugc rrrunnenr processes trcutmenr of s(udge is becomtng a
scrious pruble�m. Sludge prnduc�rd !n srwuge treahnent systems must be
dewuti�rrd u.s much ua� po.r.sfble in orJrr tn simplij~~ subsequent processes
.n~rh us dehydraNnn und incinerutiun, Jor a~umple. A dtssolved uir
J1~~turion (UAFJ methnd Is considerrd to bc more javorable than rhe
u.n~uf se?tlrnx tunk system in which thr solids ure separated by gravlty.
lshikuwujima�Hnrima Heuvy /ndustries recentfyconducted experimenrs
- with the DAF merhod with a view to making tt practical. In the ex�
periments, a purtia! reJiux oj dlssolved air Jiotntion system was used.
The results obtained in thr experimen ts are as jollows:
(1/ Thr jlont thickened or increased sludge concentration ojexcess
siudge about 3-490 over a wide range oj solid loading rutes and air�solid
rarios and the reacrion was nor excessive.
(2) Mixed sludge can afso be concentrated up to 4-S`fo, but it
correlates more to the air�solid rado than with excess sludge.
(3J The remova/ ojsuspended solids in any case, reached ro 96-9B9'o
and the sludge particles were afmost oll caught by the micro�air bu6bies.
(4J The dehydration test oj thickened sludge by DAF unit sho~+a~
- good results. The moisture content ojsiudge cake is 76-789'0.
Sludps ferap~r losd~r
Rew
~lud9~
.e Thfck~n~d
Sludp� Thlck~n~d ~~udp�
pump tludp~ bath
S~P~ret~d
wstv
Pnuuriz~d S~par~tsd
wst~r tenk pr~uuriz~d W~t~r bsth �
Air- wst~r tw~k
comp?+oOr
('ig. I. Flow Sheet of Experimental Equipment
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I~OR ON'F'I('IA1. USF: ONI.Y
SCIENCF. AND TECHNOLOGY
GOVERNMENT BUILDING UP MARINE DEVELOPMENT
Tokyo TECHNOCRAT in English Vol 14, No 4, Apr 81 p 88
_ [TeXt] . Hor the purposc uf accumulating lapan's deposition of manganese nodules in sea areas
own tcchnological skills concerning marine de- to the so~th of Hawau, using "Hakuryo-Maru
velopment, th~ Japanex: Guvernment intends to No.2", a ship specially designed for surveyance.
start in fisca! 1981 the overall development oC p~~, ~n fiscal 1981, the government starts a
_ marine technology, particularly pr~moting re- 7-year plan costing '~22 billion for the study of
se;uch and development with emphasis laid on techniques for collecting manganese nodules
the fullowing 4 puints: deposited on sea bottoms.
- I) Submarine ~urveys cover~ng dcep 3) Research und development of energy, in-
bottoms in the lapan Sea and the l'acific cluding wave force power genei:.tion and dif-
U1e1n. ferential-temperature mazine power generation.
The Government has already started survey- For differential-temperature marine power
ance of sea bottoms near lapan to establish generation, which has been under basic study
baselines for accurate Japanese territories. [n for many years, the Agency of [ndustrial
order to make more extensive surveys, the Science and Technology will start to develop
Maritime Safety Agency will budd a 2600t elemental techniques, intending to construct a
class large surveyor on a 3-year plan, starting 1000kW outpu~ class pilot plant. [t will also
in Fiscal 1981. Also, the Agency will participate stazt the study of wave force power generation
positively in the [nternational Program of utilizing breakwaters and similar structures.
Oceanic DriUing which surveys oceanic bottoms 4) Utilization of Marine Space for Marine
in the world using a deep sea excavator. Airports
2) Development oC resources, including manga- 'fhe government has promoted the util'ua-
nese nodules. tion of marine space, for Kansai International
The Government will build up survcys of the pirport, fer example.
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NOR OF'FIC'IAI. l1tiH: UNI.Y
SCIENCE AND TECHNOLOGY
JOINT ST[JDY FOR CURRENT POWER GENERATION UTILIZING NATION'S CURRENT
Tokyo TECHNOCRAT in English Vol 14, No 4, Apr 81 p 88
[Text] � Thc lapan Marine Science and Technology by bad weather or typhoons.
Center and the "fukyo Electric Power Co. have The joint research wiU include the manu-
signed an agteement for thcir joint engugement facture of a lOW output small sized generator
in res~:arch and development of current power using 2 rotury wheels 30cm in diameter and
generation which cunverts ~igantic amuunts uf about 60cm in length, a test using a!acge
energy uf the Japan current into electricity, current simulation tank and, finally, a test in a
relying purely on lapan's own tcchnology for real sea area to obtain the exteosive data neces-
power generation. sazy for making the plant practical.
They are planning to manufacturc a test
plant for Suvonin's rotor type fully submerged
current power generation, which is commonly
called "the Kaiho rotor system" and to es-
_ tablish foundations for making it practical by
conducting tank tests and current tests. No S�e surface
substantial study of current power generation
has bcen attempted in Japan. Roror waser wheei
The Kaiho rotor type current power genera- Currenc
tiun pl~nt consists uC u gener~tor with an ex- ~
tendcd rotary shaft lca~ing from both sides and
a cylindrical rotary whecl (rotor water wheel) Cabie
_ Fitted on each of both shaft extensions. When StabilizinQ whael
installed in a current with a submarine cable Anchor
attached to it, the entire power generation plant
"soars" in the current, just as a rotary kite Ses boaom
tlies in a winJ, and the wheels rotate to
generate electticity. (t the current chunges its
direction, the plant I'olluws it just as smoothly
as a kite follows a wind. lP tho plant is operated Fig. 1. Model ~iegram for Kaiho�Type Current
about IOOm decp in thc sca. it will not power Generation
interl'ere with ships and will not be disturbed
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F'OR OFFI('lAl. Util~: ONI.Y
SCIENCE Ai~iD TECHNOLOGY
SUCCESSFUL TEST OF AIR-LIFT COLLECTOR OF MANGANESE NODULES
Tokyo TECHNOCRAT in English Vol 14, No 4, Apr 81 p 89
[ Text ] Thr Narionaf Reseurch /nsrirute for Yollu� nodulesJ, a liquid /seawaterJ and a gas (oi?J and
the air in the pipe expands as it comes up to
tiun und Rrsources has recenr!}~ succeeded in u the surjace of the seawater. Thus, in order to
murlnr tesr oj an air lljt (bubble pump/ tvpe a~h~evic ejficient collection and transportation
c�ullec~rur, which is expec�ted tu be a represenra� o ma~~anese nodules, such jaetors as the
tivc system jor roflecting manganese nodules. uuge oj the pipe, J1ow rates and rates oj ar~
The air fij~ sysrem uses u thick pipe ex� g
tending to rhe sea bottom, Jceds compressed air iniecrion must be strictly designed. In order to
intu it ihrough opentngs provlded in it and make the piant p?acdcai, basic data are needed
or the appropriare combination oj rhese
.nrcks manganese nodules jrnm sea borroms up factors. The fa~esi marine tesr was intended ~o
ru bnats b}~ making use oj ihe buoyaney oj the I
injecred air. This sysiem has ihr edvanrages over obtain such basic data.
The pipe oj the air lijt used in the tesr was
nrher systems oj causing less nouble during
abour 40m long and a6our lScm in diamerer.
operation and oj showing hrgher ejjiciency of re ate with a
c�nllecnon, und ir is expecred to become a The test jed a(ighr�weighr agg 8 (
represenrati~~e technique jor coilecdng manga� mean grain diameter oj 3.Scm and a specrjic
nese nodules. gravity oj2/ in srmulation of manganese noduies
The air lijt system has a flow in the pipr oja into the pipe nt a fower location and observed
mi.Yh~re composed oj a so/id (manganese obt�~~~ g data onttranspo tatiotnsspeed,srran's-
porred quantity, etc.
Compre~sor
- .
Alr Iift pipe I
Approx. 40m
Upper eir injection port
Support
Ssmple fred pipe
Lower eir inj~cuon port ~
TVi cemere~-
Fi~;. 1. Tcst Sctup 1'or Air Lift SYstem
f'or Collectin~; Manganese Nodules
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I~()It ()M'H'I('IAI. 1?tiH: ()NI.Y
- SCIENCE AND TECHNOLOGY
SEAWATER DESALINATION PILOT PLANT BASED ON REFRIGERATION USING LNG'S LOW HEAT
Tokyo TECHNOCRAT in English Vol 14, No 4, Apr 81 p 89
[Text] Mlrs~~i Shipbuilding has recently developed a seawater desa!lnadon
piiot plant basrQ on rejrigrrotionusing !ow hrat ojLNG and has deltvered
il to the Mlnisrry ojTrade und /ndustri~.
Because oj the recentl}~ trnse situation in the demand and supply af
water, nc~ development oj water resources, particulorly the desaltnotion
oj seawatcr, is increasingl}~ expected. Since conventional technology Jor
tl~c desolinarian oj seawarer required large energy consumprion, rhe
developmenf of seawater desallnarion systems which consume energy
modr.ct!}~ n~ which can uttllzt unexpJoited energy ejjectively has been
much exptcted.
On the other hand, LNC, which ts being imported rn snikingly
increasing yuontities because oj soaring prices oj crude otl, is liquejied
at its originul sites, carrted to reservoir bases by specially providedtankers
and returned into natural gns by evaporarion bejore use. Seawnter hos
almost always 6een used as heat source jor ihls evaporation, and .low
heat hoid has most been tmitted lnto sea without betng unlized.
In order to solve these problems Naturel pas/NZ(gas)
comprehensively Srid t0 obtain ef- C~eeninq water
ficiently inexpensive fresh water
~ ~ Hot fresh weter
from seawater, the seawater desal- ~NCi~N2
ination pilot plant based on re- Q;
Nu
frigeration using low heat of LNG
has been developed. o Melting
~ tank
N i~+~~"','_,. Fresh water pump
The plant is based on the following �
principles . LNG at an ultra-low- P.od~~ed
~ wet~r
temperature (-161.5�C) is brought ~
Returned Discharped brina
into direct contact wi~~ seawater brine
to produce crystal ice in seawater.
This ice is separated from brine, ~ Slurry pump
cleaned and melted into fresh water ;
~
(see Fig. 1). ~
The main specifications of the plant
are SS f OL10WS : l~ Capacity : lOlII~~dSy p~R. p~;~Fram Showing Principles of Seawater Desalination Using LoW~
2) Quality of produced water: Hcat of LNG/LNz
below 500ppm.
- COPYRIGHT: 1981 Fu~i Marketing Research Co., Ltd.
CSO: 4120/262
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SCIENCE AND TECHNOLOGY
NEW MAFF RESEARCH THEMES DETAILED
Tokyo TECHNOCRAT in English Vol 14, No 4, Apr 81 p 92
[TeXt] � The new research themes oC the Ministry of livestock industry by-products. For this pur-
Agriculture, Porestry and Fisheries (MAF~F) for pose, polluting salmonellas will be identified
fiscal 1981 uc as foilows: and theit quantities and pathogenic properties
Biomass Conversion Project !general research clarified. Thereby, a simple testing method to
concerning the development of techniques Cor determine the degree of toxicity that may
the efficient use of biologicai resources): The occur in manufacturing and distributing fodders
regenerative capacity of biological resources and wiil be devised.
the buffer functions of forests, soils andmicro- Emergency 'fechniques to Cope with Oil
organisms will be clarified by analyzing the Conservation in Greenhouse Cultivation: An
distribution of biological resources by items, estimated 900,000 to 1,000,000 kl/year of oil
and determining the amount that can be used, is used for heating in greenhouse cultivation
the amount that is not yet used and the amount and the consumption is beGeved to be increasing
' that can be regenerated. Furthermore, eCforts by 2 to 3% each year. To ensure the steady
will be made to make possible the mass development of greenhouse horticulture, there-
cultivation of grain amaranth, water hyacinth fore, it is necessary to estabGsh a methodoingY
and large algae and to establish methods for to teduce oil consumption by selecting plant
opening up new areas uf use, such as leaf pro- types resistant to low temperature, improving
tein, Fermentative protein and wuod cliemicals, cultivating methods and improving heat insula-
Also, small-scale, high-~fficieacy energy con- tion. The project proposes that specific studies
verting equipment that can be used in t'arming, related to this issue be conducted mainly by
t'utestry and fishing communities will be manu- the National Institute of Agricultural Sciences.
factured using techniques to recover mattet and Establishment of Waste Water Treating Tech-
energy from such w;~ste products as chatf, waste niques for Rurai Communities: Water pollution
materials and livestock excrement. i'echniques resuiting from industrial development is now a
to locate and produce high-activity micro- social problem, and there is the growing danger
organisms and enzymes and to fix enzymes, of rivers being polluted due to inadequate
will be included as will membrune treating waste water treatment in rural communities.
techniques using hi~h polymer materials. These The project proposes to provide simple treating
techniques, when developed, will provide 15.7% fscilities and, at the same time, develop tech-
of all energy reyuired by agriculture, forestry niques aimed at recycling the soil biosystem by
and fisheries. Under this long-range project, t~ returning useful substances to farmlands.
continuc until fiscal 199U, K24U miilion w;U Establishment of an Optimum System to
be spent in Ciscul 1981. [ncrease the Operating Efficiency of Coastal
Development of Methods to F:valuate Safety hishing Boats: Research and development will
ul' Animal Fudders and Microbic Fodders: be made of basic factors,such as hull structure,
Methods wili be established to evaluats the engine, fish finding tecliniques and the storage
x~fety uf 1'oddery containing microbic protein of catches, all of which are indispensable for the
(SCPI, which hus promisin� application a~a efficient operation of a coastal fishing sys-
proteinou.r component ul' t~~dder , fi~h meal ur tem. Furthermore, guidelines for efficient
117
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, coastal fishing will be ptepared by simulating
particular types oC ships equipment.
Development of New Preserving Techniques
- Suitable for Processed Foods: This project
includes the development of safe additives of
natural ongin, the use of new enzymes and the
development of gas substitution packing tech-
niques and a germ-free packing techniqUe using
accelerated electronic rays.
Clarification of Pathogenic Mechanism in
Preparation for the Developm~nt of a New
Technique for the Prevention of Pine Withering:
This project is an effort to discover a method to
really control the pine withering disease by
studying the formation and activity of its
underlying toxic substance, thus revealing how
it starts and spreads.
COPYRIGHT: 1981 Fuji Marketing Research Co., Ltd.
CSO: 4120/262
118
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F'OR nH'FI('IA1. lltil~: ON1.Y
SCIENCE AND TECHNOLOGY
DEVELOPMENT OF NEW METHOD TO PREVENT FALL-OFF OF INCORPORATED GENES
Tokyo TECIiNOCRAT in English Vol 14, No 4, Apr 81 p 93
(Text] The cc~nnu! lubururury uJ' Ajir~umutu Cu. kas developed a prucess ra
subsruntiu/f~~ prrvenf the 'jall�ofj uJ incnrpurated genes", which hus
bern u bortlrnrck in ucrually appli~ing the gene recumbining techniyue
tu prudurtiun.
With [he udvu~~ce uJ genr enXineering, ir has becume possible jor
target genes ro be incorporured into microorganisms, jor example, with
relative simpliciry by using special enzymes and gene carriers called
vectors. /nterjeron, expected [o huve n carcinostntic ejject, and growth
hormnnes can be produced at low cost by simpfy cuffuring ri~ese micro�
~ organisms in v tank. However, it ojten huppens rhat even ij genes
producrd by interje~on, ete. are incurporufed into such microorganisms
as cufibucifli, thr ineorporated genes Jalf off during culture and the
ntic?oorXunisms r~ rurn to the state oj ordinury microorganisms.
At thr fuburatorti~ stage, tiirrefore, rhe ' fafi�ojj prevention" merhod
using untibioric�rrsisrunt gene vretors (curriers/ is now common!}~ used.
Tlus method involves some jrur uj the product containing antiLiotics
since �untibrotics urr addrd to the cufture soluriun oj microorganisms. ,
!n th~� cusr oJ aminu urids, produced by tAe A%inomoto Co., there has
brrn the prob/rm that vmino acids and antibiotics mingle together
brcnuse omirio acids go out oj thr budies of mieroorganisms into the
cufture soh~tion and it is too expensive to a�rparate them.
/n the new methud devrfoprd bv this company, speciai colfbacilli
thut cannar live �~ithout antibiotres are used us target microorganisms oj
Xene engfnrering. In rhfs casr, vertors thut cun live wfthout untibiotics are
usrd us vcctors ujgrne~ rnginecring. !n otHer words, the combinatiun oj
c~~libucillr Niur c�annur liv~~ wirhour unri6rntres and vectors thut can live
N~ithuut untibintic�s is the� baa�ic cumposi~iun uj Xene� engineering (see
Fi~; l/. 7'urge�r genr.a, suc�h us g~v~rs prudurinX umino ucid.r, ure united
witA vrrtnr.c in lAi.~ ~ urnblauttnn and lhevi tnrorpnrated intc~ co!lbucil(i
~ryuirr~~,c urrri6iuNrs. Thrn, thr.rr rnlibocifli produc�r rurget amino urids,
err. und, lI1C .1'GI)IC rime~, mrn inru u stugc whrrc they cun, by the
a Tamehare
: m Villerino O ukiyotsu Okuyoshino
� ~ . (SPain1 _I ~
Runne~ (upper)�~',.�' E Cabin Creekr
R}biei ~hetm Illes
~ (U.S.) (Switzerlend, SB)
. . E Provvidenze~
~p ~itslv) ~ Shinteksseqewe
� From p~~stock to ~ Stafel l ~Kitenyeme ~
, upoer pond (Switxerlsndl~ Shintone
~ Shiroysr~te
~
Guide veno , 1 Omoripewe ~ Mio ~
JYSD~~eW!� -
Runn~r (lower),.'.�' Hiweu~e Mizudono
From tellrse~ to (U.S.1
lowsr pond 1955 '60 '65 '70 '75 '80 '85
. - Stertup yeer (celendsr yeer)
Fig. 2, Progress of Maximum Effective Head in Pump-Up
Fig. 1. Uiagram of a Two-Stagc Pump Turbinc with Movable power Generation
Guidc Vanes
Moreover, current 50Qm-head class pump turbines must use impellers with 4.7m
O.D., and as heavy as 45 tons, in contrast to thefo~�1000meheadSi~ThisawilleS
impellers of 3.5m O.D., 25 tons or so in weight,
greatly facilitate their transportation, and Tokyo Electric expects that the
equipment is also available for sites far up in the mountains.
COPYRIGHT: 1981 Fu3i Marketing Research Co., Ltd.
CSO: 4120/262
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FOR OFFIC'IA1. US~: ONI.Y
SCIENCE AND TECHNOLOGY '
SYNTHESIS OF THERMALLY STABL~ OILS BY BENZYLATION OF BIPHENYL WITH BENZYL
CHLORIDE CATALYZED BY IRON (III) OXIDE
Tokyo TECHNOCRAT in English Vol 14, No 4, Apr 81 pp 51-53
[Text] The ben~ylation of biphenyl with variousamounts of benzyl
~hloride was pcrformed at RO�C ur at room temperature in the
presencc of' iron(III) oxide prepared by calcining, at 300`C,
~ron(III ) hydroxide which has b~en precipitated by hydrolyzing
FeCl3 with ammonia. The products with various viscosities were
tliermally stable up to 200-300�i , and no chlorine was detect-
ed in the products.
Several works concerning the decomposition of PCB b
methods using pyrolysis!~ radiolysis,2~ photolysis3~ and plasma~
have been reported. On the other hand, some workers have
investigated the alkylations of biphenyl in the presence of
Friedel-Crafts catalysts in order to use the products as liquid
heat stabilizers.s ~6~ Biphenyl is also used as a high�bolling heat-
ing medium by mixing it with diphenyl ether as a liquid at
room temperature Previously, M.Hino and K.Arata (Hakodate
Technical College) reported that the iron(1[I) oxide thus pre-
pared is an exceedingly effective catalyst for the polycondensa�
tion of benzyl chloride, and that the product is poly(p-
pl~enylenemethylene) and stable up to 400 C e~ In this work,
tl~ey reported that thermnlly stable oils with various viscosities
~an be easily syiithesized by the benzylation of biphenyl with
benzyl chluride in the presence uf the iron(III) oxide catalyst.
Tlie irun(III) oxide l'~[JIY51 was prepared by calcining
irun(III) hyJruxide in a glass wbc in air at 300 C for 3h;
it was then stured l71 ~ glass ampuule until use. The iron(I11)
I~ydruxiJe was precipitaced by hydrulyzing FeCl3 with aqueous
ammunia. The hyJroxide was washed, dried at 100�C, and
t'inally puwdered brluw l00 mesf~. The benzyl chloride (guar-
anteed ~eagent ut' Wako Pure Chemical Cu.) and biphenyl
(Wako Pure Chemical Cu.) were used without further purifica-
tiun.
Benzylation was carried out in bulk following two methods:
(A): ]0-60m1 of benzyl chloride were stirred, in 2-ml portions,
intu a?nixture of 20g of biphenyl (mp, 70�C) and O.lg of the
catslyst at 80�C. Each reaction uccurred immediately, with a
viulent evolution uf HCI. Benzyl chloride was added at intervals
uf 10--30s for the tirst 20m1, and afterwards at 1-2min
intervals, without any additiunal catalyst. (B): 10-SOg of
biphenyl were dissolved in SOmI of benzyl chloride at room
temperature, after which the benzylation was performed by
125
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Yield Viscosityal
Amount of benzYl chloride Amount of biph~nyl Reaction temperature
Run m1 oC 9 r~/rel
ml
20 80 25 2,76
~ 10
20 20 80 34 3.37
2
80 47 4.74
3 qp 20
20 80 60 5.97
q 60
10 RTb) 43 8.95
5 50
20 RT 53 5.58
6 50
50 30 RT 65 3.88
~ 35 gy 3.31
gc) 50 50
a) Raletiv~ vi~cotity of e 50wt% b~~z~n~ ~olution to b~nx~ne determined st 25�C in s Cannon�Fsnsk~ viscosity.
b) Room t~mp~rstur~. e) Si~e~ th~ biph~nyl w~~ not ell solubl~ fn b~nzyl ehlorid~ at room t~rrepsrsturs, the rseetion wat carried
out ~t 38'C.
0
20
d
~ b e
; 40
m a
m
~ 60
~ e
~ 80
; 320
100 I I I I
130 220 380 2140
100 200 300 400 500 800 Moleculsr w~ipht
T~mp~retur~/�C
e, b, c, end d r~f~r to th~ product~ piv~n by Runs 2, 3, 6, Conc~ntr~tion: 0.4p in 100m1 ~f THF, flow rete: 1ml/min.
end 4, r~~p~ctively. Bfph~nyl, h~stlnp rat~: 5�C/min.
Fig. 1. TG Curves of Products Fig. 2. GPC Curve of the Sample Produced by Run 3.
stirring witl~ 0.2g uf the catalyst. The reaction started im-
mediately, with an avolution uf HCl gas, and was completed
within 7--lOmin in every reactiun. After the reactioris by both
methods, the reaction mixture was diluted with benzene,
separated frum the catalyst by filtration, washed with water
several times, and dried; !inally the benzei~e was removed by
vacuum evaporatiun.
Table 1 shuws the yields and viscosities of the products.
Bruwnish oils with various viscosities were obtained in high
yields depe?iding on the ainount ratios oF benzyl chluride and'
biphenyl reacted. In the cases of excess amounts of beiizyl
~hloride (Runs 3-6), the pruducts are considered to also
contain puly(p-phenylenemethylene), judging from the high
ac[ivity ut' the catalyst t~or the polycondensation of benayl
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HOR OFFICIAL l1SE UNLY
chloriJe tu puty(p�phenylenemethylene) s~ Elemental anaiysis
showed nu chlurine in any of the products in the table. NMR
spectruscopy sliowed a singie peak at 3.85ppm (CH2) and a
multiplet at 6.7-7.Sppm (phenylene H) in the ratio 1:7 for the
samples in Runs 2 and 8.
The TG analysis of the products were done in nitrogen;
some of tiie results are shown in Fig.l , together with that of
biphenyl. The products were thermally stable up to 200-300�C,
above which decomposition occurs, and they decomposed com-
pletely at 550�C. The weight decrease in biphenyl was 100%o
below 200�C.
The molecular-weight distribution of the sample in Run 3
was determined by gel-permeation chromatography, as is shown
in Fig?. The main praducts have a molecular weight of ~220-
380; ti~is indicates that the degree of the benzylation of
hiphenyl is predominantly i 3.
The present synthesis was carried out with AICl3 and FeC13 ,
typical Lewis acid catalysts, under t}~e same conditions. The ,
reactiun was complete when 28m1 of benzyl chloride was added,
in ?�ml portiuns, to a mixture of 20g of biphenyl aud OJg of
~ICI, at tt0�C. However, further reactions did not occur with
adJitiunal benzyl chloride, in spite of anc~ther addition of the
cat,+l~~s~. It is considered that the oily product poisoned the
acidir sites uf the cetalyst surface. Another run was performed
at rcxim temperaturc with 30g of biphenyl dissolved in SOmI
u1' benxyl chloride and 0.2g of FeC13 , but the reaction was
extremely slow; 1.38~~ chlorine was detected in the product
after a reaction of 45min.
The product obtained by the present easy method of
synthesis with the conventional and active iron(III) oxide
catalyst can replace PCB, whose synthesizing method is to
liquidize biphenyl by chlorination. The present method could
also be applicaUle to naphthalene as well as biphenyl, both of
which era produced in great quantities in petroleum in-
dustries.
References:
I) L. K�.Ison and E. Rosen, Chem. Scripra, 1, 61 (1971).
2) T. T�rwai und Y. Shinozaki, Chem. Lerr., 1972, 865.
3) T. Nishiwaki. J. Ninomiya, S. Yamanaka, and K. Ando, Nippon
- Koguku Kaishi, 1972, 2225.
4) h. ~liroaki, 1~. Mitsumori, and S. Muchizxki, Chem. Lett.,
_ 1979. 739.
S1 U.B. I~rlJdy,l.F..C. Prud. Res. Develup., 8.239 (1969).
61 K. Ajim