JPRS ID: 9663 JAPAN REPORT

• Document Type: CREST
• Collection: JPRS
• Document Number (FOIA) /ESDN (CREST): CIA-RDP82-00850R000300100026-9
• Release Decision: RIF
• Original Classification: U
• Document Page Count: 133
• Document Creation Date: November 1, 2016
• Sequence Number: 26
• Content Type: REPORTS

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JPRS L/9663
14 April 1981
Japan Report
(FOUO 23/81)
~
~
_ FBIS FOREIGN BROADCAST INFORMATION SERVICE
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NOTE
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' item originate with the source. TimPS with in items are as
= given by source.
The contents of this publication in no way represent the poli-
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COPYRIGHT LAWS AND REGULA.TIONS GOVERNING OWNERSHIP OF
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JPRS LJ9653
14 April 1981
- JAPAN REPORT - (FOUO 23/81)
Tokyo TECHNdCRAT in English Vol 14, No 2, Feb 81 pp 11-15, 16-22, 32-
38, 39-44, 45-48, 48-511, 51-54, 55-57, 62-71, 74-78, 86, 88-90
~ CONTENTS
SCIENCE AND TECHNOLOGY
Applications of Transfer Robots
(Makoto Iida)
1
Precision Small Robots, Their Applications
!
(Shigeru Iwai, Satoshi Shigeno)
10
, Antiwear Coating by Ion Plating--Ion Plating for Cutting
, Tools of High Speed Steel
- (Akira Kono)
23
~ High-Speed and Hard Anodizing .
~ (Yoship Fukuda, Toshiro Fukush3.ma)
36
= Long- Term Prospects of Japan's Steel Industry in 1980's
48
_ Motor Operation Control by an Inverter
55
Space Materials in TT-500A Rocket No 8: Interim Report
on Test
62
Robots for Maintenance of M,achine, Equipment; Their
Future Profile 68
Development of Advanced Coal Transportation System 71
Satel'ite Stations for Natural Gas Conversion Using
Syn thetic Method 72
Pollutionless C-Heavy Oil i.ombustion Technology--
y Fluidized Bed Boiler Developed ......................................o..... 73
- a - [III - ASIA - 111 FOUO]
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Energ}-Saving System for Buildings--Over 50% Energy-Cost
- Reduction Possible
74
geCtlndary Reaction Associated With Eutectoid
Transformation in Cu-Be A11oy.............................................
75
Superconducting Properties of in Situ Cu-22.5massyNb-Sn
Composites
76
- Separate Determination of Work-Hardening, Softeni.ng
Rates in Pure Metals
77
' Phase Transformation, Shape Memory Effect in In-Pb
Alloys
78
A Series of Cemented Carbide End Mills by Catc:gories
79
Deve?opment of Erosion Diagr.osis Technique for
- Retractory Bodies of Blast Furnaces
81
Large-Capacity Torus-Type Electromagnetic Pump for
Liquid Sodium........,.e
83
Scro11-Type Gas Compressor
84
Development of Heat Pump System Using Gas Engine To
- Drive Compressor
85
Jemands for Large Machine Tools .............o...............................
87
Sintered Materials Under Super-High Pressure
88
Metal Dies for Small Batch Production
89
SFT-1 Type CNC Cutting Machine
90
Double Column-Type Machining Center
91
Cutting Tools With Easy Chip Treatment
93
New Icebreaker About To Be Built
94
'Cargo Pumg' for Liquefied-Gas Carriers Now in
Commerci^I Production
95
Automobile Industry Promotes International
Reorganization
96
= Roll-on/Roll-off Automobile Carrier
98
- b -
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Four-Bit Microcomputer Developed by Hitachi 99
- High-Performance Electric Insulatina Material 100
Semiconductor Wafer Cleaner, Tirier.,......a 101
Competition in Development of EB Resist Products at
Its Height 102
High-Speed Memory Testing System 103
New Interdevice Isolation Technology for LSI 104
Prospect of Information Industry in 1980's 106
_ 1M Bit ROM f or Genexating Chinese Characters 107
- Method for Inputting Data for Three-Dimensional
Figures With a Tablet 108
= Mass-Production ?'echnology for Distributed Refractive
Index-Type Lens........................................................... 110
Gas Flowmeter Using Ultrasonic Sensor ..........................o............ 111
New Digital Dew Puint Meter Adopts Use of Crystal
Oscillator 112
Measuring Magnetic Field lntensity Usiug Light 113
Liquid Level Indicator ...........................e.......................... 114
- Establishment of Mansfacturing Technique for Polycrystal
Sintered Substance 115
Electric Power Production by Surplus Steam 116
Wet Type Digestion Gas Resulfurization Plant 117
- Basic Research for Marine Generaiir. Plant 118
Meassring Water Temperature Sensor Time Constants............o 119
- Briefs
Oilshale Development With Brazil 121
International Cuoperation of Heat Pump 121
Metallic Mirror Processing Equipment 121
Hydraulic Power System 122
Gear Measuring Center, Laboratory 122
Production Type NC Automatic Lathe 122
c
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New Machining Center
122
World's Biggest Bulldozer
123
Long-Life Gamma Ray Detector
123
Singapore Software Development
123
- Completion of RIPS
123
New Digital Signal ZYansmitting System
124
- New Glass Fiber
124
Fine Ceramics Discussion Meeting
124
Sludge Into Compost
125
Deep-Sea Research Submergible
-125
Earthquake-Proof Computer
125
Earthquake-Proof Bu-ilding Tests
126
Permanent Home Equipped With Microcomputer
126
_ U.S.-Japan Machinery Competition �
126
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; APPLICATIONS OF TRANSFER ROBO'1'S
Tokyo TECHNOCRAT in English Vol 14, No 2, Feb 81 pp 11-15
; [Article by Makoto Iida, chief, Autamation Promotion Section, Technical Department, -
Toshiba Seiki Co., Ltd.] -
[Text]
1. Introduction
It is ironic that the present trend in industrial robot
devetopment is heading away froni the d'uection of their
initial development into exclusiveness, that is, specific robots
for specific purposes. From the perspective of robot develop-
ment, this trend naturally makes us thiuk twice about its
desirability. From the point of view of whether the trend
is helping meet the purposes ef robots, however, the trend
ia seen as a naturai consequence of our country's industrial
tevel. The transfer robot introduced in this article follows
the aforementionsd trend. It is a fixed sequence robot that
has simple mechanisms. Its main use purpose is the transfer
of materials in press work, but it can also be used in assembly,
processing, and transfer work involving a small number of
stations.
2. Ou tline of RHP Series
T11e majority of present-day industrial robdts have their
operating space defined by. cylindrical coordinates, with their
operating territory restricted to within the space of their
rotation. Because of this, they are not suited for operation
in a linear work space. The RFiP series was developed to
operate in a linear work space, and to accommodate this, they
have their operating space defined by rectangular coordinates.
Their profiles are shown in Fig. l.
An RHP series robot consists of a drive system and an
operation system. The luad cransfer weight is 1.4kg/operation
system, and one drive system can drive up to two operation
1
r
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systems. There are two types of arm movement: 2-arm in-
dependent drive (D type), and transfer arm (DT type).
Profiles and specifica!ions of each are shown in Figs.2 and
3,ttspectively.
In Fig.4, the D type's right and left arms are driven
independently of each other by two sets of cams in the drive
system. The cam diagrams aze drawn such that in travelling
from A to B and B to C, the ums can follow the paths that
enable them to reach their yositions in minimum time. The
robot's can process the azm's horizontal transfer movement
of '210mmx2 in 1.5 seconds, as shown in the specif'ications,
because of the cam system.
In the case of DT type robots, they have a set of carr.s,
and their operations are C-A, A-B, and B-+C for A-B
transfer. 'fhe arm waits at the middle point "C" for the work
to finush. This operstion is available for use not only in press
jobs but can also be used as a ditect flow transfer device. It
is considered a simple and low�priced lincaz-3ype base MC.
Introduced here aze actual cases where RHP series robots
have been used for processing.
3. Introduction of D Type Robots
3-1. Procxssing of Chain Sprockets (See Fig.S)
This is the simplest operation for a robot in press work
where chain sprockets (1100--2200) are made. The machina
used was an RHP-7D robot, and ~he work involved feeding
pieces to and taking them out of a 35�ton press. The cycle
tinie was 2 seconds. By attac.hing an escapement to the tip
of the loading conveyor, a gross feed precision of �0.2mm
was maintained.
(b) RHP�70, 7DT
Fig. 1. Shapes of RHP Series
2
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Limit twiteh
to (eonfirms Pnu poinp uP;
20 tipnal for eyele stnrt)
3 100VAC
power sourc�
i 6 Vy
_ 7 o Electromapnotic valve for
go 100VAC
Limit switch for (for itsrtinp prep)
sUrtinQ pran
Pin
ExtKnol connector
Mudel 700
co n tro I l~r
Fig. 8. External Connector Connecting Diagram
3-4. Examples of Mechanical Hands (manipulators)
For an industrial robot to be a full-fledged robot, it must
have what amount to human hands. Shown in Figs.9 and 10
are some of the standardiz�d mechanical hands used in
industrial robots. The mechanical hand shown in Fig.l l is an
: exclusive vacuum�type Eloating manipulator thai can grasp
(absorb) two parts at the sanne time and assemble them.
- Shown above are various models of compact, high�precision
- industrial robots, and some examples of their applications.
In humans, hand work is doae by actually touching the parts,
while the brain contrQls the niovement of the hands and wrists
to create the desired state. With indiistrial robots, the hand
division is closely related to the type of job it is to perform
as well as to the objects it is to handle, and it is very difficult
to give it a mechanical function with the versatility of human
hands. T1us is why robot hands are offared by makers as nption-
al items.
However, as long as hands are treated as options, industrial
robots will remain exclusive automata, each fitted with a
specific purpose, no matter what claims are made about the
utility value of giving arms multi-purpose features. The task
facing the industry today is to overcome the technical limits
inherent when exclusive hands are options, promote the effort
- to manufacture them as modules, and develop hands with
multi-purpose features.
Elaetromepnetic chuck adforptlon furface
. ~
~
oft
( ^ T
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'Guide for washer
Fig. 9. Double Chuck-Type Handle
21
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- Ax(s ~
Scnw
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Grip
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,
�
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Frame, / I
Pivot
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Fig. 10. Finger That Can Be Moved Horizontally

Nippl*NF
Vacuum ped
Fig. 11. Vacuum-Type Floating Manipulator for
Model 100
COPYRIGHT: 1981 Fuji Marketing Research Co., Ltd.
~ CSO: 4120
- 22
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ANTIWEAR COATING BY ION PLATING--ION PLATING FOR CUTTING TOOLS OF HIGH SPEED STEEL
_ Tokyo TECHNOCRAT in English Vol 14, No 2, Feb 81 pp 32-38
[Article by Akira Kono, product manager, ULVAC Corporation]
[Te.xt]
1. Principles and Features of Ion Plating
I Ion plating is a method of deposition by the bombard-
- ment of evaporated molecules which have been positively
I ionized in discharge, onto negadvely biased substrates. In order
to sustarin glow discharge, an inert gas (10-2 -!0-4 torr) is fed
into the system and a voltage of sc+me IOOV is applied between
the evaporation source and the substrate. These principles an
~ illustrated in Fig. 1.1>
The greatest feature of ion plating is higher adhesion of
cuatutgs to substrates than that given by other PVD methods.
.Adhesion of ion plated films is shown in Table I as compared
with conventional vacuum vapor deposition. The table indicates
that ion plated films have adhesion 50 - 100 times that of
~ ordinary vapor deposited films.
This can be ascribed to the following two factors.
; 1) Prior to evaporation, Ar glow discharge is introduced to the
system by negatively biased substrates, and ionized Ar sputters
j away the surface ccntaminants of the substrates, consisting of
adsorbed gas, fat, oil and oxides. This allows the evaporation
on clean surfaces.
2) The evaporant, ionized in the glow discharge area is accel-
erated by an electric field, aztd clashes violendy against the
substrates, which produces a thin alloyign layer composed
ssubstrates, which rnables a thin alloying layer composed out
of the substrates and the evaporant between them.
An example of surface cleaning effects by ion bombardment
is shown in Fig. 2 and [he difference in the interface between
ordinary vapor deposition and ion plating in Fig. 3.
The second important feature of ion plating is to easily
provide compound films. Reactive evaporation has been
attempted by many elaborators. It is the method wtuch evapo-
rates a reactive metal into the reduced active gas atmosphere
23
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- to form a compound film. So far, despite efforts to minimize
evaporation rates because of slow reaction, it has been difficult
to obtaari compound films which are stoichiometrically uniform.
= Ion plating, on the other hand, is quite easy to provide stoi��
dhiotnetrically wuform compound films by the activadon effect
- of glow dischazge.
Subitrete
Gas ~
tion
e
i
Plsuna /
nj
e
Power
_ CostinQ~
. suOPiV
i�1 u x
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P nau n
barrier
T
-
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~vaporstor
Vaeuum
chamber
Vscuun
pu mps
Fig.
~
1. Scnematic of Ion Plating
Table 1. Adhesion
of lon Plated Films on Various
Materials
Matriz (kp/cm2)
Evap onnt
Mstal Ceamies
P I a~t icf
Ai
150
100
e Cu
> 300 > 300
120
q Cr
> 300 I > 300
> 300
a
A120;
p
70 70
I
Si02
> 300 I > 300 ~
a
Q
5 I
< 1
< t
M
~ e Cu
W _
5
~
~
7
y
24
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dN
- dE
CI
N
F~
S
C
Veeuum deposition (533'K) ion-olatiny (533�K)
Ah. ion
mbard
b
e
I Ni
o
m
n
t
I
N
a
S
Ar
I
C
I
i
~
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F�
Q
i
Fig. 2. Auger Eloctron Spectroscopy of Fe�Ni Alloy Before and After
Bombard Cleaning
(Before Bombard Cleaning Scarcely Appear Fe or Ni Atoms, but
After 10 Min Bombard Cleaning (2,OOOA) Impurities on the Surface
are Almost Removed)
-500V bia$
~
100
~
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0.1
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u ~
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Oepth from che surfacs
(l) (2)
Fig. 3. Depth Profiles of Auger Electron Spectro-
scopy
(1) Evaporated Au Film on Cu
(2) lon Plated An Film on Cu
Photo 1. Cross Sectional Micro-Structure of lon (S. Komiya et al; Japan J. Appl. Phys.
Plated and Vacuum Evaporated Ta Film SuPPIe. 2, Pr 1) 119741 363
(Ta is Evaporated without Biasing at First,
and Then Ebaporated with Biasing-500V) '
Some rypes of compound films obtained by ion plating are
shown in Table 2, together with their hardnesses.
"Ihe third feature of ion plating is that the films formed
have excellent mechaaical properties. Photo 1 shows a den-
dribc strucrure which is inevitable in the usual vacuum evapora-
cion. In ion plating, the bombardment prevents growth of
this swcture and instead helps produce a desirable equiaxial
crystal srructure. At the same time, it increases the density of
the formed films.
25
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Table 2. Hardness of lon Plated Compound Films
at 500 to 550�C
Kindo+coatinqs
Nudn"s (ks/mm.)
TIC
3,500
Ti k
2,800
C r3 CZ
3.500
CrN
2,000
VC I
Z,500
NbC I
2.000
Mo2C I
2.400
Improvemeat of Ion Plating
It has alnady been mentioned that ion plating owes its main
features to evaporated mnlecules ionized in the r1r glow dis-
chazge charge.
- DC glow dischazge is rypically abot to ionize molecules up
to at most 2- 3%. In order to promote ionizadon and make
the features of ion plating more prominent, efforts have been
made to increase the ioniiation ratio with several proposed
improvemenu. Conceptual diagrans for such improvements
are shown in Fig. 4. The multi-cathode method2> aims to
promote ionization with the aid of thermal electrons from
the hot W filaments placed in the evaporation area. The high-
, frequency method (RF ion plating)3) and I-Gun method4)
(induction gun ion plating) tries to activate ionization by
elecuons trapped in a high-frequency magnetic field. The
auxiliary probe method is designed to attain higher percent-
ages of ionization ratio of evaporated molecules with an intense
dischazge sustained by the positively biased probe located
close to the evaporation source. There are alsn some other
methods proposed; One is a meihod wiuui ubcs a special
low-voltage high-current electroa gun (a hot hollow cathode
discharge gun) instead of the usual high�voltage electron gun,
as aa evaporation source, to strildngly increase the ianization
ratio by this lazge curnnt.s) Another is a cluster ion methodb)
_ whi,ch ailows ionized molecules to evaporate in clusters with a
nwnber of neuual molecules to create an effect equivalent to
the siau of iacreased ionizatior,. These methods generally
increase the ianization ratio by a factor of about 10. _
26
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+igf, vano.
-i i
Hot cathode
~ 1
_ ,I.I1
,
1 i;~;;
Multi-eathOds meefiod
7l1TJ
Hiph voltop
Hiqh vol"
RF
Coil
0 ~ (II//r6
,
0
~
Nign ,..q,.ncY
meehod Af
(b)
~
,
f 1 ~ Irobe
~
H,
Gu
Hiph voltipo
,~I III%
,
SU'o~a
0 0
Induaion lnductlon heetinp
hMtinp mothod
(c)
Prove method Hot hOllow cathode
Oitnharp method
Idl W
Fig. 4. Some Improved Methods of lon Plating
3. Applications of Ion Plating
Ion plating was once called "dry plating" as a pollucion�free
- plating method �to replace conventional electro plating, and
- there prevailed an illusion thai it would quickly replace electro-
plating. Today, in practice taldng advantage of the above
- features, it has achieved steady application primarily in forming
compound films, which cannot be coated by electroplating.
And its appli:,ation to andabrasive plating appears to be replac-
ing hard chrome plating, which is the most expensive of all
electroplating systems.
3-1. Plating of High-Speed Steel Cutting Tools with Ti C
andTiN7,a,9,io,1i~.
As an ideal surface treatment method for cutting tools
made df high-speed steel (which requires two contradictory
characteristics, high tenacity and high anti-wear, in addition
27
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- to strict dimensional accuracy), ion plating with nitrides and
carbides has achieved practical utilization in the past few years.
Ion plating on high-speed steel has the following advantages:
9) lt is able to tighdy coat highly tenacious high-speed steel
with very hard films (Ti C: 3,000 kg/mm2 ; Ti N: 2,500 kg/
mm2
- b) The coating ternperature is sufficiendy lower than tempering
temperature of high speed steel (600�C). Therefore, it does
nat permit� substrates to be deformed and trazasformed during
processing. Thus, it is applicable to precision tools.
c) &cause compounds such as Ti N and Ti C have less aff~nity
- for ardinary steel than for high�speed steel, ion plated tools
with these compounds involves less seizure and are likely to
- provide smoother finishedsurfaces.
- d) Since coating thickness is allowed to be as small as about 24,
it will not affect surface roughness. Thus, it will not change
the roughness of finished surfaces.
As a result, ion plating is very effestive as an anti-wear
- stirface coating method for tools made of high-speed steel,
particularly hob cutters and pinion cuttets, which especially
require dimensional accuracy. In addition, the advantageous
situation which results from increased coating cosu being small
relative to the high unit costs of precision tools is playing an
important role in the prevalence oi this technology.
i4n example of a machining test with Ti N coated hob
cutters is shown in Fig.S. The hob is coated with TiN 21A
thick, which has essentialiy, a hardness of 2,500kgJmm'.
Practical use of hob cutters and pinion cutters in a pro-
duction line is shown in Fig.6. The use of TiN coated
hob cutters doubled cutting speed with a substantial reduction
in tool wear. In comparison in tecros of cycle time, this means
- that the efficiency of processing was nearly doubled while
tool life was substarttially increased. Additionally, the tech-
nique effected a reouction in shaving time (as a subsequent
process) because high speed cutting lift no pluckings on ma-
chined gear surfaces. With hob cutters, the effects of matrices
and cutting speeds are shown in Fig.7. With matrices of coated
tools used in low-speed cutting ranges, tenacity seems to play a
mon important role than thermal resistance and antiwear.
In high-speed cutting, on the other hand, resistance to heat
and abrasion is more important for matrices of coated tools
than is tenacity. (So, when coating matrices with low tenacity
are used, high-riBdity hobbing machines have to be used to
prevent tipping.)
An example of coating of endmills with TiN is shown in
Fig. 8. It is Irnown that characteristics depend considerably
~ on materials to b4 cut and the shape of endmills. Also it is
generally known that, although it is very effective in dry cutting
without cutting oil, this plating is not so effective in low-speed
cutting as in high-speed cutting whan cutting oil is used.
Also, it has been proved that the lives of drills can be pro-
longed by the use of coatings.
28
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The factor which is limiting the spread of applications of ion
' plating to high-speed steel toals is processing cost. In order to
process a large quantity of relatively small tools such as drills
wtd end mills, specimens have to be rotated and tumed around
at a temperature of around 500�C. This causes the problem
of manufacturing effective pgs which restricts the uses the
~ plating technology. At the present moment, it seems to be
, no economical approach to coat drills.
In addidon, applications also have been found in press
tools of high speed steels and hot die steels. But because they
widely vary in shape and service condidons, coating conditions
- have to be developed in cooperation with users.
,.s
1.6
1.4
E 1.2
E
i
; t.o
0.8
0.6
0,4
SKMSS TiN coatinp I
0.2 ~ I
Oi
1 3 5 7 9 11 13 15 17 1940
BIlCe number
Comparispn of woor bstwsen non-coaced hqb and T(N coated hob
(with a feare 20 at ths larpest wear)
Fiequirements for hob cuttiny
Meehine: Hobbinq machine msde by Shinohsra Kikei Co.
- Work msterial: S45C se foryed (H qC 18�25) +
Cutting speed:
40m/min
Fud:
1 mm/work�nv.
_ Hob fhapo:
..j75 x 78 x.,,31. 75
Geering:
m2PA200 ; 2-14; 100mm flnish
Shift:
6mm; on@ point; 10-pieee cuttinq
_ Rubrication oil
v
Fig. 5. A Machining Test Oata of TiN Coated Hob Cutter") _
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1.6
1.4
E 0.55
E
:
Y 0.4 ~
C "
0
0.2 Z
NLY
1.47
~I
.
0
u
Z
I
I 0.09
TiN coatin0
Machininp eondision ConvontionN ImprowC eonditions
condisiom
MachfninpApwd 61m/min 125m/min
Food 1.66mm/table rev 1.48mm/table nv
Hob fhift 3.5mm/2 unib 3.5mm/2 unib
CYeIo tim� 7.8min/2 units 4.38min/2 units
Hob: m-614, N-12, 3 heWs, SKMSS,
C3ear: spar, NT-46. 8.48.5. SCM 812
lol
Hob eutter
0.6 0.59 Lapnt vwer
0.5 0.5 Mean wear
E 0.4
n
0
S
~ 0.3
U. 8efon nqrfndin9
(with s TiN film on the faes)
0.2 ist rprindinp
2nd +regrinding
j th~fiN film
0.1 on
pinon eurnrn: m,2.5, NT-84, SKM 9, powsPar. NT-37, SCM 415,
euttin0 eondltions: euttor ftroke 700/1,050 Rr/m1n, euttinp speed
44/66m/min, eireumfenntlal food 0.5/0.24mm/str, ndiN hod
0.04/0.01 mm/ftr, number of euts 120
(b)
Pinbn curnr
Fig. 6. Field Test Data of TiN Couted Hob and Pinion
Pinion Cutterse)
30
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0.4
M34
non-eoated
� 0,3 nA3~t co.dnp P
~ SKM~
~ non
tt- ~
ert~d
Y 0.2 SKH9 coadna

. ~
: 0.1 i
0
50 100 Iso xoo
Machininy Ienpth (m)
H ob: m-3, N-12, prar: spar,
. S45C (H gt 80), maehininq conditions:
V-46m/min, f-3mm/Uble nv
11) Effeett of hob matrieu in lovwtpwd euKin4
(a) Flank weer ,
M34
0.4 Non-eoatsd
E SKH9
E 0.3 eostinp 9 M34 eoatinp
p
.
~ d /d
M42 eostinq
~
~ 0.1 i
0
l0 20 ao ao so so 70
Machininy Ienyth (m)
E (b) Cnrn vwar
E
~ 0.13 SKN9eoaHnq," 4
" M34 cosdng
i
~ 0.10 -4
~
~i 0 M42 fystwm costinq
~
~ 0.06
~
0
10 20 30 40 'SO 60 70
Maehininp Ionpth (m)
Hob: m-3, N-12, year: spa, SCM41 S(H8140), machininp: V-120m/
� min, f-3mm/table nv.
(2) Effoeo of hotr metrkN in hiyh�spNd cutttnq
Fiq. 7. Effect of Matrix on Wear Resistance of TiN Coated
Hob CutterH)
31
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(mm,
0.1
~
3
Y
C
~
w
0.1
' x
s
~
FOR OFFICIAL USE ONLY
0 1 2 3 4 3

Maehininp Ienyth
TiN coetin0 I
6 7 (m)
Tool: ondmill
(p10 x 26 x 76 KMCZ M wrMs douWe bled$
Maehinin0 eonditiom: V-18m/min
F-130mm/m in
20 x 1.0 ftM cuttina
Maarid to be eut: SKD 4 NB 310
Fig. S. Typical Results of Machining Test with TiN Coated
Endmill7)
3.2, Decorative Antiwear Coatings
- As the price of gold rises, increasing attention is being
paid to TiN ion plating for coatings golden in color and having
greater resistance to corrosion and abrasion than do gold plat-
ingi. TiN plated watch cases are already on the market and
this plating technique is being extended to watch bands.
Color tones are freely variable from whitish gold to reddish
gold by varying the flow rates of Nz in roactive ion plating.
It should be carefully noted that inclusion of carbon and
- oxygen in coatings will makes color tones red�dark.
Coatings approx. 1.5 - 2.0� thick will provide far better
resistance to s, atching, corrosion and sweat than conventional
gold plating.
Chrome nitride is also hard (Hd: 3,500kg/mm=) and its
color is mild whitish silver, so, its practical use for decorative
coatings on watch accessories can soon be expected.
' 3-3. lon Plating as an Alternative Technology to Hard Chrome
Plating tighter As restrictions on poUution ato acuinre gand for ~disposal
becoming increasingly diff cult 9
of plating sludge, along with increasing cosu for antipollution
prxessing, nnewed attsntion is being paid to ion plating as a
= techrological altemative to hard-cltrome ptating.
Generally it is desind to nplace convendonal 20 - 251A
chrome platlng with ion plating with 2- S� TiN or chrome
nitride of gnater hardneu.
32
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v ~
~
� t ;:,4:.~..

.

� - ~ t ~ . ~
AH nOuHyoiOiW L.W ElOt / NJpwnu oiod (1/) ~
lL
42
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2
o
77T ata rlc aefd film eoor6
.10 .
0 Q b
a
" 4~~ � `~`G t
t
~ 200 r
0 L-u-~
0 4 8 12 16 20
Pore number
N/1013m'Z
r--- - - - � - ~
F

-0
op j
o e I i ~
o
~
0 ' ' o (
~ CP o~ ~ ~ ~ ~
, ~ ,
I (
L~ l._i ~
20 30 40 50 0 0.2 0.4 0.8
Pore rsdlu� Total area of pprb/
P'/nm until sna *r2N
Fig. 6. Dependence of Hardness of Films on Number, Radius
and Total Area of Pores
5. Uiscussion
~ When the pH of a tartaric-oxalic acid electrolyte is raised
by addition of triethanolamine, the electrochemical dissolution
of the barrier layer is so suppressed that the bath voltage
i gensrally increases to maintain a constant current flow. The
� ~ role of triethanolamine in this case is coesidered to be only
i suppression of dissolutian of the film by reducing the acidity
of the tartaric-oxalic acid electrolyte, as in the oxalic acid-
triethnolamine bath.12) ~ The porous layer contains a considerable amount of electro-
I lyte anions,is> the anion content of the phosphoric, 16)
oxali,c,ll) or sulfuric17) acid film becoming maximum at a
` point between the wall/solution interface and the cell boundary.
~ Electrolyte anions are considered to migrate through the
! barrier layer. Assuming that electrolyte anions are immobile,
~ the porous layer arising from the barrier layer formed only
j by anion (02- and OH-) migration18) would contain no
~ etectrolyte anions.
i The radius of uxalate ions seems to be smaller than that
of tartrate ions Z'hus oxalate ions are more mobile than
! tartrate ions in the barrier layer. The solvent action of
~ oxalic acici on the oxide Film is stronger than chat of tartaric
acid. The bath voltage rises gradually with anodizing time
(Fig.l). As the porous layer grows, the supply of oxalic acid
by diffusion from the bulk of the solution to the surface of
the barrier layer is retarded,19) the dissolution of the barrier
- layer is suppreued and the layer gadually becomes thicker,
leading to a gradual rise in bath voltage. [n 0.2mo1 dm'3
_ oxalic acid baths, the Ef at pH 1?5 is lower than that at pH
1.00. At pH 1.25, a local rise in temperature uf the anode
migllt occur20)owing to uneven current distribution. However.
- apparently uniform ftlms were formed.
According to the theory of ionic equilibria,21> in pH range
43
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0 to 1.25, little tattaric acid dissociates, while 5 to 4817(, of
the oxalic acid dissociates into HC204' ions. Fur instance,
at pH 1.00, 1)9% uf the tartaric acid remains undissocisted,
wNile 65% of the oxalic acid remains undissociated and 35%
of the oxalic acid is present as HC204' ions. When this mixed
acid has the same,pH value, HC104 ion concentration increases
with the addition of oxalic acid, causing a decrease in bath
voltage.
No cracks were observed in tilms obtained in high tem-
perature processing. From the fact22> that cracks increase
as the anode warms up to room temperature after withdrawal,
it can be concluded that the film formed by the low tempera-
ture process may easily be cracked under the influence of
tensile stress caused by expansion' of the anode. On the other
hand, in the case of the high tempera[ure process, when the
anode is cuoled to room temperature after withdrawal, the
film under$oes compressive stress by contraction of the anode,
but it can withstand the stress.
The hardness of the film is controlled by the geometrical
structure of the t`ilm, but not the carbon or anion content
oF the film. The hardness of the film is closely related
to its porosity,23) but the porosity varies with the number
of pores and radius of pores. Hardness seems to be related to
the wall thickness. The relatiun between these parameters
and the hardness was examined in detail.
Higher pH gave a harder ftlm with a smaller number of
pores and smaller area of pores, or lower porosity (Fig.4a).
The distance between the pores, or wall thickness, increases
with increase in pH (Photo 1). Lower oxalic acid concentration
gave a harder film with a smaller number of pores and lower
porosity (Fig.4b), the cell wall becoming thicker. Lower
tempetature also give a harder film with a smaller number
oY pores and lower porosity (Fig.Sa). The cell wall became
thicker with the lowering of temperature, the pazameters
changing with current density (Fig.Sb). When the current
density was high, the number of pores was small but the
porosity was high and the hardness value small. In this case,
the relation between the number of pores and the hardness
was opposite to that obtained in other cases. The bath
voltage at 5.65A dm'2 was higher than at 2.26A dm'2, thus
the cell wall near the pore base should have been thicker.
However, the thicknesses of the walls near the surface were
nearly the same as those of walls formed at 2.26A dm'2
(Photo 2b). When the current density was high, considerable
heat was generated from the anode, making heat transmission
insufficient and causing easy dissolution of the film. No
def3nite relation was found to exist between hardness and
the radius of the pores (Fig. 6).
When the bath voltage was raised, the cell wall as well
as the barrier layer became thicker and the number of pores
decreased (Fig.7), leading to a decrease in porosity and
increase in hardness. Thus, in many cases, hardness was
related to number of pores, wall thickness and porosity.
However, the number of pores was not closely related to
hardness (Fig.6). As shown in Photo 2, film (a) is harder
44
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.(a) (b) fc)
I I
500 nm
Photo 2. Porous Structures (Replica Image) and Hardnesses of Films. (a) 1 mol dm-3
Tartaric Acid-0.4 mol dm-3 Oxalic Acid-0.34 mol dm-3 Triethanolamine,
pH 1.25, 40� C, 2.26 A dm'2 , 50 min. (b) The Same Bath as (a), 5.65 A
dm'2, 20 min. (c) 1 mol dm-3 Tartaric Acid-0.6 mol dm-3 Oxalic Acid-0.43
mol dm'3 Triethanolamine, pH 1.00, 40�C, 2.26 A dm�2, 50 min.
than film (b), while (a) has a larger number of pores than (b).
This is due to the lower porosity of (a). Film (b) is harder
than film (c), while (b) has a higher porosity than (c). This
is due to the thicker wall of (b).
- The hardness of the fUm is contralled by the wall thickness
and porosity of the film, but not the anion content of the
film; the thicker the wall and the lower the porosity, the
harder the film.
6. Conclusions
- HIgh temperature hard anodizing of A6063 alloy was
tested in baths of 1 mol dm'3 tartaric acid with 0.2 to 0.6 mol
dm'3 oxalic aad and 0 to 0.54 mol dm'3 triethanolamine, at
30 to 50�C, and at current densities of 2.26 and 5.65A dm'3.
- The results were as follows:
1) In the tartaric-oxalic acid baths, the films formed by
addition of 0:2 mol dm'3 oxalic acid gave hardnesses above
Hv 400, but the bath voltage was too high (above IOOV). '
45
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Nv gp0 550 480
:Y/1013m-~ g.08 7.13 15.6
as=N 0.21 0.37 0.27

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an ~ww~ ~
Por*
Porou
IayN
Barria
IoYK
Fig. 7. Porous Structure (Cross Section) and Hardness of Film
= When the oxalic acid concentradon was increased to 0.4 to
0.6 mol dm'3, the hardness of the Films as well as the batli
voltage decreased.
2) When 1 mol dm'3 tartaric acid-0.4 to 0.6 mol dm'3
oxalic acid baths were adjusted to FH 1.00 and 1.25 with
triethanolamine (0.26 to 0.54 mot dm'3), crack�free films with `
hardnesses above Hv 430 were formed at 40�C with voltage
65 to 85V. ~
3) The hardness of the film is independent of the anion
content of the film, increasing with increase in che chickness
of the cell wall and decrease in porosity.
Referencea:
1) S. Wernick and R. Pinner, "The Scrface Treatment and Finishing
of Aluminium and [ts Alloys;" 4th ed, Robert Draper Ltd.,
Teddiagton (1972), Vol.2, p.566.
2) P. Csokaa and M. Hoilo, Werkst. Korros., 12, 288 (1961)
3) S. Tajima, S. [toh, and T. Fukushima. Denki Kagaku. 23. 342.
- 395 (1955).
_ 4) T.L. Sharma and Y.N. Trehan. NML Technical Journal lindia).
18, 54 (1976).
5) J.N. Kape, Metallurgia (Brit.). 60, 181 (1959)
6) J.N. Kape, Brit. Patent 1173597 (1965).
7) T. Fukushima and Y. Fukuda, Japan, Patent 705694 (1973).
8) Y. rukuda, J. Hetal Fin. Soc. Jpn.. 27, 398 (1976).
9) Y. Fukuda. J. Netal Fin. Soc. Jpn.. 27, 681 (1976).
10) Y. Fukuda. J. Metal Fin. Soc. lpn., 29. 33 (1978)�
11) Y. Fukuda. Nippon Kagaku Kaishi, 1974. 1868; Trans. Nat. Res.
Inst. Metals, 17, 239 (1975).
12) Y. FukLia, Nippon Kagaku Kaishi, 1975. 1299; Ttans. Nat. Rcs.
Inst. Hetals. 18, 197 (1976).
13) JIS-H4100, alloy composition: MB, 0S7; Fe, 0.19; Si. 0.23:
Mn, 0.03; Cu. 0.008%. T 5; quenched from high tempetature
during extcusion, followed by tempering (ca. 205�C, l h).
14) When NaOH was added to wlutions containing 0.2 mol dm'3 or
more oxalic acid. precipitation was observed.
46
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Mard fiim
Soft f Hm

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F'OR OFFICiAL USE ONLy
15) S. 'tajima, "Advance in Conosion Science and Technology," ed �
by M.G. Fontana and R.W. Staehle, Pknum Press, New York
(1971), Vol.l, p. 281. _
- 16) H. Takahash: and M. N�rgayama, Nippon Kagaku Kaishi. 1974,
453.
_ 17) Y. Fukuda and'f. Fukushima, Pseprint for 52th Lecture Neeting '
of Metal Fin roc. Jpn., p.80 (1975).
18) J. SIejka and C. Ortega, J. Electrochem. Soc., 124, 883 (1977). .
19) S. Hoshino, T. Imamura, S. Matsumoto, and K. Kojima, J. Metal
Fin. Soc.1pn., 28, 167 (1977). _
20) Mizuki, N. Baba, and S. Tajima, J. Metai Fin. Soc. lpn., 28. 30 =
(1977).
21) H. Freiser and Q. Fernando, "[onic Equilibria in Analytical
Chemistry;" translated into Japanese by T. Fujinaga aod E.
Sekido, Kagaku Dojin, Kyoto (1972), p.65.
22) Ref. 1, p,592. -
23) F. Keller, M.S. Hunter, and D.L. tiobinson, J. Electrochem. Soc., -
100, 411 (2953). ~
COPYRIGHT: 1981 Fuji Marketing Research Co., Ltd. _
-
_i
i
~ Cso : 4120 -
~ -
~ -
I
I `
~ -
47
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~
a
LONG-TERM PROSPECTS OF JApAN'S STEEL INDUSTRY IN 19801 S
Takyo TECHNOCRAT in English Vol 14, No 2, Feb 81 pp 45-48
[Text]
Sinca Nove;nber 1979, The Ja-gan Iron and Steel Fcderation
(JISF) had conducted surveys on the long-term prospects
mainly from the steel demand and resource/energy problem
aspects. The steel demand forecast for fiscal 1985 .^iade in
May, 1979 was outmoded by the second oil aisis wtich
caused drastic chaages in economic trCnds both at home and
abroad. Therefote, the long�term steel demand forecast up
to fiscal 1985 was revised and, at the same time, that for
fisca11990 was prepared.
_ The following is a summary of the siuvey conducted by JISF.
1. Total Output Is Estimated at 130-140 Mil. Tons
- for FY 1990
Japan's economy ia the 1980's is interdependent on the
world's economy, particularly in energy and politico-economic
trends.
~ pssuming that increases in oil prices continue and that
the growth rate of public investment drops off, the real
economic growth rate is prajected at 4.5% for the fiscal
- 1978-90 period. This figure ia azrived at by averaging the
projacted growth rates of 4.89o for the fiscal 1978-85 and
- 4.2%for the 1985-90 periuds.
The mean anriual growth rate of private capital investment
between fiscal 1978 azad 1990 will remain at 4.9%. That of
private housing invos4ment will be 3.1%, reflecting a slight
decrease in the number of new housing projects. Based on
tt�eu figures, the growth rate of gross domestic fixed capital
formation (GDFCF) is expected to be 4.19'o and the ratio
of GDFCF to gcoss national expenditure will be down to
31.5�lo in fiscal 1990 from 33.3% in fiscal 1978.
ps in the previous forecast, the long�tErm forecast for
domestic steel demand was made using two different methods;
the macro-forecasting method whereby domestic demand for
48
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steel products was estimated on the basis of macrocconomic
factors, and the cumulative-forecastinR method whereby total
- steel demand was estimated on the basis of the demand
eMpected in selected steel consuming sectors.
To incorporate changes in demand structure emerging after
the oil crisis, macro�forecasting was canied out in two ways;
a one taking private capital investment as the most important
factor and the other focusing on gross domestic fixed capital
formation.
= As for cumulative-forecasting, changes in demand structure
by different steel consuming sectors and changes in the basic
unit of steel product consumption were taken into considera-
_ tion. Summarized below are demand trends in major industries
- consuming ordinary steel products and specialty steel produets.
_ Civil Enginearing: Although civil engineering in the private
sector is expacted to show a relatively constant increase,
growth in public investment will decreaee substantially. As a
. result, deterioration in the growth rate of steel consumption
in the civil engineering field as a whole will be inevitable.
Construction: Though the floor area of construction work
related to private capital investment will increase constantly,
a substantial decrease in the growth of private house construc-
- tior, is expected. Accordingly, the growth rate of steel con-
_ sumption in this field will remain low.
_ Shipbuilding: Improved demand for ship construction is
, expected reflecting worldwide tendencies to decelerate ship
- speeds to save fuel and to adopt shorter depreciation periods
for ships. These factors contribute to an increase in the number
of ships required by the marine transport industry. Accordingly,
= steel damand in this field is expected to turn upward.
= Automobiles: Deterioration in the growth rate of steel
= consumption will be inevitable due to a saturation of the
domestic auto market, a slowdown in exports, and the reduced
- amount of steel used in the production of lighter autos.
= Industrial Machinery: Because of a stable domestic demand
for machines related to private capital investment and an
, expected upturn in the growth of exports, steel consumption
is expected to increase in this field.
- Electrical Machinery: Though the growth rate of demand
for household electrical appliances will slowdown due to a
J saturation of the market, electrical equipment, electronics
equipment and other types of equipment are showing favorable
trends in both domestic demand and exports. Accordingly, a
stable growth of steel consumption is expected in this field.
Others: The growth rate of steel consumption in the field
of household/office appliances will ?.eteriorate due to a satura-
tion of the steel fumiture mzrket. In containers, a stable
steel demand is expected bec.ause of an increasing demand
_ for canned products. 1n proces.sed products, the growth rate
' will remain low partly because ef a decrease in ordinary wire
_ exports.
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1
1
1
Unit; millton tons
140
44
125
120 1~
106 120 (Macro 1)
101
00 OUtput (C~muJativ~)
89 ~B9 92
BO 84 (IMscro II)
�
60 qp~nrit eon~umption
40
20 qctwl Ertlmated
FY1988 '70 73 '78 '80 48 '90
Fig. 1. Projected Output and ApparentConsumption
of Crude Steel
Specialty Steel Products: Demand in the atrto industry;
whicll accounts for 40% of domestic demand for specialty
steel products, is expected to slowdown. However, it is also
expected that demand in the industrial machinery and eloctrical
machinery industries will mark a relatively higher growth,
reflecting higher production !eyels.
Based on the factors mentioned above, it is estimated by
- macro�forecasting that total domestic consumption of steel
products vvill be 77.5-82.6 million tons in fiscal 1985 and
84.9-93.5 million tons in fiscal 1990. According to cumula:ive-
- forecasting, it will be 79 million tons in fiscal 1985 and 90.7
million tons in fiscal 1990. T'he mean annual growth rate
between fiscal 1978 and 1990 is estimated at 2.6-3.4% by
macro-forecasting and at 3.2% by cumulative-forecasting.
Continuous casting has been higtily evaluated as an effective
means to improve productivity and product quslity. It is
also capable of realizing a su5stantial improvement in yield
and in the saving of enetgy. As a riatter of course, the CC
ratie is expected to rise even further in the 1980's, which will
load to a higher yield. Improved yield allowed the industry
to "save" 7 million tons of crude steel per year between fiscal
1973 and 1979. Even if the yield remains at the fiscal 1979
lavel, the amount of crude steel saved would reach about 5
million tons in fiscal 1985 and 6 million tons in fiscal 1990.
Reflecting this improved yield, the apparent consumption
of crude steel is estimated te total 84.2-89.5 million tons
in fiscal 1985 and 91.9-109.0 million tons in fiscal 1990
by macro-forecasting, and 85.7 million tons in fiscal 1985
and 98.1 million tons in fiscai 1990 by cumulative�forecasting.
~ T'he mean annual growth rate between fiscal 1978 and 1990
is estimated to be 2.3-3.1% by macro-forecasting and 2.8%
by cumulative-forecasting.
It should be noted that growth rate of crude steel apparent
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Table 1. Long�1'erm Steel Demand Prospects
(Unit: mfllion tons)
FY 79E~
FY 1990
Mrsn annual rate af Inereaw/Oscreesel%)
M~cro
Maoro
7978-8b
1986-90
1878-90
FY1973
FY1978
Cumu�
; Cumu
Cumu�
Mauo
Cumu
Macro
Cumu�
Mecro
(sctual)
(sawl)
Iativ*
1
II
l+tiw
I
II
1973-78
~tiw
I
11
~tive
17
1,
t~tive
I
II
o
Ordinary tteel
66.3
55.2
70.2
92.9
88.2
80.7
82.3
74.5
-3.6
3.S
4.0
3.1
2.8
2.4
1.8
3.2
3.4
2.5
~ a
producq
I
Specislty st~ell
8.8 ~
7.2
8.8
9.7
9.3
70.0
11.2
10.6
1.7
2,9
4.3
3.8
2.6
3.0
2.4
2.8
3.7
3.2
~
products
0 8
Totel
72.9
62.4
79.0
82.8
77.5
90.7
93.6
84.9
-3.1
3.4
4.1
3.1
2.8
2.5
1.8
3.2
3.4
2.6
Crudo steel apper-
~ 4
7Q 4
88.7
89.8
84.2
98.1
00.9
91.9
-4.8
2.8
~.6
2
2.7
2.4
1.8
2.8
3.1
2.3
rnt comumptlon
consumption is lower than that uf steel product consumption
because of improved yield.
; Because there are so many uncertainties in the trade environ-
ment, it is difficult to make an exact forecast on Japan's
steel trade. On the premise that net steel export in the 1980's
; will be 35-40 million tons on a crude steel basis, it is expected
~ that Japan's crude steel output will be 120.0-125.0 million
i tons in fiscal 1985 and I30.0-140.0 million tons in fiscal 1990.
2. Countermeasures for Resource/Energy Problems
1f the exuting contract amount is to be applied for aon
ore supply in the fiscal 1985-90 period, a serious shurtage
uf supply is expected. This will be true not only for Japan
but for tlie whule world. Accordingly, it will be necessaiy
for Japan to deve(op new iron ure mines.
Resource/energy problems are one of the most important
subjects in the 1980's tor the Japanese steel industry. Supply
and demand of raw msceraisl and fuels are estimated below
based on the expected crude steel output mentioned earlier.
a) Iron Ore
T}ie exploitation o1 new iron ore mines will require a huge
amount of capital and Japan will be expected to contribute
to lietping suppiying countries coiistruct their infrastructures
; by extending loans or participating in capital investment.
; Japan must carry uut these plans in urder to guarantee future
supplies of resources.
Because of its very high dependence on foreign resources,
the Japanese steel itidustry lias been introJucing lazger vessels
and improved transport systems. As higti prices of bunker
oil are expected to continu@, it is necessary to further promote
rationalization of transport inciuding fuel cost saving and
introduction of very large vessels. It will also become necessary
- to arracige sea routes and port facilities to accept such very
large vessels. As in tlie 1970's, it is essential for Japan tu
- maintain friendly relations with resource�producing countries
throughout the 1980's. Other subjects to wliich Japan has to
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(1,000 ton.i
3.600
3.400
3,200
3,000
2,800
2,600
2.400
2,200
2,000
1,800
1,60C
1,50C
1,40(
1,30(
1,20C
1,101
1,001
90
80
7C
6C
5C
4C
3(
2(
11
By volume
3y area
,
,
,
,
.
To M1'ddle East
To Europe
(Wsst & Easc) To the EC area
Jen AF Jul Oct Jan Apr Jul Oct Jan APr
1979 1980
1978
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give special consideration include diversification of supply
sources and the establishment uf effective measures to assure
a balance of supply and demand.
b) Coal
Demand for cuking coal is expected to increase as progress
will be made in substituting coal for heary uil blown to blast
furnaces. On the other hand, a substantial short supply of
coking coal is forecast for the fiscal 1985-90 period if the
existing contract amaunt is maintained. It is'necessary, there-
fore, to solicit leading coal producing countries such as
Australia, Canada, and China to carry out development programs
for new coal mines. Measures to secure coal are exactly the
same as those required for iron ore.
~ In price, it is anticipated that sky-rocketing oil prices will
I have far-reaching effects on all other energy prices. To avoid
such a situation as much as possibla, the steel industry must
have an orderly purchasing system and, at the same time,
maintain close cooperation with irdustries consuming non-
; coking coal to establish systematic countermeasures among
; industxies as a whole.
; Technical subjects to be examined include the blowing of
I powdered coal into blast furnaces, improvement of techniques
to utilize non-coking coal for general purposes, such as a method
~ to produce formcd coke, and the establishment of ineasures
i to utilize by-product gas. Output of by-product gas is expected
to increase as a result of substituting coking coal for heavy
- oil utilized in blast furnaces.
c) Fenous Scrap
In Japan, ferrous scrap has a particular improtance as a
primary resource which supports the existence of steelmakers
using electric furnaces, and as a recyclEd resource which meets
requirements for energy�saving and resource conservation.
Under such circumstances, its supply and demand, which may
be affected by availability trends of fenous scrap abroad, is
a growing concern. According to our forecast, there will be
a slight shortage in fiscal 1985 but a balanad supply and
demand will be possible by fiscal 1990. Though circulating
scrap generated from steelworks will dec,~rease due to improved
yields, capital and process scrap will increase as steel used
during the highgrowth period will turn into scrap. The domestic
supply as a whole is expected to increase.
d) Energy
Petroleum products: Japan's steel industry has been carrying
ouc energy-saving efforts for years. To deal with the unstable
oil supply and expected oil price increases, the indusiry will
further promote oil�free uperation and energy�saving programs.
In this light, the operation of blast furnaces without the use
of oil will be t'urther facilitated. Efforts to save fuel oil in
steel�rolling and power generation, and substitute them with
by-product gas will be stepped up. If these measures are
implemented on schedule, annual oil consumption of the
industry in the fiscal 1985-90 period will be lower than the
fiscal 1978 level despite a higher crude steel output. It is neces-
sary, however, ro take a flexible attitude toward replacing
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oil with coal and co implement this program in accordance
with further developments of the energy situation.
Electric power: The steel industry must prepare itself for
_ ats electric power shortage and rate increases anticipated in
_ tho future.
- Integrated steel works have been striving to improve the
rate of self-sufficiency by using the electric power generated
on the premises, by setting up on-site power stations jointly
with local power companies. and by applying blast furnace top
- pressure for power generation.
Parallel with these efforts, self�sufficiency will further be
encouraged by utilizing the gas generated by an increasuig
amount of coal in blast furnace operation aimed at oil-free
operation and by setting up small�scale waste gas recovery
systems.
Although no significant change is anticipated in the depend-
ence on the purchased power by electric furnace operators,
fuKther power saving will be achieved by this ;roup of steel-
makers by using recovered waste gases to melt down scrap.
To make these forecasts, we focused on demaild, resource
- and energy problems among various subjects that Japan's steel
industry will have to deai with in the 1980's. Other important
subjects including the stable supply of steel products, improve-
ment of management, the upgrading ot facilities, the develop-
- ment of new products, and the innovation of production
techniques were not taken into consideration.
COPYRIGHT: 1981 Fuji Marketing Research Co., Ltd.
CSO: 4120
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MOTOR OPERATION CONTRUL BY AN INVERTER
Tukyo TECHNOCRAT in English Vol 14, No 2, Feb 81 pp 48-51
[ Text ]
~ Since saving and more rational use of energy are among
the essential condiuons for industry to survive, neazly all
enterprises, factories, institutions are mafcing desperate efforts
to decrease power consumption. On the other hand, choice
- of a powor source is a problem because reduction or elimination
of labor and introduction of automation are in progcess
I simultaneously. And, to be considered as fialf3lling both
requirements, precise control of motor operadon is now being
higjtlighted in Japan.
Up to the present time, too, controlling the rotation-
al speed of motors has been made use of considerably.
Methods for this aze by d.c. systems, eddy-cunent coupling,
� and primary-voltage control. An advance in the techniques
of thyristor and transistor control, in addition to these, is
making it possible to use widely, an inverter for precise rota-
i tional control of a motor. [n the near future, the inverter
system will be replacing the ulder systems.
Power consumption by use of electric motors, in the field
of general industries, is said to amount to about 60% of all
that used. The rationalization of the use of e(ectricity for
electric motors is being taken up as a priority cause for saving
energy in enterprise management, with the view to cost
reduction and securing stable supplies of electrical power. And
; this tendency, it is considered,wiil bestrengthened even further.
- ~ There are three courses to advance the saving of energy in
I electric motor applications:
(1) Use of power saving type motors with small losses in
the motots .
- (2) More highly efficient operation by use of rationalizing
controi systems
(3) Optimization of shaE't output by reconsidering drive
capacity
It is necessary to establish an operational scheme for
analyzing and examining these comprehensively. (1) !s re-
presented by a power saving type motor with higher efficiency
than standard motors. (2) Is, in the case of driving a fluctuating
load, corresponding to variable�speed operation by a pole-
changing motor, a variable-speed motor, or an inverter device.
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One of these first attracted attention as the ideal drive
system for pumps of every kind, and blowers. This received
notice because such have wide applications throughout the
whole industry. As the yresent energy consumption for such
is lgrge, and there is a great possibility of attaining energy
energy saving.
Power consumption of pumps and blowers driven by
motors in Japan amounts to more than 150 billion kW a year
(a 1'attle over V3 trillion in power cost) equal to about a half
of industry's total power consumption. Therefore, it can be
said that it is extremely important to reduce the amount of
energy consumption in this sector.
On the other hand, devices such as pumps and blowErs
having variable loads, often controlled by valves, a dampers,
or vanes, which have been lised for many years to control
the flow of quantity, remarkable effect ou saving energy can
be had when controlling by variable speed rather than by an
a.c. motor driving at constant speed. Development of this
ldnd of drive system has been expected for a long timc.
The technique of converting an a.c. motor into a variable
speed motor not only fills the variable speed need for pumps
and blowers mentioned earlier, but also has greater merits,
even compared with conventional Ward-Leonard system using
a d.c. motor. And it is also a technique being developed with
intention of replacing d.c. systems by a.c. rystems.
As for use, it is being put to practical use for established
pumps in various classes to sevecal thousand kW, f~rst, mainly
in domestic steel, industries.
Cases of application have the following features: Operation
methods, like batch processing in plants as is often seen, and
the conversion to a variable-speed type drive has remarkable
effect in saving energy. As for equipment investment, many
cases with the term oi repayment in less than one year can
be seen, and, as for expoRing abroad, too, they have an
actual expoR record for large�sized variable-speed rystems,
with a capacity of 7,000h.p., used in the steel industry and
oil loading of pettoleum pipe�line systems.
Recently, pumps with capacities ranging from several
hundreds to 1,000kW also have been used, more in most
fields except for steel, as their permissible term of repayment
is prolonged.
And, while economical and high-performance control devi~es
using new elements, such as G-TR(giant transistor), etc.,
have been put to practical use for driving pumps and blowers
with small-to-medium capacity less than 100kW, this can
meet the comparatively small-scale demand in each field
and has come to be widely used as a mesure to save energy.
Further, as a variable-speed drive system for pumps and
blowers, there ars mechanical systems ssch as a liydraulic
coupling, gas-turbine drive, or diesel engine, besides electric
motors. But, the electric system has greater merit, in general,
in terms of maintenance, efficiency, and so on. While the
methvd best meeting the requirement of a plant isused,many
other restrictions are often imposed in the case of actual
applicatiun, reliability, and economical efficiency of electric
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- systems have been drastically improved recently, and the
application areas of this system is expanding.
An inverter is a device to convert d.c. into a.c., operates
variable�speed control by controlling the powei�source fra-
quency of the inverter motor. As it has merits of being main-
tenance�free and saving�power, and existing equipmsnt is
usable untouched, it has attracted the most interest and has
been utilized more frequently. It can be classified into
_ current-type and voltage�type, or into a thyristor system or
transistor system according to the conversion element.
Main features of an inverter control system are as follows:
(1) The speed can be changed continuously over a wide range.
- (2) It is excellent in maintenance and environment�resistance
- because it has no consumption parts like brushes.
(3) Synchronous motors can be operated and controlled
simultaneously with high accuracy.
(4) Various torque characteristics can be easily ob!ained
by changing the frequency and voltage.
' (5) High efficiency.
~ (6) High control performance in quick acceleration and
, deceleration running, four-quadrant running, and so on.
~ Voltage�type is cn3racterized by small internal impedance
~ viewed from the output terminals. lt needs a regenerative
; converter for electric power. Judging from its characteristics,
- ~ it is fit for the following cases:
~ (1) When one-directional running and sequential load start
are possible at uniform runnirg speed of large�sized motors
; or multiple motors.
I (2) When quick�response of control is not necessary in a
! motor under load and with small�to�medium capacity.
~ (3) In the case of continuous running with a high accuracy,
~ at an arbitrary frequency, in an open loop.
On ttte othe* hand, in the current�type, the direction of
input d.c. is constant and the output impedance is !arge. It
- i can be drived by a pair of converters, it does not need a
- ~ smoothing capacitor, and it can be small-sized and of light
~ weight. As four-quadrants running is possible (power regenera-
tIon is possible), wiiich is also a distinctive feature of this type.
It is suited for use with an induction motor.
Pulse�amplitude modulation(PAM) system has so far been
used as an output voltage control for constant-voltage type
i inverters. This is a system to control pulse width of the output
voltage waveform witli output of a square-wave inverter
~ circuit connected in series. It lias a good power factor for
input power source, is suited for large capacity installations,
_ and is leacling to adaptive control of the output voltage. But,
to obtain polyphase uutput, an inverter transformer and
separate inverter circuits for each device are necessary, and
' thcn control becomes complicated. It has also a defect
that higher harnionic components at low output become com-
- paratively large when the range of output voltage conitol is
wide.
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Table 1. a-c Variable-Speed Drive SYstems
Small Smsll-to-modlum Medium Mediurn-to�larye Larqe
Control
capacity capacity cspeei2% capacity capacity
U~es
fyst~m
Moto
3.7 5.0 10 22 46 50 tOQ 132 500 1,000 5,000 10,000(kW)
Trentistor
invertsr
V o Itspe-cy p�
POwef
(1:Nl
' thyrist0~
wvin9
(1:11
IM
invartar
Current-cYpe thyristor
inwrter
Th ristor uh.rbiu.
Medium-to-hiph
(1:1 )
SM
~
voltaye thyristor motor
i
i ;
i
Foreed commuta-
~
i ~
l
tton th rlstor motor
To remove these defects, pulse-width modulation control.
- (PWM) system has recently often been adopted. This is a
_ system to control the output voltage by on-0ff controlling,
plural in a multiple fashion, the main thyristor in one inverter
circuit. PWM needs no output transformer, and the power
factor is as good as with PAM. Further, the output capacity
is not limited, and it is suitable for small capacities, too.
However, since an increase in higher harmonics depends on
a choice of the onoff control system of modulation frequency,
makers are developing PWMI system inverters, each based on
= their original technique.
- The vector control system, which can control a cage-
induction motor on equal terr.ms with a d.c. motor, has
become the subject of much discussion in recent years.
Separating primary current into the field current component
and torque current component, it controls two components
segarately and transmits their resultant vector to the motor.
It can be applied in the field where usual d.c. motors have
been used, it makes possible severe running of reversible
regeneration, field control, torque control, and very quick-
response control. Furthermore, ather advartages of this system
are: goad protection, high efficiency, capacity easily tQ be
- made larger, and the moment of inertia of the motor to be
made smaller. While it is now applied in paper machine lines
and steel rolling mills, it is likely to be more widely spread
from large capacity motors to small ones.
Development of a thyristor and a transistor, which are
used as the power element for an inverter, also makes large
contributions to spread of the inverter system. A thyristor
is a semiconductor that can control and operate quickly a
high-voltage and large-power circuit by a small gate signai.
Then it plays an important role in variable-speed motor
systems, too. A thyristor inverter has been used, with its
- characteristics put to a good use, for some time now in the
industrial field. Develc7ind GTO (gate turnoff thyristor) and
making it highly efiicient are supposed to extend further
control capacity of a thyristor inverter and the range of
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applications. Once usual thynstors are turned off, they cannot
be turned on by a controlling gate. As for GTO, it can be
_ turned off by a curnnt flow of inverse direction, which
makes possible high-speed switching. Thyristors are adopted
meWy from the viewpoint of struccure and price, in inverters
controlling for a capacicy from medium to !arge systems.
Hence, circuits will be made simpler and more highty efficient.
Demand for inverters using trat.;istors, as smallwapacity
variable�speed systems for general purpose, has suddenly
_ increased. Owing to development of G�TR (giant transistor),
etc., the inverter system is becoming much smaller and lighter,
~ with high-speed switching characteristics put to use and PWM
system adopted. It costs less than a thyristor system, and
! is also quite reliable. Parts of circuits are becoming a unit,
_ i and maintenance and examination are facilitated. This transistor
system is considered to be spread widely th.roughout the
~ entire industrial field, where variable�speed cvntrol has not
~ been possible until now.
Ex. 1. Examples of Saving Power by an inverter
(ttie method of calculation)
Thn� ar� meehsnbms of vuious kind� aiminp at saviny
power by usfng an inverce. Lot us tske e blower, whow ulculs-
tfon mothod is eimple, as a peneral sxample. Thi followinp
relationi are ueually found with a blower:
(1) Airflow is proportionsl to the number of revolut(onf.
(2) Preaura is proportional to the puare of th� number of
revolutions.
(3) Shaft power is proportionsl to th� cub� of number of
revolutlona.
Thet it to uy, when only 80% airflow is neeafsary, 80'X,
velocity and about 30% (chs cub� of 0.8) shafc ppwer ere
suHicient. In the "mo way, es e 50% alrflow, 50l4 velocity and
12.596 power ire enouyh.
As tor damper control, sheft power ean be dsereered only by
3594 at the moa, even when it is cotally enclowd. Thorefors,
no Iou then 82.5% of ths shaft powsr, the sum of a half of 35%
and 669G, is nqufred to rWuce the sirflow to half.
(A) Caae of 100% Continuous Runninq
Annual powsr consumption - 19.4 million kWh
Annuel power rate - M29.1 mlllion
Economy of electric power . 0
(8) CaW of Dampsr Convol
i Annusl power eonsumpt(on . 17.52 million kWh
Annual power rots . 1026.28 million�
! Economy of olectric power . M2,82 million
(C) Cese of Invsrter Control
Annuel power contumption . 13.70 million kWh
Annuel powar rats .V20.55 millfon ysn
Economy of eisctric power . V8.55 mi:lmn
[Noce] 300