" C " SHIFT

   Changed out the belt on the molding sander- the one they’re using for rework.

 

  MP-2   Installed a new bit in the belt door screw gun.

 

 Made up a new extension cord for the fan tester – don’t know were they all go !

 

 MP-17 They shut the press down for awhile, so I put new o-rings in all the directional valves on the block on the clamp end “ AGAIN “

 

 Still Troubleshooting the dryer in the shop – it seems to be cycling correctly, but it is still over heating when it shifts beds. I may need to call for

    tech. assistance  Monday.  

3.12.10 D shift

Mp#13- stopped and they were saying that the clamp was opening past its setpoint causing the ejectors to malfunction. After closer inspection, found that the ejector plate in the mold was bound up. We greased the plate and pins, and after coersion, we got it moving and up and running again. It did it one more time before the end of the shift.

Continued with P.M.'s

Sean

March 11, 2010

MP24 – Started up the machine and the top core cylinder would not pull with 2000psi.  Lowered the thermolator temp to 120 degrees.  Increased cycle time to 36 seconds.  Lowered the pack and hold pressure to 350psi.  Went from 12 sec on cooling time to 16 sec.  Fred came out and looked at the mold and saw the top core was dragging on its way out, he also noticed that it was very dry.  He sprayed a healthy dose of injector rod lube in and around both cores.  The cores have pulled ever since.  Something was binding in the top core tooling.  To Temporarily solve the core push back problem on injection we changed the sequence to # 3 and set the cores first to allow time for cores to fully pressurize, added a sprue break function, and used a relay to break the output to the core set, using the n/c contacts,.to capture full pressure against the cores.  The input for inject unit forward confirmed, 137, is used to energize the relay and remove power to the valve prior to inject.  Clamp high pressure might be a better choice if a mold can’t use a sprue break but n/o contacts would have to be utilized, I believe the high pressure switch is signal off when tonnage is achieved.

 

MP10 – Branson 910 Sonic Welder – Worked on it off and on last two days.  This is what I have learned.  Alignment is critical, the horn should push evenly around the part flange and bottom surface should be parallel with the part flange.  Adjusted the stroke so that it would travel far enough to weld but not far enough so the horn would bottom out on the lower part if the top part was missing.  Slowed the down speed so the other controls and settings had time to react.  Reduced the down pressure to 20psi.  Increased the trigger pressure setting to 6, to allow time for our flimsy top part to settle, before welding.  Tuned the Sonics by depressing the test push button for 5 seconds, then while holding the test button in, adjusted the trim pot above to read the lowest digital number on the read out.  Here’s where settings ended up:  Weld Time was at 2.000, Hold Time was at .300, AB Delay was at .050, AB Time was at .050.  We may have power supply issues since we can’t seem to get the settings back to original.  I was informed today, as of September of this year, Branson will no longer support this piece of equipment because of obsolescence. 

 

MP17 seems to be leaking from everywhere and sooner or later we will have to deal with it.

 

The Eagle baseplate mold is back and needs to be plumbed and wired.  I will start with the plumbing and see how far I can get.

 

Thanks and have nice day,  any questions please don’t hesitate to call.  3/11/10.

 

Mark McKee

Technical Specialist

Oreck Manufacturing Company

1400 Salem Rd

Cookeville,  TN  38506

mmckee@oreck.com

PH      931.646.7856

CELL  931.644.5289

FAX    931.646.7851

 

MP24

I worked on the core problem on the new cord dump mold in MP24 for a while last night. The problem we were having was with core pull in automatic sequence. After the cooling time, the cores would try to pull but only one would. We had to put the machine in manual cycle and wait. After about 30 to 45 seconds you could set the cores again then pull them. If you tried to just pull them, it wouldn't work. I checked the pressure on the set and pull side of the cores and it was reading around 2000psi. I verified that the set side pressure was dropping to zero before the pull side was energized. We then dry cycled the press without parts and the problem didn't occur. Since having parts in the mold was required to cause the problem, we tried decreasing the injection time. We had the injection time down fro 5 to 3.2 seconds. And even until the parts were short-shots and still no luck. We turned the front half of the mold down from 150 to 100 degrees and then tried increasing the cooling time from 12 to 30 seconds without any change.

Mark is going to try and turn the core pressure down to 1000psi to see if maybe the core or cylinder is sticking it the set position. The mold ran fine when it only had around 250 or 300psi on the cores but the core was being pushed back. I talked to Charlie on B shift and he said when he ran the sample run in MP17 he had the same problem with the core being pressed back but was able to process it out by decreasing his pack pressure. He said he only ran a couple hundred in single cycle though.

If turning the pressure down fixes the problem, we may have to take a closer look at the cylinders or whatever is causing the cores to stick so it will be able to run in other presses without modifying the pressure each time.

Collin

3.9.10 nights D shift

Mp#24- Gary, Collin, Ronnie, and myself looked at it. The problem communicated to me was that the cores were bleeding back and there was no core pressure in automatic cycle.

After looking at it further, we determined that the cores were locking into "system" pressure in automatic (as we compared test results from press #8) but not in manual.

In manual we were seeing "set system pressure" as what was set on the controller (85%) etc. 2000 psi. When watching it in automatic, parts were filling out at 400psi so that is all the cores were getting.

When Mark and I tricked out the machine this morning so that settings for inject were higher, we had 1800 inject prs and core prs likewise.

Because the only cavity with the "bledback" effect on it was Cav#2, I had to rule that there was probably an issue with the mold fit. Possibly in the core linkages for the affected cavity. Gil looked at it as well and agreed.

other than that, worked on P.M.'s the rest of the night. See work orders for details.

Submitted PTO for Thursday- April 29, 2010.

Going on California trip.

Sean

Sean

3.8.10 nights D shift

Mp#23- finished installing the remote E-stop disconnect. Checked it.

Also labelled 480 panel and receptacles on press#22.

MP#3- material hopper kept calling even though it was full, changed sensor and corrected problem.

Repaired both thermolators that were red tagged outside the shop.

Replaced the flex conduit on press#6 for the yellow alarm light. It was damaged and exposing wires.

Will continue with PM,s tomorrow as well.

Sean

" C " SHIFT

 MP-24  Made up adapter box for core plugs.

 

 MP-11  Single cav. top cover mold leaking @ core pull sensor – it was loose. The leak that is filling up the jug is coming from the clamp seal.

 

 MP-17  The oil recycle pump burned up; pan overflowed.  Replaced pump & left cover off until it fills up to see if it needs to be primed.

 

 Got part numbers & prices for clamp seals on MP-11 & inj. seals on MP-25 – filled out purchase req.

 

 

       R.UPCHURCH

       MOLDING MAINT.

3/7/10

DR17 on MP20 regen heaters were not working. Two of the three elements were bad. I took the last one from MRO and found one in the molding nonstock parts in MRO.

Replaced two broken DME heater connections on a mold pulled tonight.

Fixed the feed-throat water on MP13

Collin