12.30.11- D-shift Sean

Mp#15- Motor coupling had a catastrphic failure and will need replaced. I removed the coupling and inspected the motor shaft and the pump shaft. Both are in good shape, pump is not locked up and moves freely. It simply appears that the coupling has worn out over time. It is laying in the shop on next to the vise. We need to order one when you read this Josh, Mark or Ronnie. They are running part number 09-79048-03 (Fascia w/ pad print) and the mold is closed up. I advised Roger that the clamp could be opened with a portapower if he needed to pull out the tool to run else where, but he said it was not necessary. I looked it MRO and did not locate another Coupling.

Have a happy new year. Keep it between the lines!

Sean

12.27.11 D-shift Sean

Dryer DR-10 on the mezzanine had low regen temp alarm. Found bad heaters and replaced them.

Mp#-24 had a leaking hydraulic hose on the core line fitting. Tightened it up, stopped the leak.

The Fan housing press with fan seal verification is ready to be cheked out and make the final adjustments to it. It should be ready to use on Friday.

Give me a call if there are any questions, Thanks.

Sean

12.16.11 D-shift Sean

Mp#7- The ejector bar studs broke and he could not get the plate to retract completely, checked it out and found the nut with the broken stud peice was lodged under the plate. Freed it and got it working again. Also noticed the ejector back switch was broken. I replaced it and checked operation.

Pump#5 Loading system- The surge bins #1 and #2 ran out of material. The pneumatic loading valve malfunctioned, solenoid valve bad. I replaced the whole thing so they could restore operations as quickly as possible. Need to re-order the solenoid valve and a spare.

Mp#26- The ejector were not working correctly. Found that the ejector plate of the mold was jammed up. Put some chain lube spray grease on it and adjusted them correctly. Restarted for production.

Continued with Pm's on press #24.

Also began changing the fan housing press to sensors and finishing it up. The Turck sensor vending machine screwed up when delivering the cables. It will still work on other items though. Maybe Elaine or vendor can get it straightened out soon.

Have a nice day.

Sean

12.12.11 D-shift Sean

Mp#21- Pm'd press and robot. Replaced the sled forward position limit switch. Mark had mentioned it was screwed up awhile back. There was a direct replacement for it in MRO in the aisle with assembly's prox switches etc.

Order?**The star robot pendant "control" pushbutton switch on the side has a rubber cover that is now worn out or worn off. May try to see if Star sells the rubber grommet type cover by itself and get a few of them?

11-29-11 D-shift Sean

11-29-11 D-shift Sean

11.28.11- D-shift Sean

Mp#5- Finished re-installing the core on Mold#77041-top cover tool. When I checked it out, the core switch on the "pull" side was not working. Had to cut it out to remove the bad switch and installed a new one from mro. Checked operation for leaks and performance, turned it over to techs at 8pm, who started it a little after 12:30.

Mp#12- The core box on the press had not been standardized yet and they were in a hurry to start it up, rigged it up with an adapter to accomodate the ejector back limit switch, etc.
Need to complete the install correctly when the press is available.

Mp#7- Collar mold cores jammed up again, tested the hydraulics with the test cylinder and it worked fine. Advised that they pull the tool at 2am.

Continued working out the mechanics and design ideas for the fan press poke yoke project. Building parts and gathering up components still. Looked again for the plc that was there the other day, could not locate it, found another in the cabinet that I can make work.
Quick thought:
Mark had mentioned once that OSHA did not recognize the use of plc logic for anti-tie down safety switches, however, they were using them this way on those test fixtures that we tore down the other day. Need to know if I can do that or not with this project, if not: will need a safety relay.

11.18.11 - D-shift

MP#17- They set that mold that needed to run with cores tonight, then pulled it out after I told them it could not run in there yet.

Do we need to wire in air eject or cores for this machine?

I was not certain as to what was decided as far as that goes, but I thought that Josh was going to have them install air cylinders on the tool.

Please let me know what we need to do so as not to attempt any rigging unauthorized!

What are we going to tie into? Air? Core 1? etc. Need a control switch installed? Is there outputs assigned? Software ready for it?

Roger put me on the spot with it and I wasn't really sure what to tell him so give me a call later or talk to Ronnie today so I can pick up where he leaves off today. Thanks.

Also got the cav 2 gate cutter disassembled, the intake test fixture disassembled, the air ten gate cutter stell table stripped down, and the welder table disassembled and palletized.

Saved the opto switches for the fan hsg assy project and plc from intake tester.

Sean

11.15.11- Sean

Mp#20- Put on a nozzle heater band.

Mp#1- They set a mold in the press that was too short for the daylight again. Roger requested that I make up some spacer bars to bolt onto the moving platen so it could be installed.
I drilled and marked them with "Caution" and put threaded 1/2" holes on top so they could be moved with lifting rings or eye bolts.

It was late before he got it set so I was only able to clean the outside of the press and around it .
I noticed the lube oil line is broken on the non-operator side skate and I could not locate any fittings with ferules for that tubing.

I did replace the grease tube and noticed that we are running very low on that grease, especially now that we have 2 presses, we should order some more for them.

Mp#10- replaced missing screws from the nut feeder tracks and unstuck a screw that had found its way into it.

Have a nice day.

Sean

11.6.11-Weekend...Sean

Mp#7- The water manifolds to the feedthroat are rusted out and dripping water. They are running the press but when it goes down it will need re-done. Probably need to cut the manifold out and throw it away.
The sled cylinder is leaking pretty good on it also. Need to get a replacement seal kit.

Mp#17- Ronnie and I continued working on it this weekend. As Josh and I discussed setting the dip switch to enable the "shifted key boards" , I looked at presses #1 and #23. The boards are different from each other and a different dip switch has been left on each one.
Press#1 has dip 1 switch #3 on
Press#23 has dip 1 switch #2 on
With this information, I decided to wait and lets just ask Nissei.

Another issue came up when we decided to run it. Not so sure if it is a safety issue but needs to be pointed out.
In semi-override mode- after making parts cycle, with door open after a few seconds, due to mold spring tension against ejectors, the plate drifts backward and an alarm for "Ejector Axis Overload" occurs.
I was asked If there is a way to set ejectors to stop in the "back" position after 1 or more strokes so the pins stay back before the operator opens the door?
I couldn't see a way to do that within the process parameters so this is a question that nissei may have an answer to? Let me know if you find anything out please.

Mp#23- operator side skate on the moving platen is broken. When it is down again, I will try to remove it and measure it out and make another one...or we can just order one?

Mp#1- replaced the cover from the back of the injection unit... don't know how or why it came off?

Have a great day...give me a call if there is anything on your mind.

Sean

11.1.11

MP#6-
Baseplate presses messed up tonight. I had to borrow the booster from one and put it on the other so they could run the poly carb. The one in the shop needs the regulator replaced on the booster, I could not find one. It also needs an air cylinder for the fixture shuttle. I could not locate one of those either. Need to order the parts to repair the booster and replacement cylinder.

Mp#9- The conveyor belt came off track enough to stop working. Re-tracked it but have not tightened it up yet as it needs to be checked again over the next few days...keep an eye on it please Mike or Gary.

New Hopper in the shop has the bottom feed tube done. Needs the loader installed and a threaded pipe cap put back on the drain.

Ronnie found a bed motor for that 200lb dryer that is tagged out. If no one gets to it over the next couple of days I will on Friday.

Give me a call if you need me to come in or just want to bs.

Sean

10.23.11 D-shift Weekend...Sean

Mp#1- replaced heaterband and thermocouple on the nozzle. Also constructed an end of arm tool for the canister filter cover. Labelled it on the tool but have not updated the location sheet in EOAT storage area.
Also built one for the D-grip overmold tool.

Mp#3- Nozzle solid state relay went bad. Replaced it and a fuse. Checked operation, O.K. to run.

Mp# 22- assisted the process technician Roy Smith with setting up and programming the slider mold. Although he programmed it well, he did not save the program to the memory in the controller so he will have to reprogram again the next time it goes in.

Small grinder in the shop-
Started working on the small grinder, broke the end plate on the rotor. I built another one on sunday and got it put on the rotor but haven't finished putting it back together yet.

Large grinder in the shop, looked at attempting to dis-assemble the rotor. We can probably turn the shaft down after breaking the sections apart?

DR16- Has a bad index motor, looks like the gear oil has leaked out all over the carousel. It is shot.
We do not have any in MRO. There are (4) 100 lb per hour dryer motors in there but none for the 200lb per/hr dryers.
It is a dayton brand, should be an old PR for them somewhere.

Have a nice day, give me a call if you need anything.

Sean

10.18.11 D-shift Sean

Continued with PM's.

Mp#4- They set the Top cover mold in and Ronnie had just put the core switch in. It was not adjusted yet and there were several other core wire related problems. I repaired wires and adjusted the switch until all was working correctly. O.K. to run.

Mp#22- Worked with the process tech Roy Smith to set up the edge valve body to run on the robot.
I fabricated a tool arm for mold #74008 and walked him through programing each step, then copying the "takeout only fascia" and renaming it 74008 valve body, then saving it again after the changes to the program were made. It is saved under the "takeout only" folder in slot #9.

Give me a call if there are any questions or you need to share anything with me.

I will return on Friday! Have a great day!

Sean

10.17.11 D-shift Sean

Mp#20- The hot stamp was losing heat control and dropping temperature. Ronnie had looked at it and checked most everything and I went over it further and really did not see any bad components initially. I went ahead and replaced the thermocouple but that did not solve the problem. I ended up putting the nest for the parts they were running on another hot stamp press so they could continue the production run.

Mp#1- They set a new tool in today and the locator ring on the press appeared to have been smashed a little too much to set the tool in. I turned it out on the lathe a little so he could put the tool in, but it needs to be replaced. If we already have one?, somebody leave it out so we can get that in whenever it is between changes.

The dryer behind press#8 (New Nova Tech) has been stopping 4 or 5 times tonight. The material handler said he had just been restarting it. It was alarming for "RIN - Over". I asked him if it was recovering on its own and he said he didnt really know. I will get with Ronnie about that before I leave.

The fans they are running on press#12 have hairs from the vibratory weld flash. They have been using pieces of rubber to de-flash the parting line area. The operators and team leaders have been coming to maintenance requesting rubber for this purpose. I directed them to MRO, but the type of rubber they are using is not found in MRO...so, I kept a piece of it (all that I could find left) and left it on my tool cart for a sample if anyone goes to get more at IRG or somewhere? I asked Roger to fill out a stock item request for it and that aluminum foil tape they use everywhere in molding. That is not in MRO either.

 The notes for the PLC program on the connector tester are on the tablet on my tool cart and there is a back up program with commentary markup in the maintenance plc programs folder also.

Give me a call if you have any questions.

Sean

10.13.11 D-shift Sean

Mp#25- had a bleedoff back to the first band. Replaced all of the heaterbands on the nozzle and endcap after removing the plastic. It was likely caused from the temp controller being set to "manual" mode and running over setpoint because I put everything back on and when I turned it back on it was in manual and ran up to 713 degrees when I checked it.

Mp#18- They were grinding mixed colors of abs to run the intake pivots and there was lots of tramp metal getting into the barrel. Had to remove the endcap and clean it out. I examined the screwtip and it appeared to be worn and of the OEM castle ring style tips. I did not locate one in MRO or anywhere so we probably need to order one and get it on. We can order a brody ring style tip instead of purchasing a new barrel temporarily, or just try to put another stock tip in it again? It is a 60mm.
It is running now so ??

Mp#3- Replaced the injection cylinder shaft seal on the operator side. Bill shut it down when I came in Thursday and it took about an hr and a half. Running good with no leaks now. We have 3 more gland/seals in stock.

Also had another grinder clog up at 18, the screen got bent pretty bad. There was not another large screen for the big rapids in MRO so it would be a good idea to order another replacement.

Also there is a small rapid in the shop with bearings down. Ronnie was going to order bearings for it (I think?), if not we need a pair of bearing for it as well to finish that repair.

Reminder also, #1 needs the belts replaced, I am have not heard where we are at with that.?

Give me a call if there are any questions and have a nice day.

Sean

10.4.11 D-shift Sean

Continued with PM's and oil cleanups.

MP#12-

The F1 fan housing was welding so good that it was passing the destructive test so much that even excessive pressure would not separate the two halves to remove the test insert parts. Potter told them to bang the parts on the ground to bust them open, after a several hours of this, they asked me to see what other method could work to separate the halves.

I put the smaller arbor press from the maintenance shop back there so they could use it as a "nut cracker" to separate the fan housing. At least it is safer than slamming them on the ground as parts were flying wildly as the insert shot out of the fan when it broke.

Josh may want to have Walter take a look at what they are doing when they test them and provide some feedback on constructing something more permanent to remove the insert after testing since they test every 30 minutes when it is running production.

Be back on friday evening, keep me in the loop!

Sean

10.3.11 D-shift Sean

Mp#8- Lost pressure to the End of arm tool "Kick" cylinders. Ended up replacing them both and a gripper bracket. Also replaced a broken air fitting on the valve body up on the robot itself. Tightened up the Y-axis screws that hold the primary and secondary arms together. O.k. to run, but was down several hours while Gary Hunt and I worked on it.

Will re-do the spare arm for the fan housing today. It was in the cabinet but was missing several parts.

Loading system had problems loading the surge bins from the silos. Found several problems related to loss of vacuum from air leaks and bad seals. Corrected the issues and everything is loading fine again.

Have a nice day.

Sean

9.29.11- D-shift...Sean

Mp#4- Repaired the oil leak on the Filter. Had to replace o-ring on fitting and sealed up with indian head. Checked for leaks, O.K. to run.

Mp#5- Robot has stopped a once over the conveyor. Has not stopped since I adjusted speeds.

Continued with PM's and helped with processing some. Most of the presses that needed PM'd were running but worked on what was down. This has been reflective of the past few months.

Have a good weekend. Give me a call ...

Sean

9.24-25.11 Weekend...D-shift

Continued with PM's.

I noticed that many of the C-axis parts on the AEC robots have reached a point where they need rebuilt.
I looked up the components in the book that will need replaced and found the website and number to get a quote. I would recommend getting (6-10) each to begin replacing them and make them stock items until we replace the robots.

Additionally, we should consider the option of setting up a "rebuild kit" for the Y-axis arms. We could take the Y-arms down, replace bearings, belt, and aluminum extrusions as needed.
We could begin with (1) "kit" and try to trickle them in one a month or so?...Just a thought.

Here is the link to the AEC website where the parts number is, etc.
I left a copy of the part numbers and diagram on Joshs' desk.
http://www.aecinternet.com/index.cfm/datakey/3/category/Parts%20%26%20Service/subcategory/Parts/productID/1632.html

Also, had some trouble with the nutpress on #10 LH side. I ended up cutting more clearance in the small cover plate so they could pass through easier. It has ran great since.

MP#1- I noticed the ejector axis servo drive belt is damaged. It is still functional, but needs replaced.
Since we had that trouble with the belt on the clamp axis we may want to either schedule Nissei in to look at them both or order the belts, etc?

Give me a call if there are any questions, or leave me a blog so I will know what's been going on.

I never heard if the static charger was bad or what was done to resolve the issue Gary mentioned last Wednesday?

Thanks,

Sean

9.14.11 D-shift Sean

Continued with PM's.

Rebuilt several of the heat guns tonight.

Cleaned out all the water strainers on the presses. They were not as bad as usual this time.

Added some oil to MP#8 about 15 gallons. It appeared there had been a leak on the machine. I cleaned up the oil around the clamp and beside the press when they shut it down.

Have a nice day!

Sean

Mp#4- Error 00047 problem.
For some reason the machine is rebooting and stopping in level 1. When powered down it usually comes up alright. Tonight I looked into it and found a red LED fault on slot 5 output card. After checking everything in the circuit, I found no problem with it, it just will not clear. That turned out to be unrelated to the more immediate problem. For that I tried the power supply that was in MRO and it DID NOT WORK at all. So, I put the old one back in. It has not stopped anymore in the last 9 hours it has been running so it may have been a loose connection in the power supply or card cage.??

Continued with #15 , finished drilling the holes on the stationary platen, got all but 10 tapped (by hand was the fast apparent way). Will continue on further tonight.

Have a great day.

Sean

8.23.11 D-shift Sean

Mp#11- Core not setting when the clamp closes. Cores appeared to be working correctly manually. Replaced the core switch and cable that appeared damaged. Problem still persisted, it would stop about every ten shots. Finally slowed the clamp down and adjusted the core cylinder flow controls until it began running without stopping. Evidently it was a process issue and not a mechanical problem.

Worked out the BOM and electrical diagram for the Temp Control Modification to the Milacron machines. Giving the copy to Mark Mckee.

Call if there are any questions.

Sean

8.18.11 D-shift Sean

Continued with PM's. Worked on Press#21 most of the night.

Was able to build one good liquid color pump from those that were torn up in shop. Right now there are 3 with bad control boards, 1 of those is probably toast but it might still be sent off for repair. I am guessing that most of them have had water in them or been dropped really hard. I put them back near the welding table for now, will continue to salvage them for parts as needed.

Have a good weekend, call if you have any questions.

Sean

8.17.11 D-shift Sean

MP#2- Zone #3 - (10p.m.)dropped out. Checked the circuit, it was good. Mercury relay appeared to be magnetized. Pecked on it, it resumed heating, no further problems.

Mp#20- The part drop tray under press needed an angle board to divert the parts towards the operator. The original plexiglas part had broken. Used it for a template and constructed a new one from Aluminum sheet, transfered the handles to it and installed.

Continued with PM's on presses 13 and 14 tonight, and painted some on the gray presses.

Call if there are any questions.

Sean

8.12-14.11 Weekend D-shift Sean

The conveyor in the shop needs a belt, I looked in MRO for another one but could not locate any.

I was able to find a pdf on the servo controllers/ servo motors in press# 22. There is some software available that assists in tuning and parameter adjustments of the drivers called Panaterm. There appeared to be some ways within the drivers to change response profiles on velocity and positions, etc. as well as look at actual values while it is running.
Since it did run fine all weekend without loosing position values , I would assume that this problem is, in fact, related to the static issue.?

Worked on PM's all weekend.
Mp#10 and #7. Painted on #7.

Installed the track sensor and adjusted operation for the connector nut press on #10. It is fit to run.

The overhead water pipes have been banging around all weekend, Jeremy and Ronnie were in here looking at them on saturday, my guess is that it is air in the lines? I told Roger to send out an email to Walter about it.

Have a nice day, call if there are any questions.

Sean

8.8.11 D-shift Sean

Mp#3- replaced the oil filter. Cleaned the oil filter clog sensor. Installed both strainers and cleaned tank with rags some more. It is ready to refill ,etc.

Assisted process techs some tonight.

Continued with PM's.

Sean

7.31.11 D-shift Sean

Worked on the Milacron dryer again, I found a loose connection on the control board, one of the IC chips was not seated very well. Reconnected and ran for a few hours without further problems.

Have a great day.

Sean

7.30.11 D-shift ...Sean

Mp#3- FHD current #1 alarm, found pump overload tripped, reset it and checked operation.

Mp#10- Nut press was not vibrating. Found sensor on RH side is bad, lens on it appears to be etched from solvent and will not focus now. I could not locate a replacement in MRO, so we may need to order a new one. Tricked it out so that it will still run from the LH side only. Posted a reminder on the PM board also.

Continued with PM.

MP#1- still running, will install the temp switch in the tank on auxilliary hydraulic power unit when it goes down next. I posted a reminder on the PM board in case A or B shift catch it down next.

Call if there are any questions. Have a nice day.

Sean

7.26.11 D-shift sean

Mp#5- Tank cleaned out, filter changed, and filter-clog sensor cleaned out. Ready to refill.

Continued with PM's.

Mp#25- needs a hose on back of clamp. I will submit measurements for it on Friday.

Call if there are any questions.

Have a good day.

Sean

7.20.11 D-shift Sean

Mp#2- Power supply in 486 controller quit working. I put the one out of press#4 in it and it has been running fine. The one from MRO did not work. I also tried it in#4 and it did not work either, the 12v shuts down after a few minutes with power applied to it.

GR#1 - replaced the rotating knives and the bed knives. Checked operation at press #5, O.K. to run.

The auxilliary hydraulic core unit for MP#1 got really hot so I shut it down to cool off, Mark is looking for the schematics for it, likely something is not relieving properly.

Sean

Saturday July 16, 2011 D-shift

The grinder on press #12 had the blades rubbing when I came in. I adjusted the bottom stationary blade. Checked operation, O.K. to run.

Cleaned out all of the robot control cabinets and replaced the raceway covers inside.

Continued working on PM's most of the night. Cleaned up oil under #8- it just looked like it had been there under the clamp a long time, not leaking anywhere. Painted the area around the valves, under the clamp.

Have a great day!

Sean

6.18.11 weekend D-shift Sean

Mp#4- Steemer Nozzle Body Mold
Had problems with the core 1 set limit flag being missing, not allowing sensor to pick up the set position. No way to fix it right without pulling out the mold. I made a tooling work order and posted it on the machine. Advised the technicians to use the timers or pull it out. They later had trouble with the part sticking in the front of the mold and thought it was the core not pulling completely. I was able to process it to where it stopped sticking for the most part. Gil looked at it and said they would get to it when itcame out.

Vacuumed up oil and cleaned up oil that was on the floor around the presses. Continued with PM's. Cleaned up in the shop also.

Installed several more of the lockout mechanisms for the pump motor E-stop switches. Only have about 3 or 4 left to do now.

We are shutting down at 6am Saturday morning due to the schedule change. Give me a call or send me a message if you need me in an extra day this week, otherwise see you Wednesday.

Sean

6.13.11 D-shift... Sean

Mp#2- Runaway nozzle temp. Mercury contactor looked like it had been pushed sideways some. I straightened it up, no further problems, but, I did look in MRO for another solid state relay to replace the contactor and did not find anymore.

Mp#4- replaced 24V4 fuse, Jason said that it got blown during a mold change, inspected it and found no smashed wires or anything.

Worked on PM's and changed out some of the E-stop switches to add the lockout feature for Walter.

They were running MP#3 so I could not continue with the current sensor installation.

Call if there are any questions. Have a nice day.

Sean

5.22.11 D-shift Sean

Mp#10-
Worked on the nut press for the connector. The nuts that were loaded into it were oily and I had to tear it down and clean everything. It may still need some minor adjusting where the track runs into the press on the right side.

Continued with PM's.
I have been cleaning the water filter screens out, they are very dirty right now.

Have a great day.

Sean

5.21.11 D-shift Sean

Mp#11- Replaced the A-axis sensors an wired them in, found where A-home had also been jumped in the cabinet. Put it back correctly and checked it out thoroughly, good to go now. Not that we use the A- axis much, but recently we could be using it to separate parts with two sides, etc.
The guide-rod under the clamp cylinder came off, just needs to be put back on when it goes down again.

Bill said one of the loading system pumps gave them trouble today, gasket got sucked out causing lost suction on press 18.

Mp#1- Extruder started messing up and tripping the servo alarm. Took the panels off and discovered the lube had run dry although the grease tube holder appeared to have grease, it was not compressed by the spring. I replaced it and also had to clean out the screw threads and regrease them by hand. Got everything working again and then shot every fitting full of grease I could find. O.K. to run.

Note: The process techs or whoever cleans out the hoppers needs to stop blowing dust and material all over #1. It had plastic worked into the ball screw threads so bad it looked like teflon tape. It has not been that long since I cleaned it out last time.

Replaced the nozzle band on #21 at the techs request.

Mp#2- Zone 3 quit heating. Checked heater bands, thermocuople, found that the wire to the coil on the mercury contactor was loose. Tightened it up and checked operation, no further problems.

Have a nice day.

Sean

May 9, 2011

May 9, 2011

 

Worked with Gary on part present sensors for R2 Facia

 

MP1 clamp making noise removed guards at the end of machine, found broken screws in motor gear, gear had slid, belt hanging off, removed broken screws, pulled gear back in place, tighten bolts, greased all fittings on that end, replaced guards, looks OK

 

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    931.646.7615

 

Week of May 2nd, 2011

Week of May 2nd , 2011

Replaced FHD board and pressure transducer on MP5.

Rebuilt sled cylinder on MP20.

Ran High Voltage lines on MP22 product arm. Provide means for easily
disconnecting EOAT on insert side.

Valves for Mezanine purge valves are on table.

Conair dryer push button touch pad is on table.

MP24 was faulted and would not clear the error. Ended up switching from
manual to auto and back and then reset cleared.

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 931.646.7615

test

 

 

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    931.646.7615

 

5.03.11 D-shift

MP#20- Changed out all 3 heater bands on the nozzle. Nozzle bleeding back at sprue after just a few shots.

I changed the sled pressure sensor and adjusted it. Still continued to bleed back. Changed the nozzle tip out and checked alignment, had problems where the shims had come out.

I made some new ones with the material we had in the molding projects cabinet. Put them on, adjusted sled alignment again, checked operation, appears to be doing fine now.

Mp#4- Repaired wires on Core 2. Replaced the entire cable which was too short anyway on the Steemer Nozzle Mold.

Continued with PM's.

Call if there any questions.

4.23.11 Weekend D-shift Sean

Mp#5- has some problems with the clamp. When it opens it opens as though tonnage pressure has not be released well and it slams open shaking the entire press, enough to cause the robot to loose control power briefly.

Mp#20- Changed out a nozzle heater band and repaired a T/C connection.

Worked on the R2 Fascia Project some more. It is now on the table in the shop.

Cleaned up the shop and put some new tape on the floor in places. Took out the trash, etc.

Have a great Easter Weekend! Call if there are questions.


Sean

4-19-11(Mike Daniels)

Changed contactor on mp21 front zone.

 

Mp6 adjusted clippers on eoat they where gouging part.

 

Mp1 stopped a few times with a inj. Axis overload (overheat) alarm. Found bad fan in control cabinet replaced it haven’t had anymore problems from it.

 

Assisted techs.

 

Mike Daniels

Technical Specialist

Oreck Manufacturing

1400 Salem Rd

Cookeville,  TN  38506

Cell 931.287.6252

 

Eat. Sleep. Fish.

 

4-18-11

Mp16 removed nozzle tip and adapter because it was leaking between the two. Cleaned and milled surfaces and reinstalled.

 

Worked on PMs

 

Swept shop

 

Mike Daniels

Technical Specialist

Oreck Manufacturing

1400 Salem Rd

Cookeville,  TN  38506

Cell 931.287.6252

 

Eat. Sleep. Fish.

 

Ronnie Upchurch

MP-3  Replaced one rear zone heater band & nozzle tip band.

 

MRO-  Sorted out parts on west end shelves- ( non stock items ). Made some of them stock items, Moved some to trailer, & threw the rest out.

 

MP-7  The nozzle contactor may be about to go out. Tech called me to the press & said the nozzle wouldn’t heat. When I opened the cabinet to check it out,

         The heats started working. I f it quits again, I’ll change it out.

 

MP-18  The hot stamp heat was cutting off. I checked the T.C. connection & checked for any other loose connections. Put it back together & turned it on,

      OK for now.

 

MP-5  The hot stamp foil jog motor is indexing slow. It’s keeping up. Didn’t get a chance to check it out. Maybe it will hold out till they finish the run &

        give us time to work on it.   

 

Program change on MP3

Since the mold was broken by eject retract with a part still on it.  Temporarily we have changed the PLC program on press 3 with added safe guards to prevent mold from retracting the ejectors if the you do not have vacuum confirmation and there is a back check on the vacuum sensor to make sure the switch is adjusted properly.  Multi-eject, Y up after eject,  and eject retract before X back has been disabled.  We will work on a better solution as time allows.

 

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    931.646.7615

 

FW: Good Friday

 

 

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    931.646.7615

 

---

From: Jerome Flowers
Sent: Friday, April 15, 2011 4:17 PM
To: Mark McKee
Subject: Re: Good Friday

 

Hey Mark

I forgot to tell you. We are working Friday and taking off Sunday for our Holiday.
Jerome Flowers
Molding Manager

---

From: Mark McKee
To: Jerome Flowers
Cc: Ken Paschall
Sent: Thu Apr 14 05:09:55 2011
Subject: Good Friday

What is the molding schedule for the Good Friday weekend.  I need to communicate this to the guys.

 

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    931.646.7615

 

Ronnie Upchurch

MP-16  Wouldn’t shoot. One of the nozzle heater bands was bad, but it didn’t help that they heated the nozzle with a torch ( Sanaprene ). Needless to say,

       It was like concrete. I took the nozzle & adapter apart & cleaned. Reinstalled with new heater bands & a tip with a larger oraface.

 

MP-3  Breland said he wanted clippers set up for the canister. We looked at it & talked to Jerome. He said it would be easier to break the runner off & use

       a heat gun on the stress mark.

FW: New Star XQ-600V

To change the cycle start timer in the new Star XQ-600V press “maint” and “down arrow” till you see RY3 OFF Timer.

 

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    931.646.7615

 

---

From: Hiro Natsume [mailto:hirostartn@bellsouth.net]
Sent: Thursday, April 14, 2011 6:44 AM
To: Mark McKee
Subject: RE: New Star XQ-600V

 

Press 'maint' and down alrrow till you see RY3 OFF timer.

Good luck!

Hiro Natsume
Star Automation, Inc.
615-545-7661

---

From: Mark McKee <MMcKee@ORECK.com>
Sent: Thursday, April 14, 2011 5:49 AM
To: Hiro Natsume <hirostartn@bellsouth.net>
Subject: New Star XQ-600V

Good morning,

 

Where is the cycle start timer you changed in the robot to make it run?

 

Thanks,

 

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    931.646.7615

 

4.13.11 D-shift Sean

Mp#22- Pm'd machine and robot. Cleaned up conveyor belt and IML station.

Worked on minor support stuff off and on all night for techs, material handler, and moldsetter.

Assisted process techs some, we had one go home early tonight.

Have a great day. I will be back early today around 4pm.

Sean

4.13.11 D-shift Sean

4-11-11 Mike Daniels

Mp3 had some problems with nozzle heats running to 485 and the set point was 450. The contactor was good. Done some tweeking with the offset and gain. Still no good. I eliminated 2 bands as someone had crammed too many bands on a long nozzle extension and a long nozzle tip causing degradation of material causing splay That’s why I was called there for in first place. Heats are consistent now.

 

Worked on PMs

 

 

Mike Daniels

Technical Specialist

Oreck Manufacturing

1400 Salem Rd

Cookeville,  TN  38506

Cell 931.287.6252

 

Eat. Sleep. Fish.

 

4.9/10.11 D-shift Sean (Weekend)

Mp#7- replaced all the nozzle bands and thermocouple from a bleedoff. Mp#16- replaced the nozzle band and removed bleed off. Mp#12- Checked all of the heater bands on the barrel (at Potter's request). Also hooked up the dewpoint meter to see if dryer was working correctly. I did find some loose heaterbands on the nozzle, but all of the barrel bands were good. Mp#23- Replaced the conveyor drive belt on one of the small conveyors. Installed the lockouts on the E-stop pushbuttons until I ran out of them. I still need several more to have them installed on all presses. Repaired the heat guns that were in the shop. Both had bad heaters and one of them needed brushes. Checked operation and tagged them, located them in the auxilliary equipment area in molding. Mp#8- Verified the core sequence switch was right for the old fan mold (Potters's request). Replaced nozzle heater bands on this one also. Mp#5- rebuilt the core cylinder on non-operator side. Reinstalled only to find the pull switch was bad. Broke it off in the plate when I tried to remove it and had to pull the plate and core back off again. Got that fixed and then the machine started alarming prefill valve did not open in time. I zeroed the tonnage offset and checked comm vec values for that problem and it started working good after that. I did take some photos of the classic IML station and started putting the door latches on the R2 IML station but kept getting interupted. Call if you have any questions or just want to touch base. Sean

Ronnie Upchurch

MP-3  Replaced the mercury contactor on the front zone.

MP-6  Vacuumed oil pan – AGAIN -  We have another motor & pump in the bunker – just need the time & man power to put it in.

I’ve been checking the vacuum sensors on the phaser robots- found three of them adjusted too high. They need to be setting these up for each eoat.

MP-10  I tried out the prototype part for the nut press , it looks like it will work fine.

MP-2 They hung the main frame & the core plugs were missing again. Also one of the hydraulic quick-connects was broke off, and the eject. back safety

         switch wire was mashed between the mold & platen, other than that, it was in great shape.

MP-2  Small blowback- took out nozzle heater band & fuse.

MP-1 Blow back- Pulled nozzle wires apart. It had a ¾ tip on it & the mold was ½” . I thought they were going to make them all ¾ .

Power outage- Tripped the north buss breaker & shut down the compressor. Reset.

I put gear oil in MP-2,3,& 4.

MP-5 Core plugs on the mold were broken. I hard wired them in to get them going. Will change them out when they pull it.

MP-4 I had no signal from the input card for Y reference. I pulled one out of MP-3 & tried it, worked fine. I put the one I thought was bad in MP-3- It ran good.

         It must have been a bad edge connection.                                                                                                                                                                           MP-8  Core not moving—Had a bad quick connect.

MP-5  The core cylinder on the non-operator side blew a seal . I pulled the cylinder & put it in the shop. Sean was repairing it when I left.  

4.8.11 D-shift Sean

Robot on #11- stopped a few times. The x-axis was giving an error. I slowed the speed value down from 11000 to 8500 and that seemed to help as it did not stop anymore through the night. Press#16- Cleared a nozzle bleed-off. Press#14- replaced a nozzle heaterband. Installed the E-stop switch lock out devices on presses#2,4,6,7,8,9,10,18,and 22. I am keeping up with them on the PM board. Bill Potter requested that Ronnie get Gil to replace the worn out section of the 14mm allen socket they use for changing molds. It is worn out. Transfered the heat treat item as directions prescribed, left it laying on the table beside the oven. Swept the shop floor once over. I will continue with Pm's tomorrow and whatever else is available for repairs pending, projects, etc. Call or email if there are any questions. Have a great day. Sean

4.5.11 D-shift Sean

Mp#26- Worked on the robot interface some more tonight. I have it where it will run through one cycle completely but then I get an alarm for the X18 input "cycle start interlock signal not received". It doesn't appear that the cycle start signal is being received from the robot. It may just be a set-up thing. I got with Mark and he is going to look at it later. Meanwhile... Mp#21- D shift left the press down at 6 o'clock Thursday morning because the cable for the fan mold had broken and tooling was going to make up something more permanent to pull out the stripper plate. C shift left the Nylon in the barrel not purged. It stayed in there through day shift and into night shift when Bill let me know around 1:00 or 2:00 a.m. that it would not pull material through it. The material had turned into degraded hard plastic that resembled hard clay. After attempting to remove the material conventionally, maintenance began pulling the screw out of the barrel to unwrap it. Call if you have any questions. Have a nice day. Sean

4.4.11 D-shift Sean

Mp#11 Robot- X-axis encoder had a broken coupling. Replaced it and found a loose wire possibly. O.K. and running. Mp#26- Continued wiring interface. Ran into a problem locating the x51. The print called for a CS- Control switch for the "automatic signal". We have the HMI which has a bit that sets or something. Anyway, there was not a X51 on the terminal strip. Mark and I are looking at other possibilities for narrowing that input down. Had a power surge at around midnite and reset the compressor. Have a good day. Sean

3-3-11 Mike Daniels

Battled with robot on mp10 most of the weekend it would stop in random positions I checked power supplies the 12volt supply seemed a little hot but was working. Gary also checked all the connections it ran for a few more hrs then started stopping frequently again. Gary was working on it Sunday and discovered a relay that may have been bad, hasn’t missed a lick since.

 

Mp26 drilled and tapped platen and installed robot, plumbed the air in and ran cables. I believe Sean is going to finish the interfacing process.

 

Dr18 in shop. I finished putting process heaters in and installed new blower/motor there is a board lying in the rack not sure where it goes or if it’s bad as I didn’t remove it. And that’s where we are on that.

 

Worked some on PMs.

 

 

Mike Daniels

Technical Specialist

Oreck Manufacturing

1400 Salem Rd

Cookeville,  TN  38506

Cell 931.287.6252

 

Eat. Sleep. Fish.

 

3.31.11 D-shift Sean

Mp#26- Installed the box with SPI base and routed the cable for the sprue picker interface. Will Continue interfacing it in on Monday. DR#11- replaced the process heat contactor. Moved some of the equipment out of the shop that has been waiting on parts. Tagged the items with signs. Including the Hot Stamp press Randy Russell was working on. Cleaned up in shop to make room for the R2 Fascia IML project. Continued with PM's. Have a great weekend. Call if there is anything I can help with! Sean

R2 FACIA PROJECT

We are about to begin the new R2 Facia project which will involve 7 or 8 new part numbers for molding, these will be run on MP22.  A new station will be constructed with a shuttle mechanism to present individually formed labels using two nests (operator loaded) on a subplate that mimic the mold. Gary will head up the physical building (construction, tooling) of this station, but may ask any of us to help out as needed to complete in a timely manner.  Sean will work with me on the electrical.  If anyone signs out components for this project in MRO, please sign out to R2 Facia.

 

The new Star robot for MP26 should arrive anytime.  A robot interface will need to be installed and the top of the machine will need to be drilled and tapped.  I would like Mike to install the hole pattern for the robot on the top of the machine.

 

Ronnie is ordering parts for the Conair dryer in the shop.

 

Parts are on order for the Interroll Decline Conveyor in shop.

 

Branson came in on the welder for the Ultimate Canister Vacuum Inlet Assembly, the setting are as follows:

Weld Time         .350

Hold                  .5

Trigger              3.5

Air Pressure      25psi

AB                    OFF

Stroke               3.5 inches

Adjustable Leveling plate is level.

 

Parts should be here anytime for the new Pilot Destruction Mechanism.  This may replace the duck bill style.

 

 

 

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    931.646.7615

 

Ronnie Upchurch

MP-25  Had to unwire the relay & gripper so they could use the “B” side eoat.  The input must be bad; it’s staying made.

 

MP-2  Core set wouldn’t work. I found some cut wires.

 

DR-29  Novatec – I changed the desiccant. It was discolored & contaminated.

 

MP-6  Vacuumed oil pan.

Parts

Gentlemen,

 

FYI

 

Conair 1250W regen heaters are on order,  ½-13 all thread is a stock item in MRO and is located in the extrusion rack.

 

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    931.646.7615

 

3.27.11 Weekend D-shift Sean

Had several dryer problems this weekend. Seeing that many of them are related to dirty filters and worn out hoses, etc. Are the techs still doing dryer pm's? Some had other issues, bad heaters, desicant problems, etc. Waiting to hear more on the Calibration procedure for MP#21. It ran fine all night tonight but still leaking , maybe worse. The clamp seal is leaking worse than before. Pump is operating a little warmer than the other day, but not running hot. MP#12-The connector test fixture had some problems failing test and leaking pressure. I flipped the rubber peice around and reinstalled it and it worked fine but the indicator lamp bulb was missing. Found one in MRO and replaced it. Mp#2- replaced the Zone #2 thermocouple. It was reading off temp significantly. There is a short list of items to be ordered that Ronnie and I left on the desk in the shop. Items like a regen heater element for conair dryers,etc. I will be back on Wednesday. See you then. Have a good day! Sean

Ronnie Upchurch

MP-18  The machine disconnect & switch gear came apart. I turned the power on so they could do a mold change. The E-stop button on the control panel

            fell off, I reinstalled it.

 

DR-11 Mezzanine – Process alarm. I found the rotation backwards. Rewired.

 

DR-6  Mezzanine – Temp. wasn’t coming up. I found the bed motor drive gear had slipped down on the shaft & wasn’t contacting the bed gear. Readjusted.

 

MP-4  Had a small blowback. Had to replace the T.C. wire

 

MP-18  Had to replace the safety docking switch on the grinder.

 

MP-9  Replaced the robot conveyor relay.

 

MP-25 I don’t know why the relay isn’t bypassing the gripper switch. When they shut it down we’ll be able to tear into it.

Ronnie Upchurch

MP-24  Installed a relay to give a gripper signal when the arm is in the up position. MP-22 & 25 already have a relay.

 

I worked with Tony Cannon & Doug Mason setting up the Branson welder for the vacuum inlet assembly.

 

We got in eight different sizes of rubber plugs to use on hydraulic lines & valves. I put them under the hose crimp bench.

 

MP-10 is to stay down all weekend. The nut press fixture has to be changed to work with the engineering change made to the part. Mark & Gary will

          finish it on Monday.

3.23.11 B-shift Sean

MP#21- I adjusted on it for a long time last night and finally got it to where it responds and is shooting good parts. It is still not responding like it should be though. The extruder is working at a functional level but could be better, it is a little slower than it ought to be. Josh mentioned that we may try to get a calibration procedure for it on Thursday.
I ran it on the robot for 2 hours and then shut it down because Marty did not have an operator for it. I posted a note on the door to let techs know that it has had the pump rebuilt and system pressures may be different than before.

Robot on #25 needs a new runner gripper sensor. We could not use it because it is reading "on" all the time and alarming LS4S alarm the robot when you put it into auto. I checked it out and found the wires had pulled back into the conduit and may have shorted. I tried to leave them disconnected but the alarm still would not clear. So I borrowed the sensor from #24 and it did not work either. May have a problem with the board. I left it disconnected until we get a new sensor. The wiring will need to be double checked before installing the sensor.
The robot works, just not the sprue grip arm because of the sensor alarm LS4S.

Have a great day,

Sean

3.22.11 D-shift Sean

MP#2-Mounted R2 topcover belt door fixture onto the other fixtures table so they could use it. Evidently we took the table to use on another project. I drilled the table so either fixture can be swapped out with the same table. When they are not using it, we can make something more permanent.

Mp#21- Hooked up the ASL filtration cart and let it run on it for a month. Try to watch that the pressure gage does not go over 35. If it does, we will need to backflush it. Procedure for that is on the cart. We can move it around every month to each of the presses we think may need it.

Continued with PM's.

Have a great day.

Sean

Ronnie Upchurch

MP-21  Got info from Toshiba tech. to check pump pressure – Press is ready to run.

 

MP-4  Replaced two hydraulic hoses & adjusted the angle of the fittings to keep the hoses off the deck.

 

Wiring cores & eject. switches on new molds.

Ronnie Upchurch

MP-12  They had some more trouble with the injection encoder rail gear. I found a new gear in the L-1 cabinet. Mark installed it. I put some grease on the extruder

            follower  arm – it was squealin !  I’ll order some more of the rail gears.

 

MP-24  I hooked up an eject. back safety switch.

 

MP-21  I drained the oil tank & pulled the tank inlet strainers. They were both 90% clogged. I cleaned them in the parts washer & reinstalled. Josh wants to run

            the static filter on it for awhile; because there’s still some sediment in the bottom. I cleaned out what I could reach with the oil vac.

 

MP-25  Cinn. Milacron dryer kept going into high temp. alarm. First I thought it was the mercury contactor sticking. It turned out to be a loose connection – the

            process temp. probe at the board.

3.21.11 D-shift Sean

Mp#21- Filled it all the way up with oil. Ronnie and I found the Suction line gage missing and reinstalled it on the pump. It would not load up with any pressure. I noticed the suction gage was not indicating any suction so I removed the gage and tried to prime oil into the pump, then replaced the gage and tried it again. Still not building any pressure. The nozzle will move and the ejectors did briefly but then quit. I tried to probe several valves (M1,M7, 102,104,gatevalve, etc.) in an effort to possibly "unstick" anything but no luck. Left it down to let air settle out of it and because I am afraid it may be damaged from running with the gage missing.





Mp#22- IML was running and the "low Label" light was staying on. He thought it was a sensor but it just turned out to be low of labels.





Mp#8- The operator they call "The Crow" fell asleep on the fans and crashed the robot. I have a picture for you.





















Continued with PM's.

Have a good day.

Sean

Ronnie Upchurch

MP-21  Mark & I installed the pump. I started it up & it ran quiet, but after a short time, it started heating up & it is still pumping air into the tank. I believe the

           tank inlet screen is stopped up & the only way to get to it is to drain the tank. I locked it out again & we can get back on it Monday.

 

I helped Henry get the new molds off the truck. The three smaller molds had fallen off the pallet – no damage – just a pain to get to.