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.

3-20-11 B shift

Mp12 the strip gear on injection position sensor broke not sure how. Its just glued on so I cleaned reglued so if you have issues with screw position check this first.

 

Worked on PMs            

 

 

 

Mike Daniels

Technical Specialist

Oreck Manufacturing

1400 Salem Rd

Cookeville,  TN  38506

Cell 931.287.6252

 

Eat. Sleep. Fish.