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
Wednesday, November 2, 2011
Monday, October 24, 2011
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
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
Wednesday, October 19, 2011
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
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
Tuesday, October 18, 2011
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
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
Friday, October 14, 2011
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
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
Wednesday, October 5, 2011
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
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
Tuesday, October 4, 2011
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
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
Friday, September 30, 2011
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
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
Monday, September 26, 2011
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
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
Thursday, September 15, 2011
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
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
Sunday, September 11, 2011
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
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
Wednesday, August 24, 2011
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
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
Friday, August 19, 2011
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
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
Thursday, August 18, 2011
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
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
Monday, August 15, 2011
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
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
Tuesday, August 9, 2011
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
Assisted process techs some tonight.
Continued with PM's.
Sean
Sunday, July 31, 2011
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
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
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
Wednesday, July 27, 2011
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
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
Thursday, July 21, 2011
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
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
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