2.4.10 night shift Sean

I was looking at the star website for info on the new robot and stumbled on a spin off idea for the robot riser we are about to construct for running the steemer mainframe tool. It is riser that swings back out of the way: here is the link> http://www.starautomation.com/images/Pivot%20Base%20~%20L1%20~%206-14-04.pdf
It looks like all we would need to do is use a larger bottom plate with some gussets for support? Just an idea?

I was going down Ronnies List of Machines low on oil.
Refilled Presses 6,11,12,and 14 with hydraulic oil, there is maybe enough to top off the others if they are not too low and the spare oil vat will be out. #11 was the lowest. There is still #18,#19,#20, and #24 to do.

#13- tied in power to robot receptacle and powered it up. The mold safety gate alarm is present on the picker and the machine is saying E-stop circuit activated. They wanted to go ahead and run without it for now so I will check it out further when it is down next.

There was an Assembly issue with the fan housing pressure tester . Had a bad fiber optic receiver on the "part sense" input 6. There were no more in MRO so I informed Rich about it this morning. He (Gary) was asked to but did not provide a work order.

FYI- I have seen an influx of small tool room work since Chris left and they did not replace him. Mostly repairs such as making ejector bar spacers and broken stud extractions. I have also noticed many locator rings for the sprues are getting smashed up lately. We have pressed a few out and turned out the I.D.'s so the molds would fit center. We may need to order some extra locator rings so they can be replaced if needed.?

2.3.10 night shift

Robot Support Column: I cut it and welded it. I still need to check that the riser that comes in will match up to the drawings that I had to go by.

Installed both color pump signal receptacles in #13 and #19...checked them both with color pumps, good to go.

#19- The techs on my shift were saying that it was down because Collin needed to work on the heaters? I looked at them and noticed that the actual temps were off about 20 degrees from setpoint. I compared the PID settings with those of #22 (same control and on tempersture) and changed them to match 22. Came back an hour later and changed the Middle zone's Integral setting to 150 because it was over about 20. Mark and I checked it at 6am and it was right on so they should be fine now.

#3- had a "Fatal Error" "Communication Error 39 Variable Readkey".
Powered it down and re-referenced robot...seemed to be O.K. afterward.
We'll keep an eye on it.

Sean

#19 cores

I looked at the core problem on MP19. It seems the core pull output (166) isn't supplying enough current to even energize the core valve relay. When the load is removed, the output works. But if either the wire going to the relay coil or wire 929, which should power the core, is hooked up to the output, then the voltage drops out. The amperage reading to the 24VDC relay coil is 1.6mA. The set side, which is working, is conducting around 44mA. Both are powered from the same 60mA source. I think the NPN transistor may be bad on the output board. They were going to start the machine back up so I didn't have time to find the actual transistor itself. If we had access to reprogram the controller, we could use output 165 which is free.

Collin

Nozzle Band Wire Nuts

Hey Guys,

In the future, when changing nozzle heater bands, do not use the non-insulated high temp crimp connectors.  Use insulated wire nuts- just make sure you tape them well enough so the plastic will not melt. 

We are getting into situations where the non-insulated high temp crimp connectors are being used, but not taped up very well, and they are shorting out.

I do not want anyone to get hurt over something stupid.

 

Thanks

 

  Joshua Ledbetter

  Manufacturing Engineer

  Oreck Manufacturing Company

  931-239-3235

 

Weekend _night shift D _1.31.10

Mp#13- I got it leveled up, still needs the power tied into the robot and checked out for correct operation.
There are two primary side transformer fuses inside the cabinet that need to be pulled out!
I wasn't sure if we were going to add another 480 there also or not?

MP#19- Cores are still not working, looked at it and found tank/pressure lines were backward. I corrected that, still did not work. After looking at prints, it was apparent that we had the wrong style of solenoid valve. We were using a regular 24vdc, looked like what we needed was the 4 wire type the other newer nissei's have on them (with the circuit built in). I attempted to use small relays to isolate the signal from the load of the coils. One side is working but the other side(929) is not putting out a signal. Not sure if it is a program thing or exceeding the 60ma load may have caused a fault, etc.? Ronnie said that when he checked it out, one side works, then if you swap wires to coil, the other side works so it definitely looks like a signal problem at this point.

I tried to clean and organize the shop tonight and put away a bunch of items back into MRO, etc. The filter cart hasn't been checked out but Mark and I discussed getting it going...there was an issue with the motor coming in wired incorrectly and it looked like it had been very hot before. I printed off a ser vice manual and got some info on it.

Call if there are any questions.

Sean

" C " Shift

   MP-11    Core set not reading;   The wires had pulled out of the plug. Repaired.

 

  MP- 5   Getting “ prefill time out alarm “.      Changed offset.

 

   Got filter unit off trailer , cleaned, &  mounted on cart. Need to check on filters.

 

I  made some measurements on the main frame mold & MP – 2 . I measured  from the center of the sprue bushing  to the top of the mold.  While the mold was out of MP-2 , I was able to measure from the center of the platen . I marked the uprights . The marks are  one inch above the highest point on the

       mold .  We will need at least 10 inches between the uprights for clearance.

 

 

 

     R.Upchurch

     Molding Maint.

This Weekend

Hey Guys,

They are running 6 presses today and plan on running tonight.  Do not put yourself in danger to come in here.  If you can make it, plan on working.

For anyone working this weekend, here are some projects that need to be addressed-

 

1)     MP13 still needs to be leveled.  I still need to order two more feet to put under it, put it can be leveled with the four that it has.  The level is on MP19 with a magnetic V-Block to help stabilize it when placing on top of a tie bar.

2)     MP19 needs to be leveled also.  There are some minor things that still need to be done to 19 as well, including hanging material pipes, etc.

3)     MP19 cores do not work.  Pull works, but Set does not.  We’re still not sure if the pressure and tank lines are plumbed correctly.  Also, the solenoid could be wired wrong.  Input switches are wired correctly.

4)     MP01 pump still needs to be addressed.  New pump is $8K and 45 day lead time.  I want someone to take measurements of Mainframe mold to see what would have to be done to robot riser on MP02-MP05 to accommodate hanging this mold (Spreading the riser legs out).  That way we can run the mainframe somewhere else until we figure out what we are going to do with MP01.

5)     Someone can get the hydrostatic oil filer out of the storage trailer and put casters on it and see what it will take to get it functional.  We need to get that trailer cleaned out sometime to store extra stuff.

6)     Someone can also bring in those little conveyors and see what we can use them for.

 

Thanks

 

  Joshua Ledbetter

  Manufacturing Engineer

  Oreck Manufacturing Company

  931-239-3235

 

1/27/10

MP1 pump number two was making a loud noise. I took the coupling loose and the motor and coupling seem fine. It sounds like the pump bearing is out.

Robot number 10 alarmed only one time tonight with in the mold. It gave a "Mold not open. Robot in unsafe position." alarm

MP23 over stroked the ejector limit switch and had to be dialed back into zero.

Robot on #3 hit the conveyor belt and tripped the 220V breaker inside the press.

Worked on new MP19 tonight

" C " Shift

   MP – 16    Installed a plug for the eject. back safety switch.

 

  MP – 19   Pulling everything off the press that we may need later; scrapping the rest.

 

  MP – 25   Nozzle was blowing back,  Checked level of sled.  Breland said it’s been doing it on the last three molds. They’re suppose to be

                 trying a new tip on it & letting us know how it’s doing.

 

 

 

   R. Upchurch

   Molding Maint.

1.20.10 night shift

#23- finished putting screw back together. Set a mold in and made sure nozzle was aligned correctly. The machine had not used cores before so I put quick connects on. Also wired the core switches up on the mold and put QD fittings on it as well. When I tried it out, cores would not work. I remembered Collin saying that he had found a problem on the circuit board inside the valve on 22, so I swapped out boards to eliminate that. Still did not work. I swapped out hydraulic hoses. Still not working.

I was at the point of replacing the quick connect fittings I put on the machine but there are none left in MRO. You can manually probe the valves while someone energizes switch and the cores will move, they just do not seem like they are getting an output signal. I tried to bypass the switches and run it on timers but it still will not work.

I went through it all with Mark and Ronnie, we got to a point where we had isolated a problem with the valve.

Sean

1.18.10 nights shift D

Mp#15-had a bleedoff back about 3 bands. We cleaned it off and patched it up without replacing anything but the nozzle clamp. O.K. to run.



Mp#7- put a material loading sensor on the hopper sight glass at the request of Process Techs. Had to get one from the Turck vending machine. Used the number 00344.



Mp#23- put another 120vac receptacle at the rear of the machine per Mitch's work order request.



Robot on press # 2 - Did a pm on it. Mounted some brackets to hold the HMI touch panel securely to pendant. I still need to do one on #11 when it is down.

Robot on press#25- Also did pm. Cleaned, greased, inspected, tightened screws etc.



The single cavity topcover mold is leaking on press#11. It was pulled out with a workorder last time it ran, instead of moving it to a repair location, someone just put it back in the racks. Bill mentioned to me that it was back there with the work order, but by then it was already scheduled to go back in on our shift and run again. I asked Marty if he wanted to shut it down to fix the leak, he said no.



I did notice that many of the ISO work instructions on the Online Document website have not been revised since 2002, etc. Including the molding maintenance work order request instruction. We were looking for the procedure for mixing up the ink for the pad printer. It was not there or at the support site.

Need to order some cabinet fans like we use in the robot control panels and DME boxes. Need both 240 and 12oVAC. 3 are out in the robot panels, and I think one of the Cincinatti's has one out also. Then the DME's run on 240vac and we do not have any of those either.

Call if you need me to come in or have any questions.

Sean

" C " Shift

    Tightened up the pump drain plug on the vib. welder; It had a slow leak. I’ll check it again after they run it awhile.

 

 MP-21   Vacuumed oil under sled & on rear deck.

 

Installed eject. back switch on new mold # 74017.

 

Installed conveyor tray behind MP-25.  They can try it out---- see if they need to modify it.

 

Loader # 7 on mezzanine wasn’t pulling from Gaylord. I found  two other loaders leaking at the vacuum ports. I changed out the seals

 

 

 

          R.Upchurch

          “ C “ Shift  Maint..

1.17.10 night shift D

MP#10 - robot was stopping above conveyor after part delivery. Ronnie and I looked at it briefly,didn't see anything obvious. We adjusted tracking on Z-belt. I did a PM on it after they shut it down an hour later and dry cycled it for about 20 minutes, it did not stop anymore. Will keep an eye on it.

MP#2- Robot had no apparent alarms but would not give permission to close to machine, turned out that someone had left the robot in "DRY CYCLE" mode.

MP#7- looked at the baseplate tool, had open thermocouples, we checked boxes, cables, etc, turned out to be open TC's in the mold. They are running it in Manual.

I vacuumed out all the robot control cabinets and found 3 cooling fans bad.
I could not locate any in MRO so we need to order those. Also need a few other items to complete some workorders so I will leave Mark a list Monday morning.

I mounted a tray on the crane column behind the Welder on #12 to store nest screws so they will be 5-S compliant.

Worked on PM's and misc. oddball requests from the Moldsetter, process techs and team leader throughout the night. Call if there are any questions.

Sean.

" C" Shift

   MP-4  Robot not holding position & conveyor not working.  They had the “ Z” at home position set the same as “ Z “ at part drop. I changed

             The part drop setting & it homed .  The conveyor  relay  had no  incoming power---- someone had it unplugged..

 

   Hopper # 13 @ mezzanine wasn’t unloading material to MP – 5 .  The supply air to the valve wasn’t plugged in all the way  & the material line got

                  stopped up. I fixed the air line & opened the material line to clean it out.

 

  MP-16  New mold had two eject. back switches – I wired them in series & put a plug on it .

 

  MP-10  Robot stopping occasionally. Haven’t found the problem yet.

 

  MP-24  Mark worked on the cores on a new mold; both core set & pull lights were on at the same time. He found the  polarity  wrong at the plug wiring.

 

 

 

              R. Upchurch

              “ C” Shift Maint.

" C " shift

  MP- 19 Grinder  “on” push button  came apart;  installed new one.

 

 MP- 21 robot wouldn’t home ;  Limit switch on air cylinder not making. Adjusted.

 

 MP- 2  Drill not drilling everytime .  The vacuum port was clogged & drill shavings were preventing swivel fixture cylinder sensor  from making.

 

 Started working on incline conveyor catch pan.

 

 Unboxed new equipment & sorting out hyd. fittings & manifolds for new molds.

 

 

 

  R. Upchurch

  “ C “ Shift Molding Maint.

January 14, 2010

Worked some on the Eagle sole plate press controls, the main panel is wired and installed.  Gary mounted the cabinet and is working on some sensor mounts.  Ordered the solenoid valve block for this station.

 

MP20, process tech had problem with new DME cables not fitting or clamping up right.  They were six pin instead of five pin.  We have both on the floor, but we only stock the six pin.

 

MP13 shut down, ends up the front door switch was not made.  Use code 100 to find out.

 

Helped Elaine establish a healthy list of Robot EOA components and Josh ordered today from EMI.

 

Talked to EMI guys today about a quote for (3) Decline Conveyors for new machines.

 

Ordered two new hydraulic cylinders for one of the new molds.  Ortman brand.  Should be here in 4 days.  They are prepped for Go switches.

 

Ordered more Omron micro switches for new molds.

 

Ordered (2) station junction boxes from Motion.  Daman brand.  Hydraulic, 3/8” Ports, 3000psi working pressure.  Should be here 1/15/10.

 

Worked on MP14 sub station.  Replaced LH pneumatic PB on cord hook snap.

 

Loaded the truck headed for Zag with the Wittman Robot and Air Skates.

 

Mark

1/14/10

 

 

 

 

 

 

Mark McKee

Technical Specialist

Oreck Manufacturing Company

1400 Salem Rd

Cookeville,  TN  38506

mmckee@oreck.com

PH      931.646.7856

CELL  931.644.5289

FAX    931.646.7851

 

1/13/10

Took apart and tapped three hydraulic cylinders on the new molds for 3/8" pipe thread. Only had time to put fittings on one cylinder.

Made a bracket for MP22 conveyer to keep hoses off it.

Worked on dual ratio valve on MP23. It wasn't loading regrind.

Wired a new heater and thermocouple on a mold that came in the shop.

Thermolater T31 tripped the motor overloads. The motor is bad and will not start. I got a new one from MRO and a pump seal kit but didn't have time to replace them. I'll try to get to it tonight.

Collin
"C" Shift

1.12.10 night shift

Very uneventful tonight. Worked on PM's throughout the night.

Replaced ejector hose and fittings on MP#17, that were leaking. Went over fittings checking for tightness and redid o-rings as needed. Made a hose for it. ..
Question:
Do we need to put some kind of form at the hose crimper to keep track of what gets used? Who keeps things topped off there?

I did get to look at the support site and viewed some of the new equipment coming in. Looks like it is in great shape.

Let me know how I can help with the upcoming install/replacement of
machines and robots.

I will be working this weekend, be back Friday evening. Call if there are any questions.

Sean

1.11.10 night shift

#23- worked on the regrind / virgin loader blender controller. It was not functioning. Found a bad valve, when I looked at the other controller, it had a different valve, so I changed out the whole controller, and it worked fine.

#5- The robot conveyor belt tripped out, after looking at it, the NO contact was bad. I put a jumper across it since the tether had already been removed anyway. Working fine now.

Mark and I looked at the robot on #8, for future reference and to eliminate process tech changes, the Timers set-up is as follows:


Delay Before Sprue Grip: 2.50 sec (Grabbers)
Delay Before Part Grip : 2.00 sec (Kickers)
Delay After Sprue/Part Grip : 0.50

Continued working on PM's, I mentioned to Bill that he might see if Jerome would schedule the fans to run in 22 or 23 so we can have a repair window for the leaks on #21. Haven't heard anything back yet.

Also: I looked at the new mold with cores,, unless we change the cylinders we are going to need to install some mechanical switches to read set/pull with it. Maybe attach locking collars or position flags with microswitches??
They are not done tearing it down for cleaning but likely they will want to sample it soon and we will need to decide how to proceed.

Call if there are any questions...Sean

1/10/10

#15-Nozzle was leaking around threads. Tried to tighten it but it still leaked so I changed  it with one I'd faced off.

#8-Robot missing parts. I started the machine back up and fixed the robot and ran it for an hour to verify it was ok.

#9-Robot missing parts. Two of the suction cup level compensators were worn out and allowing the cups to moved around freely. Replaced them with new ones.

#15-Water leak on feedthroat fitting. The  cooling hose had been cut down to short and was catching on the sled so I added some to it and replaced the fitting.

Collin
"C" Shift

" C " Shift

  MP-16   Mold wouldn’t close.   Eject back limit switch had loose connection @ teminal strip.

 

 MP-8   EOAT  was dropping parts.  Mark & I  made some adjustments on grippers & “ Z “ axis.

 

 MP- 4. 11, 12, 14, 18, 19, & 24 are low on oil .  I’ll get them between today & the weekend while doing PM’s.

 

 MP-20  Sight glass may be plugged ;  not showing any oil.  I’ll  check it through the top tank hatch & fill , if needed.

 

       We need to get with tooling to see if any of the new molds need fittings, switches, etc.

 

 

 

 

     R. Upchurch

     “ C “ Shift Maint.

Jan 7, 2010

 

Thursday, Jan 7, 2010

 

Started the day with problems at MP10, the connector nut insertion station.  The left side was jamming every 10 parts or so, with somehow feeding (2) black nuts and trying to press them.  It ends up that it was an inertia problem with the black nut slide, it traveled so fast outward and was bumping the track so that the first nut moved forward and allowed a second nut to feed down in place to be pressed.  We disassembled the left side, installed a directional flow control on the black nut slide cylinder and adjusted it about half way and reassembled.  The problem went away. 

 

There was an eight bank D-M-E heater controller and some cards that were burned up, probably from inserting or removing cards with the power on.  Ronnie and I gathered enough new components from MRO to put a new system together.  The problem was that who ever ordered the new D-M-E controllers a few years ago, ordered them wired 240V three phase.  So we had to rewire the controller for single phase 240VAC.  After checking everything out plugged in to a mold, I attached a label indicating not to move cards with power on. 

 

Helped set up robot on press 25 for brush roll end caps.

 

Snowing today, I heard the plant was closing at 4pm because of weather.

 

 

Mark McKee

Technical Specialist

Oreck Manufacturing Company

1400 Salem Rd

Cookeville,  TN  38506

mmckee@oreck.com

PH      931.646.7856

CELL  931.644.5289

FAX    931.646.7851

 

1/7/10

1/7/10  FYI

 

Stiffener and nut press station at MP10 would not seat the stiffeners consistently in the plastic connector.  Ronnie and myself checked the machine, it was OK.  Ronnie increased the supply air pressure to max line pressure.  Still problems.  We checked the parts and it looked like the opening in the parts for the stiffener was smaller than the print allowed.  On further examination of the inside of the pocket where the metal stiffener seats, we found additional plastic down in the hole about three-quarters of the way down that provided interference.  We checked the chiller temp, set at 53 degrees.

Checked the water and water flow.  Cores for the stiffener pocket were blazing hot.  We got the process tech to slow the machine down from 54 seconds to 59 and immediately the parts looked much better and we were pressing with no problems.  I believe the correct cycle time on paper is 60 seconds.

 

Mark McKee

Technical Specialist

Oreck Manufacturing Company

1400 Salem Rd

Cookeville,  TN  38506

mmckee@oreck.com

PH      931.646.7856

CELL  931.644.5289

FAX    931.646.7851

 

1.07.10 night shift

Mp#7-had to replace fuses in the 120/240 transformer. The DME box arced when they were changing out cards.
Marty asked me to put an EOAT together for the wheel cover they were running, its running good.

MP#11- replaced 2 hydraulic hoses to the ejectors, they were worn and looked like they were leaking in several places. Checked operation, good to go.

Worked on PM's on machines and robots most of the night with other odds and ends such as making mold lock straps etc.

If there actually is bad snow, I may not be able to come in, I will try anyway if the roads are clear though.

Sean

1.03.10 night shift

Cleaned up in preparation for the "QVC film crew" which is supposedly coming in this week.

I tried to get as much tagged equipment repaired as possible. The only thing left was that dryer DR20 which for some reason iss not providing a control output for the regen beds to kick in? We may have some spare parts somewhere or I can try to swap out parts with another dryer when possible.

Had a few minor issues this weekend, I turned in workorders for most of them. Have a good day call if there are any questions.

Sean

" C " Shift

   MP-11   I shut the press down & cleaned up oil on the clamp end. Found two leaks on eject. Manifold ,  tightened , & restarted press.

 

  MP-16   Mold not closing – error 122 – not making eject. back switch .   The eject. back jumper had a broken wire.

 

  MP-17   Hose on eject. manifold sprung a leak. Made up a hose & replaced. I made a hose for the other side too, but I couldn”t  find

              any ½”  boss fittings.

 

  MP 6,7,8,10,11,& 12    Vacuumed oil pans Then emptied oil vac.  I started on # 1 ;  The vac .  will probably need to be emptied again.

" C " Shift

   MP-7     Loader not pulling material --- Hopper feed at mezzanine not opened all the way.

 

   Vibratory welder -  Had filter clog alarm ;   Installed new filter .  cleaned up all the parts & oil under welder & on top of tank.

                            I let the oil heat up & cycled it several times ;  found one leak at press. gauge fitting & another at tank lid mounting bolt.

                             After it runs awhile , I’ll check it again.

 

  MP- 25    I emptied the oil jug @ injection end of press;  this was the second time in two weeks it has over flowed . It looks like it is coming from

                 the  injection cylinder . Will need to order parts & schedule down time for repair.

 

 

         R.Upchurch

         Molding Maint.

#5 Had a fault FHD1 analog input 5 exceeds limits.Took pressure transducer off #3 injection unit and put it on #5 clamp. parts will be monday for #3.
Replaced belts on grinder #19.Put a new gripper on #22

12.29.09 night shift

Changed several heater bands on #3 at Bill Potters request. Also repaired some of the wires and re-did the paint on the barrel shroud. Checked it and it came up to temp fine.
While it was down went over some of the leaks and cleaned it up in general.

#16- had a problem with ejector back limit switch...it needed adjusting, it was making the clamp sound really awful when it closed up, and also would not lockover and build tonnage.

#4- made a new core cylinder hydraulic hose.

#5- replaced a core line quick connect and tightened all the lines up. It looked like the two fittings on that block really needed those o-ring/washer sealed types of fittings but I didn't find any to replace them with.

#11- has several leaks but is #1 priority on the schedule, so I attached work orders to the machine...1 for the tool and one to let the techs know to notify us when it is down so we can fix those lines above the clamp cylinder (ejector line fittings).

Call me if there are any questions!

Sean

12.28.09 night shift

MP#5- Mark and I put the pump in and I started it up. I ran around 40 shots of baseplates through it and shut it down. It is working fine. I then put the tool arm back on the robot and referenced it. Had to locate the loose plug connection in the controller first though because it would not power on at the pendant. It should be ready to start up this morning if they want to run it.

#11- has stopped a few times (4 or 5) throughout the night from 3217 alarm...which I think is the core switch signal...but when checking it out further, the signal IS made... so?? It starts right back so we have been keeping it going.

#2- The sled cylinder coupling was ran out too far and loose...I adjusted it and tightened. It was causing the frame to twist very badly when the sled was ran back all the way.

#25- Initially Mitch had made me aware that Zone #2 was over heating by 30 or 40 degrees. We found later that the feedthroat was partially blocked from old Nylon and liquid color residue. It kept slipping while building up a shot and taking much longer. While it was not running the barrel temps maintained and stabilized. After we cleaned it out it was fine. I also helped them process out the splay problem...they were short handed.

I came in early at 3pm so I am leaving at 4 am. Mark said he must leave early today so I may also come in early today.

I put the straps for Bill Potter in a box with his name on it in the Molding Office so he would find them.

Call if there are any questions.

Sean

12.23.09 Nights ...Sean

Mostly cleaned up in the shop and helped the process tech do a mold change etc.

Worked on the dryer in the shop, found a loose wire connection on a relay block terminal.

There is an oil line leaking on #11 (ejectors) but it was running and they did not want to stop production.

I talked to Mark last night and he is going to call me when the pump for #5 comes in on Monday so I can come in early and we can both work on it.

I wish all of our team a very Happy Holiday!

Sean

12/23/09

Worked on Star Robot on MP24.  Display was dead on power up.  Disconnected all I/O connectors on the main power board with the power off, powered up controller, and the pendant came back to life with errors.  Started plugging in connectors one at a time with the power on and CNA made the pendant lose power.  Looking at the prints, connector CNA has limit switches that are around the EOAT, on inspection of this area I found that a cable labeled LS4 that had bare wires that had got together.  I insulated the wires from each other and everything powered up no problem.  I was able to move the robot around and send it home.  So evidently a short with the 24VDC will not allow the system to power up.

 

Changed over the Z axis encoder on MP5 to a BEI encoder.  On power up the robot could not find itself, so I swapped the A+ and A- with the B+ and B- channels.  On power up this time, the robot referenced fine and homed itself.  There is a box on my desk with (1) new BEI encoder, connectors, pins and sockets, and a print.  Since we are out of the old encoder again, we should start changing over to the new encoder on a failure.  We only have (1) new encoder right now but more are on the way.

 

I replaced, dated the PCB backup battery in MP25.  It has an NC9000G controller and only has (1) back up battery.  They are supposed to be good for 5yrs.

 

I replaced, dated the PCB backup batteries in MP22.  It has (2) batteries like MP24, (1) on the back panel and (1) under a cover on the back side of the main cabinet door.

 

Called Milacron to track the pump for MP5.  They said it didn’t go out till today and wouldn’t be here until Monday, the 28^th.  I feel goobed.

 

I believe I heard that new GO switches are here and are in MRO, I think several have been robbed.

 

That is all I have for today, have a very Merry Christmas and we will see you next week.

 

Mark

 

 

Mark McKee

Technical Specialist

Oreck Manufacturing Company

1400 Salem Rd

Cookeville,  TN  38506

mmckee@oreck.com

PH      931.646.7856

CELL  931.644.5289

FAX    931.646.7851

 

I took the inverter out of #22 robot the other night because it kept tripping the breaker. It had a bad 3-phase full bridge rectifier and I found one online for $34. Mark ordered it and I put it in and tested it out and everything seems fine. They haven't ran the press so I'm not sure what program is in it.

The insert press on MP10 quit working. I found a loose bolt that the sensor has to see in order to start.

The z-axis encoder went out on MP4 robot and I think we are out of them. I switched it with the MP5 since it's waiting on a pump.

The robot on MP24 will not power up the pendant. I tried the pendant from 25 but no luck. The control board does have power but the board's lights will not come on. I planned to switch boards with another similar robot but none were down.

Collin

12.20.09 weekend Sean

MP#17-refilled with Hydraulic oil. It had ran a little low and would not lockover.

Sped up the flow controls (at Marty's request) to the ultrasonic welder on Press#4- because the operator could not keep up with the machine due to having to wipe color from the parts. I adjusted down speed of press head and operator door speed.

Remade an broken bracket for the connector press on #10.

Also helped the technicians set-ups some of the star robots to pack parts on belt better, and hook up regrind onto the matsui dryers,etc.

Cleaned up in the shop, especially around the welding area.

As far as #22, and #24 robots...I don't know what is going on with them, no info?

Call me if needed, I will be glad to come in and help with anything. See ya Wednesday evening at 6p.m.

Sean

" C " Shift

 

    MP-6   Added oil to tank.

 

    MP-4   Had to adjust core 1  pull switches.  The core 2 cylinders were leaking; tightened them, but couldn’t get the top one to stop leaking, so I

               just put one of the sensors in to plug it.

 

    I emptied the waste oil vac.

 

   MP-8   I made & installed leg pins for the robot cage.

 

   Dryer -  D 24 -  They were having trouble with this one last week.  Breland was using it to dry polycarb @ 250 degrees.  This dryer is one of the older CS101’s

                         & it struggles to run at that temp. It works great up to 200 degrees so I  put a label on it ---  set point  not to exceed  200 degrees .   If  they

                         don’t  like it , they can purchase an after cooler for it.

 

 

 

 

         R. UPCHURCH

         Molding Maint. “ C “ Shift

" C " Shift

  MP5    Installed  new 21/15 gal. pump ;  still not working. The variable volume pump is bad – no pressure @ test port & no sled movement.

            They are going to hang the other base plate mold in MP6, so we’re OK on parts.

 

MP21    The DME on the nozzle was left on , ( no mold in press )  & material blew out on moving platen. Not sure when this happened- wasn”t  today.

            I turned DME off & cleaned the platen.

 

I checked , cleaned & lubed tie bars – MP13 thru 25

More from " C " Shift - ( Friday )

       MP -13      Just before shift change , 5:30 pm,  they found a blow-back ¾  of the barrel was covered on the top side ( DELRIN )

                      I cleaned it off ,replaced 3 nozzle bands, & rewired 2 barrel bands. Luckily the connectors for the barrel heaters were on the bottom & weren’t

                      covered  up  with plastic.

                      The nozzle was loose, I turned it by hand.

" C " Shift

 MP-8      They crashed the robot on top of the cage last night; Mark repaired the eoat. The touch screen lost it’s program again, this time for good.

 

              Had one more Quick Panel in MRO,  we installed it & down-loaded program.

 

 We sent out the spare top cover drill for repair.

 

MP-5     Lost the low volume pump;  ordered a new one from Servtek. ( Saturday Delivery ) 

Today 12/17/09

Replaced pneumatic drill motor on top cover drill station.  Replaced bit.  Replaced shock absorber.  Repaired e-stop circuit.  Repaired air leaks on drill.

Set up and run parts to verify.  Cleaned up and returned to equipment storage area.

 

Wired eject back switch on MP15

 

Replaced (2) batteries in MP23 pc boards.  Machine has lost program.  Nissei to send procedure by email.  We have discs for machine in office in storage box.  I will program load tomorrow.

 

I haven’t had a chance to look at robot on MP24. 

 

Mark McKee

Technical Specialist

Oreck Manufacturing Company

1400 Salem Rd

Cookeville,  TN  38506

mmckee@oreck.com

PH      931.646.7856

CELL  931.644.5289

FAX    931.646.7851

 

RE:

Worked on number 22 robot tonight. It alarms while stacking the parts on the belt during the down stroke at random pack numbers. The alarm is displayed as a Y inverter fault and it states the Y speed cannot be controlled. I changed out the y-axis encoder, switched the Y and Z inverter cards, and checked all the connections to the circuit board under the x-axis cover. I checked the different voltages on the main transformer to make sure they were within tolerance and monitored the inverter power supply voltage while the robot was operating and everything seemed ok. I tried changing the y-axis pack speed to different values also.

Collin

8.15.09 night shift---Sean

Put a tool arm and program on the Wittman tonight. I worked with the techs so they could do hands on with it so they could understand how to make changes to positions and speeds or call up existing programs.(at their request).

Should be ready to go. We also added commentary to the program and saved it by mold number.

Had a bad locator ring in #23. I pressed it back straight and turned the I.D. back so it would work again.

The robot on #5 had some incidents of stopping over the conveyor after dropping parts.

It would simply reset and rehome.

I am guessing a potential encoder error. Has not stopped since 11 pm so ???

I'll be back on saturday, Call if you need me.

Sean Kearns
931-239-7671

12.14.09 night shift...Sean

Worked on moving stuff out of repair area. Green-tagged 3 or 4 color pumps after checking them out.

I Re-did the float switch on the leak reservoir on MP#17 and put cover back on.

Marty had asked me about the "transfer velocity" setpoint that shows up on press#3 but not on #2. I looked through both control books to see if there was a convec to turn on that would make it appear on screen but did not find anything. Both books never made mention of that setting. The 486C control has it but the 486 does not so I am guessing that it is simply in the screenware program?

I called the Milacron after hours number to see what the deal was but the guy acted like he didn't know what I was talking about.

I am not sure that it is even needed but would like to know.

Sean

" C " Shift

 

   MP- 20      Thermolator not cooling down; inlet clogged at solenoid.

 

   MP-21     Robot pivot cylinder blowing air ; removed fitting, chased threads, & replaced.

 

   Cleaned out all tower water inlet screens.

 

   Started  repair on liquid color pumps.

 

 

 

   R. Upchurch

   C  Shift Maint.

12/13/09

The screw on MP3 was wrapped with plastic but it was only near the back so we didn't have to pull it. The robot on MP4 lost communication error twice and the screen would freeze up. In order to reset it we had to power down the robot. The nozzle on MP5 caught on fire due to the sled being misaligned ,plastic bleeding off, and shorting some wires out. I replaced the nozzle band, thermocouple, and realigned the sled.

Collin

Sunday 12-13-09 A Shift

Saturday we kept getting a Y inverter fault again on the Wittman, so today I jumped out the Y Inverter Fault Monitoring Input to the control in the cabinet.  After that I dry cycled the robot for 4 hours with no problem.
If there is a minor problem still, the control will not know it and it should continue to run. If there is a real major problem, the robot will hopefully run long enough for us to get more clues to fixing the problem.
Call with any questions.
Josh
Sent From My Verizon Blackberry

Surge bins

The surge bins ran out of material tonight which was due to bin #1 material hose having holes all in it. We replaced the hose and checked the others which were all ok. Also dryer 11 on MP16 blew a fuse around 6 p.m. Day shift said it blew one on them too. It ran the rest of the night with no more problems.

Collin

Worked on number 22 robot tonight. It alarms while stacking the parts on the belt during the down stroke at random pack numbers. The alarm is displayed as a Y inverter fault and it states the Y speed cannot be controlled. I changed out the y-axis encoder, switched the Y and Z inverter cards, and checked all the connections to the circuit board under the x-axis cover. I checked the different voltages on the main transformer to make sure they were within tolerance and monitored the inverter power supply voltage while the robot was operating and everything seemed ok. I tried changing the y-axis pack speed to different values also.

12.11.09 night shift

We built another EOAT for the 4 cavity bag dock running in 22. This time we are getting the runner and delivering it to the grinder. Next program we will try to do more with part stacking, subroutines, etc.

Also, need to order some airline for tieing in those hose reels. I looked and we did not have any 1/2" hardline. (60)ft.

Sean Kearns

Inverter Fault

Anytime the Wittman gives an inverter fault, try and recognize which axis the fault occurs on (x, y, or z).
Thanks.
Josh
Sent From My Verizon Blackberry

12.09.09-night shift

Put the switch back in the reservoir pan on #17. I left the cover off to check on it again this evening.

#22-robot stopped once at 1:30 a.m. for a "inverter fault". We powered it down and re-homed it and there were no more incidents.?

Did thorough PM's on robots on presses #7 and #11. They were in definite need of cleaning and lubrication.Also cleaned the control cabinets very well.

Give me a call if there are any questions. I plan on taking Friday the 18th off (last 12hrs PTO).

Sean

Wednesday C Shift

Mark extended the y axis up roller switch on the Wittman today so that it could approach closer to the mold before the clamp opens.  This switch controls the secondary mold close interlock.
I didn't do anything on the floor.
We did schedule Branson welding training for next Tuesday. I also got a PO cut for training on the Star robots. It will be scheduled for after the first of the year.
Sent From My Verizon Blackberry

" C " Shift

   MP- 1 thru 8 -   Vacuumed oil pans, checked & lubed tie bars, & blew out control cabinet filters.

 

  MP- 17-   The oil pan ran over. The oil recovery pump clogged & oil went over the float switch; pump runs continuously. I could’nt find anymore switches;

                I’ll check w/ Collin & see if he has one.

 

 

                 Ronnie U.

              “ C “ Shift  Molding Maint.

#22 Robot

 There wasn't enough operators to run the hoky top covers tonight but Charlie and I went ahead and syncronized the robot on 22 with the ejectors. With the robot running at 100% global speed, the ejectors need to be set at 28%. We moved the cups and also dropped the EOAT positive stop bar down to keep from hitting the runner.

Also while setting up number #5 robot the CPU faulted out and had to be cleared. I noticed the pentant light is almost out. I'm not sure if we have any hid away anywhere. If not it I can order some and make them a stocked item.

Collin

Tuesday A Shift Part B

Before I left I programmed the Wittman for the Hoky “Top Cover” (80083) that they hung in MP22 today.  There was not a set up in the Nissei, so the only thing that cannot be changed on the machine is the clamp full open position and the eject forward position.  The only thing on the Wittman that needs to be changed is the cup position on the EOAT.  Also, the way the teach program is written right now, you have to time your eject speed so that the ejectors get all the way out just before the robot gets to the mold face (When robot is at full speed.  First cycle, the robot will only run 30% speed.  To change, in Auto, from the main Wittman screen, hit F6 to increase overall speed and F1 to decrease).  First cycle the eject speed needs to be ran REAL slow so that the robot can get there before the part falls off, and as you increase the robot overall speed, you need to increase the eject forward speed.

 

Thanks

 

  Joshua Ledbetter

  Manufacturing Engineer

  Oreck Manufacturing Company

  931-239-3235

 

Tuesday A Shift Days

Hello All,

Not much going on today with me.  I was watching an auction most all morning and in meetings most all afternoon while Mark covered the floor.

I did have to jump out the hydraulic filter clogged switch on MP4 today, and last weekend I had to jump it out on MP5.  I know you get this alarm sometimes when the oil is cold, but we may also have some legitimate filter clogging.

 

Thanks

 

  Joshua Ledbetter

  Manufacturing Engineer

  Oreck Manufacturing Company

  931-239-3235

 

Dec.7th A Shift

We ran the Wittman today on the Hoky Chassis in MP22.  Runs well, but some of the lights on the sub-pendant still do not work (Manual, Operate with/without Robot, Auto-Cycle Pause).  Swapped the bulb on the Operate with Robot light, and it still did not work.  Outputs for lights coming from Card A22 in the Cabinet (Operate with Robot light is Output A5).  I didn’t troubleshoot it much past that so someone still needs to figure this one out because it confuses everyone not knowing which button(s) are engaged.

 

Also got MP 5 tuned in today and dry cycled.  It is ready to run.  They are going to try and run the baseplate in it this afternoon.

 

  Joshua Ledbetter

  Manufacturing Engineer

  Oreck Manufacturing Company

  931-239-3235

 

12.06.09 nights

Wittman is running. Worked with Josh last night on programming it. I like it, and think it has potential. Attached is a video of what we had last night.

Worked on PM's and cleaned this weekend.

I wired the Dummy plug attached to 22 just like the one Josh was using so it should be O.K.

The only ones that do not have dummy plugs attached to the machines at this point are #2, and #3 presses.

Sean

" C " Shift

  MP 8 – robot touch screen display – “ waiting for download “ – Thought I would have to reload the program; I unplugged the interface cable & plugged it back in

              & it came back up.

            After the press was started, the left side palm button on the fan housing press broke. I robbed one off the spare press & installed it.

              I found two new ones in the assembly maint. cabinet – installed them on the spare press. There is one new palm button in MRO. I put the old one I had

            left, in MRO molding spare parts.