4-29-10

MP10-  Kept going down all day with the pumps kicking off.  Was getting a 5220 alarm, when indicates “Rear Door”.  On this machine, “Rear Door” does not refer to the Non-Operator side door, but the doors that are to the Rear (away from injection unit) of the machine.  I usually call these doors the “gates”.  Anyway, Mark noticed that the non-operator side rear door limit switch needed to travel a good bit before it was made so he adjusted it.

After this, the machine still kept going down.  We spent a little time troubleshooting it, but it finally got so bad it was doing it every shot they needed to run so I jumped wire #69 to #220.

This should get them running, but it needs to be removed later and the problem fixed.

It only does it when the mold is first closed, so it may be a short in a core wire or something.  The only other inputs grouped with the rear doors all seem to deal with options or the cores.  If something was shorted and dragging the voltage down on the entire group, this is the alarm you would likely see first because it kills the pump.

 

Thanks

 

  Joshua Ledbetter

  Manufacturing Engineer

  Oreck Manufacturing Company

  931-239-3235

 

4.29.10 D shift

Mp#10 stopped a few times, the techs did not say anything about it until I asked. I caught it once but it was because it had ran out of material and did not make shot size.

Mp#8- looked into redoing the other EOAT in the shop. Could not locate any 5/16 -24 threaded rod to make standoff studs for the disks. Need to get some. I sent Mark an email.
I do have some ideas we could try with the classic fan EOAT.

Began greasing and Pm'ing presses. We need to update press assignments or work out a plan of some kind that works.

Mp#18- I have been looking into the interface details to tie in the sprue picker. I think that one of the interface boxes will work. I have started on some notes that I will submit for Josh's review on Monday.
After looking at the interface schematics, I think it might be likely we can make something similar from scratch to do a few more presses that only require pickers.

Call if there are any questions.

Sean

" C " SHIFT

 MP-21   Replaced pump hydraulic Hose.

 

MP-26  Fabricated top safety door – It’ll work for now.

 

MP-24  Cores not working;  The eject. back common  on the machine side plug wasn’t hooked up. OK now.

 

MP-17  Cleaned up oil , replaced pads, & emptied jug.

 

 

 

 

R.UPCHURCH

MOLDING MAINT.

April 27, 2010

Spent several hours on our favorite two presses today, MP8 and 10

 

It all started with MP10 stopping periodically. (The pump dropping out)  We wanted to rule out machine or robot.

A jumper was placed between pins 19 and 27 in the robot interface plug to bypass the robot estop stuff.

The pump would continue to drop out here and there.  It seems to always drop out when the robot is either on its way to drop a part off or down in the conveyor guard, so basically when the machine is clamping up or building tonnage.  Looked at the control cabinet door switches and added screws to keep control power on solid.  Replaced the bottom safety switch on the back door, fixed the latch on the back door, it was rolling back some after you closed it.  The purge cover door switch cable was just bare wires twisted together, wirenutted and taped it up.  This is where we got to when MP8

Reared its ugly head.

 

MP8 would not pick parts and the EOAT was all out of whack.  So a couple of hours later we started picking parts again on a consistent basis.

We should put our heads together with our tooling and look at some improvements.  Gary and I talked and he brought up some good points that could fix some problems we saw today.  Tie the two discs together at the proper center spacing, fab and mount them so they cannot turn.  Use a single plate across the tool to represent the discs and insert the two tabs into the plate.  Separate the gripper mounts from the disc mount so they could be moved independently.  Just some thoughts, we desperately need to do something.

 

We received our new hydraulic oil today.

 

Poppet valves came in today.

 

 

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

 

4.25.10 D shift

Mp#2- repaired a broken core sensor wire.

Mp#3-repaired the vacuum switch on the robot, somehow the wires got ripped out. I tied them up neatly.

Mp#4-There was purge material all around the nozzle heater wires. Carefully cut away material and taped the wires back up out of the way.

Mp#5- had borrowed the vac switch off that robot to get #3 running and then soldered back the broken one and replaced it on #5 robot. I checked and adjusted the sensor so that it was working good. It is O.K. to run now.

The edge fan that is running in the vibratory welder is in need of ejectors to eject it from sticking in the tool fixture. Even when the parts are cold they can be difficult to remove. They may already have an engineering change planned but if not, someone needs to take another look at it.

Cleaned up and 5-s'd in the shop. Have a good week, call if there are any questions.

Sean

" C " SHIFT

  Mezzanine – Dryers 6, 21, & 32 – All  were in alarm; had to adjust index limit switches.

 

MP-22  Robot dropping parts;  Tightened up all suction cup mounts.

 

MP-16   Nozzle kept freezing off.  Replaced nozzle band.

 

Lubed all tie-bars. Wiped down & lubed tie bars on presses not running.

 

MP-21   Need to order new pump hose – back side- marked with red paint. It’s leaking at crimp.

 

  R.UPCHURCH

  MOLDING MAINT.

" C " SHIFT

 I vacuumed out all the oil pans & emptied all the oil catch bottles. Also cleaned up oil on MP-21.

 

Emptied oil vac.

 

MP-12   Eye wasn’t reading on eagle fan tester; also the air bladder was popping out of the fan when it inflated.  I adjusted the eye & cleaned the bladder

            with alcohol. Working OK.

 

Mark is ordering more hydraulic fluid & some more ½”  female quick connects to install on maifolds for the oil vac.

 

 

    R. UPCHURCH

    MOLDING MAINT.

" C " SHIFT

MP-20    Blow back -  Removed & replaced two nozzle heaters.

 

MP-21   Grinder quit.  Wire came loose from E-Stop.

 

MP-17 Oil running on floor again- jug filled up. Cleaned up. Oil tank was empty. I filled it.

 

 

 

 R. Upchurch

Molding Maint.

4.19.10 D shift

Mp#1- made 4 ejector bars per Bill Potters Request at 16- 3/4" each.
Also finished connecting front water manifold hoses on it.

Repaired the wheel press for the baseplates, it had a sensor out of adjustment and another sensor completely loose. Checked operation and moved back onto floor.

Dryer# 17-alarmed and went into shutdown mode. It did it because it was set-up in the diagnosis pages to fatal out in an overtemp condition. Simply reset it after checking it over, filters, motor operation, contactors, etc. No further problems the rest of the shift.

Hot Stamp press on #12- the process technician (Roy Smith) asked me to assist him in setting it up as he was having difficulty. We got it going after much adjustment. I recommended that using set-up sheets would help him in the future.

Ronnie and I looked over the new Press 1 and discussed lubrication, when the machine manual comes in I would like to have a look at it. I hear Nissei went up on the price of manuals now?

Reminder, I will be out on PTO Tonight as well as next week on Thursday.

Call if there are any questions.

Sean

4/17/10

Replaced the conveyor belt relay in number 4 robot

Worked on the loader on MP22. Had to adjust the sensor and the load timers

Work the rest of the night on number 8 robot. The round back stop on the EOAT broke one of the guides off. I modified another one and got it running again finally.

Collin

4.15.10 D shift

Worked on the new machine installation. Turned on the water to #26 and checked for leaks, It is O.K.
Ran air line over to #26 and put several quick connects at rear of the press.
Built and mounted the water manifold bracket for front half water onpress #1. Will continue on Monday.

Sean

4

April 14, 2010

MP10 Robot travelled too far in the Y up direction and lost power, bumped it down and referenced it and it was fine.

 

Replaced nozzle heater band on MP19.

 

Temp Controller on MP15 failed and we did not have the replacement.  Found one similar and tried it, no good.  Installed an old model to get us by until one comes in and it worked, but had to jump out the alarm to the machine.

 

Met with Lakeland Electric on MP1 electrical and made materials list.

 

Wired the two transformers on MP26.

 

That’s all I can remember,  4/14/10

 

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

 

4/12/10

Filled MP26 with hydraulic oil

Put the material hopper on MP1 and connected the airline. After the electric and material lines are installed I'll find a good location to mount the power switch.

Fixed a bad air leak on MP14

Collin Miller

4.12.10 D shift

#5- they put a new tool in and needed some core switch adapter cables, I made them up and put them on.

Worked on water for 26 all night, got to a stopping point and discussed everything with Mark as to where we were at with it.

He is going to order/pickup some additional materials.

Spoke with Gary about the hopper for #1 needing an adapter plate due to the differences in footprint, etc.

I put in for a PTO day on the 20th of this month.

Call if there are any questions.

Sean

4.11.10 D shift

MP#5- Had the same problem that 3 had the other day with that Decompress Hoses valve-A156. The coil had shot in it as well and blew the fuse. Changed coil and fuse, then restarted, then talked to Marty and Bill about a problem with the cushion moving all over the place in cycle.

Worked on inconsistent cushion problem that many of the technicians have complained about. Decided to inspect the screwtip after discussing it with Marty and Bill. Pulled it out and really could not determine that it was bad, but, put a ball check in it while it was down to eliminate that. It worked, aligned the nozzle/sled back up and tightened everything back down, re-zeroed the screw position and started it back. Had no further problems with cushion.
There is a problem with the injection unit when it sucks the screw back after building a shot, it is making a loud hydraulic "Shuttering" sound. It is really difficult to describe, but you know that there is something wrong. It is running good parts now, but we need to get that injection valve tuned better or something. Open for suggestions. Will look into it further tomorrow.

Continued with water on #26 the rest of the night.

Call if there are any questions.

Sean

" C " SHIFT

  MP-19    Installed new glass & touch screen on controller.  It was ready to go at 9:30 am .

 

 MP-10   Mark & I worked with the Branson guy on the sonic welder. Mark has more details on his blog.

 

   Vacuumed out pan on MP-6 & emptied oil vac.

 

 

 

   R.Upchurch

April 10, 2010

This morning worked with Doug Mason to set-up an alternative ultrasonic welder for the connector on MP10.  After a fair amount of tweaking, this machine which is the old Air Ten Truman Cell Bracket welder, could work in a pinch with some modifications.  We finished with 30-40 parts in a row with no failures. 

 

About 10am, Keith Raiford with Branson Ultrasonics came in to work on the Branson Model 910IW welder on MP10.  After a thorough investigation we found the following problems with our old welder:  The main power supply for the welder was dead w/ no output, (A new power supply was installed) The upper exhaust fan in the cabinet had failed, (Both fans in the cabinet were replaced to protect the ps)  The horn cylinder was replaced, The trigger switch was replaced, The trim pot on the front of the machine was jacked up and we replace it,  Both air regulators on the front of the machine were broken and we replaced them.  We bummed a packed of mylar washers from him for the horn,  Went through the horn stack and serviced it,  Tuned the machine, aligned the horn and fixture and started welding parts.  Potter was happy with the parts.  The following set-up exists:

 

38psi air pressure

1.5 weld time

.050 on hold time

5.5 trigger

 

 

 

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

 

4.10.10 D shift

#4- had a problem with temp zone#2 it was a mercury relay stuck. Pecked on it and it started working again.

Continued working on new press 26 water and New press#1.

Sean

" C " Shift

 Leave MP-10 down ;   Branson tech will be here in the morning.

 

MP-2 – They hung the supply tank again. You have to crack the eject valves open so the machine & mold plates both move, so it can read limits.

 

MP-19  Someone broke the glass on the controller.  I ordered a new glass & touch pad . It will be here tomorrow.

 

MP-8   Cores not working--- after checking everything, it ended up being one of the hydraulic quick connects.

 

MP-25   Ran a new T.C. wire for the nozzle tip heater.

 

MP-17  Oil was running out on the floor AGAIN.  Cleaned up AGAIN. Needs oil added.

 

 

 

R.Upchurch

4/8/10

MP20 broke the ejector plate bolts. Replaced them and started back up.

Hooked up the cores and ejector hoses and switches for the tank mold in MP2 but we couldn't figure out the settings to make it read the ejector switches only

The Branson welder on MP10 stuck a couple of times like it was still trying to weld when the head came back up. The operator tapped on the side of it and it quit. Later on in the shift it quit welding altogether. I checked everything out and tried a new relay in it but still couldn't get it working.

Collin

4.6.10 D- shift

Mp #3-

Stopped during production with clamp closed. The machine acted like it had lost its pump and nothing was working at all. We tried probing the variable pump load valve and got 3000 pressure so we started looking at the electrical and found a fuse blown. We changed it and it blew as soon as we started the pump. After tracing out the short, we located the coil bad on the "Decrompress Hoses valve A156". We replaced the fuses and used the coil from the sled retract valve to open the clamp and check things out. When we took the coil back off the A156 valve we noticed that it was extremely hot.

After looking at the output card, I noticed the output for A156 (slot 5/#10) was staying on constantly. I wanted to isolate it to the output card so I swapped it out with the card from slot 8. Well, it was not the cards.

So I compared it with Press#5 to see what it was doing and 5 was not coming on at all in automatic cycle. So, I stopped it long enough to see if it came on in Manual or when the pump was off. It didn't come on in either case. So, at this point I went to the sequence chart and looked at when it should be on during the cycle. It does appear to be on throughout most of the cycle except for a short break between decompression and extruder run.

So the dilemma I am faced with now is why would the control be energizing this A156 output all the time? Is there something feeding back data to the control that would make it respond this way? Maybe a bad transducer or another input signal?Or a bit set in the control? Maybe needs reprogrammed?

Call if there are any specific questions about this or anything else.

Sean

3/2/10

Worked on core # 2 pull sensors on mold # 74046-01 in MP4. Two of the three hall effect sensors will not read up the magnets in the hydraulic cylinders. The top sensor works as long as you don't tighten down the hose clamp too much. I found two more sensors in the shop and tried them. They work with a strong hand-held magnet but not on the cylinders.

Robot #10 stopped 3 times within a 5 minute period and never messed up again. Two of the stops were in the mold accompanied with a "Mold not open. Robot in unsafe position" alarm.

Cleaned the two new presses and started painting them. I will try to finish tonight.

Collin Miller
"B" shift
3/2/10

" C " SHIFT

MP- 25  Changed  nozzle T.C. to “ J “ type so it would run in auto on DME.

 

MP- 23  Nozzle adapter heater band went out ;  replaced.

 

MP- 17  Chiseled Santoprene out of grinder. It had two different colors in it. I guess it had been running all night.

 

MP- 10 Robot only stopped one time. They wanted to let it run . I guess we’ll try & fix it on the next run.

 

 

 

 R. Upchurch

 Molding Maint.

4.1.10 D shift

Clear out the area for press#1 and capped off the heat exchanger lines.

Changed out a color mixer motor on #9.

Robot on MP#10- has been stopping every hour or so. It has been stopping over the conveyor after it has dropped the parts and goes up. It readily homes back and restarts. I mentioned stopping it to work on it but Marty did not want to leave it down for any length of time.

Call if there are any questions.

Sean

MP22 Star Robot Operational Update

We had a service tech from Star Automation in here yesterday on a courtesy call to help us out on some issues we have been seeing with the TW1200 robot on MP22.  Listed below are some corrections that were made that I wanted everyone to be aware of.

 

1)     Insert Arm L5 Home Limit Switch-

We were having an irritating problem with the robot not wanting to reference or return to the home position without the L5 Limit Switch being made.  Since we’re not currently using the Insert Arm, we corrected this by moving the L5 Limit Switch closer to the traverse beam and set the “Avoid Position” for the Insert Arm to 0.  Now the Insert Arm should never move off of the L5 Limit Switch and cause this problem.  Also because we moved the Insert Arm closer to the Traverse Beam, we were able to move the Product Arm Limit Switch closer to the Traverse Beam to give us more Crosswise stroke on the Product Arm.  Now we should not have to open the mold as far to remove parts.

2)     Part Grip Circuit-

The Part Grip circuit was not functioning because the robot’s previous owner had wired the valve output down to a plug at the EOAT.  The valve was rewired and now functions correctly.

 

Also, if you’re like me, then you have been having problems getting this thing to reference when you first power it up.  I would get an alarm saying “To make sure there is no interference with the Traverse Beam and to perform Posture/Rotate in Free Operation Mode”, or something like that.  What I learned yesterday about referencing the robot and homing the robot both is that it works a whole lot better to exit all the way out to the initial screen first before homing/referencing the robot.  There are two ways to home the robot-  First you can hold the “Dead Man” button until the bar at the top of the screen turns yellow and then hold the home button, or secondly you can turn the switch on the pedestal to “Origin” and then press the green “Start” button on the pedestal.  The light on the “Start” button will blink until homing operation is complete.

 

Call or email with any other questions.

Thanks

 

 

  Joshua Ledbetter

  Manufacturing Engineer

  Oreck Manufacturing Company

  931-239-3235

 

3.28.10 D shift weekend

Worked on Pm's most of the weekend.

Put the remote and blowback option on the 1 shot loader. Checked it, it works fine.

Looked at the Jet Loaders and Jet select valves. We really need the jet selects when using them for multi loading application. Talked with Mark about it and there may be a cheaper alternative to buying jet selectors? Might be able to use conair or off brand pocket valves to do the same things? Just a thought.

I need to obtain a Yushin pendant that works. I remember there were about 4 good ones from when I initially checked them all out, but now i cannot locate them. I am going to try to get the one on 16 going first.

Started putting SPI on #16. haven't tied it in, but have the box and wiring numbered and run already.

Had mostly minor issues since we were not running very much this weekend.(SLOW).

I will be out this Thursday, call if there are any questions. I will call back on Tuesday.

Sean

" C " SHIFT

   MP – 22   Mark & I  built eoat for new handle mold.

 

  MP – 4  Nozzle heat was running away; T.C.& tip heater were damaged, also the nozzle adapter heater was shorting out. Replaced all.

 

 Emptied oil jug on MP – 11; replaced oil pads on MP – 17

 

 Started cutting material & getting hardware together to assemble more catch trays for tall conveyors.

" C " Shift

  MP- 8  Mold hit the robot again. I reworked the end of arm, & shortened the “Y”  axis up flag.  I cleaned & lubed tie bars before they started press.

 

 MP-20   Realigned  the sled.

 

 MP- 5  Lost robot power  -  The grinder jammed & tripped the breaker.

 

 

 

 R. Upchurch

Molding Maint.

3.24.10 D shift

Robot 22- Constructed end of arm tooling and programmed robot for production. Used the new style gripper cylinders Josh ordered. They work great. Like the non-rotating feature they provide.

Had some problem with the robot going too fast into the mold area and stopping. We slowed it down to 80 from 100 and it did not stop anyore.

MP#19- Cores were not outputting a decent Pull signal when I checked it with no load. 24 on the set side, and only 6 volts on the pull side. I set it up to run straight off the controller outputs of Core 2 but ran each coil through a 1/2 amp fuse in case of a short.

I checked operation and verified that core switch signals were reading correctly, labelled everything , and posted a notice to "only use core 2" at the operator panel. It should be O.K. to run now.

I need a controller pendant that works to do anymore testing on the Yushin pickers. Give me a call if there are any questions.

Sean

" C " Shift

  MP- 2    A piece of metal lodged in between the tie bar bushing retainer & the tie bar; it was gauled up.  I stoned off the area & re greased all tie bars before

              they started it up.

 

  MP-24   Tech said they were having heater problems;  the problem was the nozzle heater band was getting pushed back when they ran the sled forward.

              I moved the htr. band clamp back so it wouldn’t  hit in the sprue bushing area, reset heats to s.o.p. sheet, & let um have it.

 

  Cleaned up oil on MP-11-17-& 21

 

  MP- 19   Mark mounted  the core directional  valve. I made up new hoses for the valve & the test cylinder. Core sets but doesn’t pull; still troubleshooting.

 

 

 

   R. Upchurch

   Molding Maint. 

3.18.10 D shift

Mp#8- the robot had crashed when I came in and it had apparently only broke the center peice of the wrist assembly. We took the one from #6 off and replaced it. Had a little trouble getting it off and running smoothly, but it has been doing good.
Welded up the broken part and drilled and tapped it out, made some replacement bushing for it and put it back on #6 robot. Should be fine to run now.
Mp#23- Moldsetter was changing tool and said that after he opened it up it would not close back again. With ejectors back all the way it was reading 204.5 mm. It kept giving an Error 35- confirm ejector bwd position.
I checked that manually probing the valves (while actuating switches) would indeed work the clamp and the ejectors, so I knew it was not that. It behaved similar to the encoder problem on 25.
I tried swapping them out but it made no difference, so I put them back.
When I looked at the ejector bwck stop position there was an offset for the encoder sensor.
I added the difference that it was off by to the value that was already there and it started working. But we had to adjust the ranges some more to get it working like it should.
I cannot explain the problems root cause unless someone had changed the program by accident, but it is working now.
I also refilled #22 with oil because it was very low.

Sean

Week of March 15

Ronnie and I put pilot operated check valves for core on MP24

 

Ronnie, Sean, and I added core 2 and the new switch setup to MP22.  Gary, the manifold mount worked great.  Rewired the Eagle Top Cover mold with new switch system.

 

Investigated adding core 2 on MP23, talking to Nissei, needs another look.

 

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

 

3.14.10 Nights weekend D shift

Mp#23- Looked at Valve Block changeover situation.

Found all the fittings need to connect to hose out of the new valve block .

We will need a fitting to tie into Pressure port on Machine and Drain/Tank.

We may have something that will work, need to remove hard lines to verify.

Same goes for the lines going to Core A/B block where QD fittings attach.

I looked at how the existing valve block attaches and tried to determine the best possible retrofit.

I took measurements and completed a print for a bracket that will allow us to make a bolt on replacement.

There are notes on my desk and I discussed it with Mark also.

Yushin Picker , pulled another one from the trailor and parts needed to complete the build. Problem I ran into is that None of the pendants I have tried are working. I am going to try a few other pendant cables or sensor boards as time permits.

Did the PM on press#3- repaired the blown out grease fitting Bill Potter mentioned. Will keep an eye on it. We are trying to get back on top of these leaks and minor repairs.Keep me informed on any new policy changes or developments, thanks.

Call if there are any questions!

Sean

" C " Shift

   MP-23  Made a temporary separator for fans coming off belt.

 

  MP-23   Josh said we were going to put the new core valve on this press; they were running it this weekend. We probably need to get Jade in to

               look at it & see what fittings we need to tie it in.

 

  New top cover mold -  I tightened & double checked all the hydraulics; still need to check limit switches.

 

  Well, the new o-rings on MP-17 didn’t work ! 

 

  I worked on PM’s the last part of the shift.

 

 

 

    R.Upchurch

    Molding Maint.

" C " SHIFT

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

 

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

 

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

 

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

 

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

    tech. assistance  Monday.  

3.12.10 D shift

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

Continued with P.M.'s

Sean

March 11, 2010

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

 

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

 

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

 

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

 

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

 

Mark McKee

Technical Specialist

Oreck Manufacturing Company

1400 Salem Rd

Cookeville,  TN  38506

mmckee@oreck.com

PH      931.646.7856

CELL  931.644.5289

FAX    931.646.7851

 

MP24

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

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

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

Collin

3.9.10 nights D shift

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

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

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

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

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

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

Submitted PTO for Thursday- April 29, 2010.

Going on California trip.

Sean

Sean

3.8.10 nights D shift

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

Also labelled 480 panel and receptacles on press#22.

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

Repaired both thermolators that were red tagged outside the shop.

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

Will continue with PM,s tomorrow as well.

Sean

" C " SHIFT

 MP-24  Made up adapter box for core plugs.

 

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

 

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

 

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

 

 

       R.UPCHURCH

       MOLDING MAINT.

3/7/10

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

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

Fixed the feed-throat water on MP13

Collin

Storage trailer roll up door

FYI-

 

Ronnie Colson and Jeremy fixed the roll up door to the storage trailer today.  I just wanted to make everyone aware of it before someone tried lifting it with a forklift again.

 

Thanks

 

 

  Joshua Ledbetter

  Manufacturing Engineer

  Oreck Manufacturing Company

  931-239-3235

 

3.3.10 nights D shift

MP#10 Robot- was stopping in mold and at part drop. Found a loose sensor connection on the C axis. Tightened it up. No further problems from that, but then an hour later it would stop over the part drop area with parts. I found that the Z position was not going all the way to set point. Noticed that the belt was off track and loose. Adjusted tracking and tightened it up and had no further problems with 10.

Mp#9 Robot- stopped once at 4am and would not home. Powered it down and reset. referenced it and it would try to home after reference but it could not go to Z at mold position (set at 30) because it was already against the back stop (reading 40 as actual value). We jogged it into the mold and aligned it with parts and it appeared that the Z in mold needed to be at 72 at that point. So we changed that value only to 72 and it started running fine until it went down an hour later. Mark and I discussed changing out to the new encoder style on that axis possibly. Also talked to Potter about that too.

Mp#13- Mold setter was having trouble removing mold from machine. we used die bars to pry it out, then next tool wouldn't fit without forcing so we went around the I.D. of locating ring with a die grinder and cleaned it up. Then tool fit good. O.K. to run.

Finished E-stop install on #22 and checked operation of it. Ran the box and flex for #23 but have not tied it in as they were still running the press. I will continue with that and signs tomorrow. Call if there are any questions, I'll be glad to help.

Sean

MP16

Gary and Mark changed out a bad heater band on MP16, and also found that the zone 1 TC was not pushed in all the way and was heating 70 degrees above set point.

 

 

  Joshua Ledbetter

  Manufacturing Engineer

  Oreck Manufacturing Company

  931-239-3235

 

Monday March 1st

Ordered a new rotary encoder for MP25- it should be here tomorrow.  Mark got the one on there to read somewhat, it may be good enough to limp through until the new one comes in.  We were waiting on them to put a mold in there so that we could really test it out.

 

Also, three “new” 2003 model Jet Loaders came in for MP23-MP25.  One of them has a busted up display and no filter, so I will need to order some parts for it.  Collin, see if you can get two of them ready to run.  I will try and get a good manual for them before I leave today.

 

Thanks

 

  Joshua Ledbetter

  Manufacturing Engineer

  Oreck Manufacturing Company

  931-239-3235

 

2. 27/28 .10 nights Sean

Mp#25-
It is down and needs an encoder for the ejectors. They had problems with it after changing the mold and it would not read, I worked on it and got it to read but it would never close the clamp and it would give an alarm like: "confirm setting for ejector bwd limit." I wanted to eliminate that it was n't the limit switch cicuit so I checked the door switch, and ejector back limit switch jumper and cable.(was fine). I spoke with Mark and gave him the Encoder information and model number.

Made EOAT for the Edge top cover on #11.

Got the signs turned around for the Machine Disconnect locations.

I am sending an email to Jerome asking for some time to get leaks fixed on press# 17.

Call if there are any questions.

Sean

" C " SHIFT

MP-16  Tech said barrel heats were running too high.  I checked heaters, contacts, T.C. connections,& cables. Everything checked OK.  The heat profile was 500 to

       535. ( Nylon )   For some reason, we had to run the heats 50 to 55 degrees under & parts ran fine.

 

MP- 17  Mold 74005-01 broke a pin “ again “.  I found the thin switch had been wired N/C.  I changed it & Gill repaired the mold. It should be back in & running

       Before the end of the shift.

 

MP-21   I vacuumed up oil & cleaned around press.

 

DR-23  I put this dryer on the mezz. In place of  DR-19 . We need to order large bed gear for DR-19    Conair part #  183875

 

 

 

         R. Upchurch

         Molding Maint.  

" C " Shift

 MP- 13 Eject. cylinder bolts broke. Replaced.

 

Dryer- 19  Turntable motor mounts broke & large drive gear stripped. No new gears in stock. Will order more gears Monday.

 

MP- 1  Mark finished pulling valves – we put the frame & covers back on. I should be ready to go .

 

MP- 25  Ejector not working -  Tech said he wiggled the plug on the eject. transducer & it broke off. I was able to straighten the pins enough to plug it back in &

         tape it up. The end that broke off was on transducer. We will have to order a new one to fix it properly.

 

We checked the oil storage building, & the drums had not been emptied, so we loaded four empty drums on a spill pallet & brought them inside.

 

 

 

      R.Upchurch

      Molding Maint.

2.26.10 nights D shift.

DR26- repaired the carousel position switch with new screws, no further problems with it.

Gr13- repaired hinge pin, made a new one.

Mp#3- screw was wrapped with plastic and it would not build consistent shot.(kept stopping). Jacked up the barrel heats to 550 and let it soak for about 45 minutes then ran a bunch of clear PC regrind purge and compound through it until it was shiny clean. Ran great the rest of the night.

Mp#2- was down so I checked the core 2 circuit, at first it would not work, then I moved the pressure line to the P1 circuit and it had 2000 psi. Checked it with the test rig that was in the shop and it worked fine. O.K. to run.
Also on 2, I cleaned up the oil that was in the floor there, I couldn't really tell where it was coming from, but it was under the mold area mostly and appeared to have dripped down... was there a leaky mold on A or B shift?

Started swapping orientation of the U-bolts on the disconnect signs, should be finished by this weekend.
Did we decide what to do with the 200volt conveyors in the shop? I can put them back in the trailer? Let me know.

Sean

2/24/10

I removed the adapter heater band from MP22 to put on 23 so it could start up. It's wired into the same terminals as the nozzle (R1 and S1)

MP20 broke all the ejector plates bolts and had to be replaced. Also the plate guide bar was badly bend. Darryl and I straightened it in the shop press enough to be useable.

MP21 stopped working while in production. Nothing would move but the sled. Also the clamp and screw position wouldn't read. We powered it down about 3 times and it allowed us to move the clamp so we could reset the mold thickness. Everything started working then. I've seen it do this once before a while back with the same problem and solution.

Collin

2.24.10 night shift D

Mp#5- fhd current input #1 exceeds limits alarm.
Changed the fhd current index for extruder max out value to 12000 from 16000. Per Josh's advice. No further issues this shift.

Mp#16- Used the heater band from #1 to get the heaters going on it. Noticed the sprue-break limit switch adjustment ring was slid back a little more than all the way up. This may have contributed to some bleeding off that occurred. Put a note on the press for operators to remind the techs each hour to check for bleed off.

Found a 400 ton FN7000 1999 model online last night. It had a 575volt.
http://www.usedplasticinjectionmoldingmachines.com/2010/02/04/1999-398-ton-used-nissei-injection-molding-machine/

Another one:
http://www.kitmondo.com/ViewListing.aspx?lid=242651&prodName=Nissei_FN7000

This is the 575 volt one:http://www.elitemachinerysystems.com/machine_details.php?prod_id=645

" C " Shift

 Still working on stripping MP-1.  We drained the hydraulic suction lines, & water from the heat exchanger. Mark removed the conduit & recepticles.

    I  removed the rear frame to access the pump & motor.

 

All the waste oil drums were full , so I moved them to the oil storage building for pick up. Walter said it would probably be Thursday before they could pick

     It up.  If we need an empty drum before then, there are two in oil storage.

 

 

 

 

 

 

           R.Upchurch

           Molding Maint.

2.23.10 night shift D

Mp#5- had lots of metal in the nozzle. Typical baseplates? Grind it till we find it?

Mp#2- Nozzle has been running away somewhat. I noticed first zone was 5o degrees hotter than the nozzle the way setpoints were set. I checked the mercury relay and noticed it was not plumb, straightened it back up and tightened the screw on it. Compared pg 96 values with those of #5 press and set the PID for then nozzle the same. Also increased the scan time from 5 secs to 2 secs. (#5 was set at 1 sec). Next move is to change out from mercury to solid state relay, but I think much of the heat is coming from the process.

Started pulling more stuff from #1. Also made progress on the Yushin 900. I need to change out some sensors and replace missing parts and it should be O.K. to go.

Call if there are any questions.

Sean

Monday Feb 22, 2010

Tagged out power on MP1.  Started stripping parts of value from MP1

 

Received New Motor Starter Parts for MP3.  Assembled and Installed in MP3.

 

Received additional seal nuts for 3/8-24 Go Switches.  Put in MRO in Go Switch Tray.

 

Received new clamp on Reed Switches for magnet piston type cylinders.

 

We have the Nissei Gas Springs for Display controllers that need to be installed.  They are on the table.

 

Ordered new Machine moving skates.  Salesman will pick up the old ones tomorrow.  RMA #’s on my desk.

 

We should receive the motor for MP3 sometime Wednesday.

 

Ordered the core stack for MP19.

 

Put connectors on new Encoder for AEC Robots and put in MRO.

 

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

 

#16 heater bands

MP 16 had a bad blow-back which cover all the bands but three and destroyed all the insulation from the barrel shroud. I was able to reuse most of the bands but we are missing or out of stock one of the nozzle bands. It's a 240V (2.5" X 1.5"). I left the old one laying on the press. The nozzle thermocouple is wired in and the tip band is on the press also.

Collin