" C " Shift

• Wiped down & lubed all tie bars before start up. Made sure the chiller & pumps were operating.

 

MP-19  Replaced broken oiler fitting ;bottom  non – operator side.

 

MP-11  Robot not going to home position ; turned off main robot power & rebooted- OK

 

D-32 ( mezzanine )   Alarm 11 -  Adjusted index switch.

 

MP-9  Robot  Z  axis brake not releasing – checked all connections, & cleaned the contacts. Working fine now

 

MP-22  Tech burned his arm while purging out barrel. I checked to make sure we didn’t have a heater problem. The last shift that ran did a mold change &

           didn’t purge the barrel. They went from Santopren to nylon. When the new set up was loaded, it was 200 degrees higher

           than the new material being  loaded.

 

 

 

 R. Upchurch  

6.16.10 Nights

MP#6- Charlie thinks the screw tip may be worn out on it. They ran the big blue Hoky and had short shots off and on all night. We may need to do a static test on that one as well.

Worked on robot PM's all night. Replaced the vacuum generator unit on #20 robot, it was still functional but leaking air really bad. The gasket on the pilot valve was blown. It can be repaired if we can get a new gasket. I think Mark is going to check with Motion Ind.

Sean

" C " Shift

MP-9  Robot wasn’t homing;  the reference block had been moved & one of the home blocks was loose. I got that straightened out & then there was

          no vacuum on the cups. There was water in the system; bled it off & set the vac verify switch—ok to run.

 

MP-17  The nozzle heat controller was in hi - temp alarm & wouldn’t heat.  There was a loose T.C. connection at the controller—Repaired.

 

MP-12  The grinder was making a noise ;  I cleaned it out – the material was hot & just about to start melting. I let it cool down, & had to adjust the rear

           stationary blade. I reassembled the grinder & got them to turn up the regrind load time. OK to run.

 

 

 

 

  R.Upchurch  

6.10.10 D-shift

D shift had 2 process techs out wed/thurs so today I did spend some time assisting with set-ups etc.

MP#9- built and end of arm tool for mold # 78165 and roughed in the parameters.

Made a tool for them to insert the magnet in the fans they were welding at #12.

As it stands, I told Darryl that I will not be working Saturday and Sunday, but if he needed me to come in and fix anything that was down, all he had to do was give me a call. My number is posted in the molding office.

Sean

" C " Shift

MP-3   Left side gate cutters not cutting good; I swapped out cutting tables. I changed out the left side cutters. It’s always harder to cut the polycarb parts.

          We need to order spare cutters.

 

MP-13   I installed the new screw tip . They hung a mold in it.

 

 

 

 

 

 

 

 

R.Upchurch

6.8.10-D shift

Mp#4- changed the thernocouple, reused the heaterband. Darryl requested that I remove the purge that was stuck to the wires.

Mp#15- helped Jeff set-up the Sprue picker. It needed some maintenance and also needs some work on a screw that is stripped out where they adjust the in/out from the mold<>.

MP#21- hot stamp had a blown fuse. Replaced it and it began working fine. Replaced a gage on one of the air regulators, cleaned, lubed and tightened things up on it.

Worked on liquid color pumps that were in the shop. Cleaned, repaired and generally just fixed what needed fixing on them. Still have a few more that may need parts.

Call if there are any questions.

Sean

MP19 Nozzle Touch Alarm

If anyone gets an alarm on MP19 that says “Nozzle Touch PS2 Unconfirmed”, here is the fix-

Go to clamp factory screen by hitting “Shift” and then the “Clamp” screen button.  Go to the page titled “Mold Adjust 1”.  At the top there is a setting named “HPCV”.  Not really sure what it is or what it does, but it controls what the pump loads to for nozzle contact force.  I found it set at 60% the other day when we were getting the alarm and set it to 99% and this fixed the problem.  Evidently they had the problem again over the weekend and I’m assuming the value got set back to 60% when someone reloaded a new process set up.  We changed again from 60% to 99% and this fixed the problem.

Call with any further questions.

 

  Joshua Ledbetter

  Molding Maintenance Manager

  Manufacturing Engineer

  Oreck Manufacturing Company

  931-239-3235

 

6.6.10 D shift

Finished repairing the connector nest for vibratory welder. Replaced broken/missing screws loctited them. Cleaned and inspected the tool. It looks like the adjustment method they have been using requires a hammer sometimes.

Lubed all of the tiebars and refilled reservoirs and greased the machines.

We need to get a repair kit for the Milacron machines complete with 3/16" nylon tubing and the ferule type fitting they use.

MP#15- has a broken lube line that needs repaired when it is down.

MP#17- has an extruder hose that is leaking. I tagged and measured it. Made a new hose up and left a note so we can change it when it is between molds.

I left a note on the Fastenal board to restock the "assorted springs" drawer. I used a spring last night to repair one of the gasket locating tools (used on the intake pivots) but didn't really have what was needed.

I left the old clamp tonnage transducer with Mark so we can possibly stock a spare.

Replaced the cabinet fan on robot #3 panel.

Basically fixed little things most of the night and helped the techs because this shift has no tooling person. We repaired the tool on press#22 that broke out all 4 keen-serts. There were only 2 left in the box so we patched it up to get it running.

Let me know how you want to do that blocked nozzle test. I am supposing you want to do a dynamic check ring reliability test for bad screw tips?


I plan to take off this evening but will work on till Friday night. Call tomorrow if there are any questions.

Sean

" C " Shift Weekend

MP-22  Tech said cores not working --  found eject. back switch wasn’t made – they forgot to tie in the knock-outs.

 

MP-2   Mid zone heat kept dropping out;  contactor was bad – replaced

 

MP-22   Checked torque on the screw gun for the valve body. Max torque on the SOP is 14 ;  It is running 12.5 – 12.75.  They had a few

            parts  crack . I think the parts may have just been too hot.

 

MP-5  One of the wheel mounting brackets on the ( small parts ) shelf unit broke off.  I took it to the shop & brazed it back on.

 

MP-5  Getting  the prefill alarm again. Changed settings & offset.  It ran until right before shift change & alarmed out FHD exceeded limit.

          I left it with Sean.

 

Cleaned up oil & changed pads on MP-17 & 21.

 

MP-11  The core pin broke & when they pulled the core cylinder off, they pulled the wires loose. Repaired.

 

 PM’s  on press 2 , 3 , & 4.   MP-3  needs new fan in robot cabinet.

 

 

 

 

R. Upchurch

6.5.10 D shift

Mp #5- the tonnage readout was stuck at 500, even after powering it down, etc.
I changed the tonnage transducer and when I powered it back up, it was a teading negative value (-28). I calibrated the offset and changed the convecs 921, 812, and 813 so they were 150 apart, etc. It worked.
Started it up and ran production at 7:10pm. Has ran good all night so far.

Changed out the screw gun on #22 because it would not stop running. I advised the process techs to monitor the screw bosses so they would notice if they were breaking out. They are doing fine so far.

Assisted Lynn Smith in changing out the welder nest and setting it up. I took the connector tool back into the shop, I have to make some repairs to it where it has been broken.

Sean

Cleaned up out on the floor and in the shop.

6.4.10 D-shift

Mp#5- stopped for the prefill alarm again. I couldn't find any information about what was done to it the other day to get it going. I tried calibrating the tonnage transducer again, but it did not work. Milacron thought there was problem with the FHD board for it to be continuing to have this problem. It is down now.

Jerome never replied to my request to schedule it down to do the screw-tip, so for now I will leave it.

I was able to extract the broken peices out of the screw for MP#13. I think it will be alright to use. Still need a new tip though.

Right now I plan on leaving at 2am Saturday night.

Will work all night Sunday.
Off on Monday.
Will work Tuesday through Friday nights.

Call if there are any questions.

P.S. Leave me some info this time on #5 so I can gain a better understanding of how to patch this thing for production. Thanks.

Sean.

" C " Shift

MP-13   Pulled the screw & screw tip. The rear seat wasn’t there. They continued to run it after it broke, so the threads in the screw were gone.

          Nissei didn’t have a 32mm screw in stock, so I called Chaseland  to make us one. They will fax the quote for the screw & tip Monday.

 

MP-14   Jason said some metal was showing up when he purged it out. Thought I was going to have to tear into that one when I finished 13.

           He got it running, so hopefully this one won’t jam up the check ring.

 

 

 

 

 

  R. Upchurch

6.3.10 B shift

Mp#13-Redid the heater bands on the nozzle. Checked and found that screw tip was indeed broken. Mitch was running it but they were scrapping too many so they eventually shut it down.

Repaired the cannister gate cutter fixture. Tested it out and it works great.

The drill press in the rework area broke the quill return spring. I was able to heat and rebend it and it is working again for now but we need to order another one. I gave Mark a lead with the drill press info.

Cleaned up oil around #17 and #21. Put some new oil absorbent down.

I am sending Jerome an email to see if he will leave #5 down on Saturday nite to do the screw tip change and barrel measurements.

Call if there are any questions.


Sean

Out of plant

I will be out tomorrow, Friday the 4th.
Josh
Sent From My Verizon Blackberry

Thursday A Shift

Suspect screw tip in 13 is broke. I've ordered a new one that will be there tomorrow. 
Josh
Sent From My Verizon Blackberry

6.1.10 D-shift

Mp#5- stopped for "Prefill did not open in time" alarm.
I was able to open the clamp by changing the offset for clamp tonnage on menu 93 from 1799 to 2250,and menu 92/convec 921, from 2000 to 2350 to get the clamp tonnage to zero, but it will not run yet. It now will alarm again but will open if you clear the alarm.
I spoke with Clarence at Milacron service who thought it sounded like the prefill valve was bad. I looked in MRO for another directional valve like it but couldn't locate one. They are using press #3 or I would have tried some parts from it maybe. I wasn't so convinced it was the valve bad yet, and I want to talk with Josh about it first.

Mp#11- Potter asked me to check the cores when I came in, I checked that the machine was working fine, used our test rig to verify switches and hoses. They had the collar tool out working on it and when it was set back in they never worked, it appears to be jammed up internally.

Worked on DME boxes, replaced cooling fan, and installed #3 jumper in all of them so they will work with the new style cards.

Changed the cord plug on liquid colr pump for 13 also.

May want to look over the gate cutting fixture that is for the cannisters. it is in the tool room because it needs another braket made. It looks like it is time for an overhaul of that fixture, I am welcome to any ideas with it.

Be back in at 6pm.

Sean

This week 5/24/10

Ordered new Saskawa servo amp from Nissei for MP1.  Should be here 6/1/10.  Called Saskawa and requested they send us our unrepaired unit and regenerative pack.

Should be here 6/1/10.  Nissei is now set up to accept P.O.’s, net 30.

 

Set up welder ejectors on MP12 for new Edge fan housing ejector cylinders, used outputs 12 and 13, top two single valves.  Firing sequence is top ejectors step 5, bottom ejectors step 6.  When door open part is laying loose for operator to remove.

 

Changed out safety latches in hoist ring hooks in molding production area.  (both hoists)

 

Installed additional 480 outlet on MP18.  Two outlets share a 30A breaker for Thermalators.

 

Fabbed and installed extrusion frame to hang heater wire junction box on MP2.  Mount junction box to new frame.  Replace and label all heater wiring.

 

Install and adjust spare Robot EOAT for fan housing on MP8

 

Replaced  (4)  2” load system hose sections up in mezzanine area with what hose we had on hand.  More hose is coming.  Replaced 2.5” material hose on top of surge bins.  Installed elbows and partially hard piped some drops.  We are trying to eliminate all vacuum leaks.

 

Install sand paper to the bottom of rework fixture for orbiter disks and realign.

 

Worked on color pump signal for MP1.  Parts are here to steal a signal from the output of the servo drive to the motor.

 

 

 

 

 

 

 

 

 

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

 

This week 5/24/10

Ordered new Saskawa servo amp from Nissei for MP1.  Should be here 6/1/10.  Called Saskawa and requested they send us our unrepaired unit and regenerative pack.

Should be here 6/1/10.  Nissei is now set up to accept P.O.’s, net 30.

 

Set up welder ejectors on MP12 for new Edge fan housing ejector cylinders, used outputs 12 and 13, top two single valves.  Firing sequence is top ejectors step 5, bottom ejectors step 6.  When door open part is laying loose for operator to remove.

 

Changed out safety latches in hoist ring hooks in molding production area.  (both hoists)

 

Installed additional 480 outlet on MP18.  Two outlets share a 30A breaker for Thermalators.

 

Fabbed and installed extrusion frame to hang heater wire junction box on MP2.  Mount junction box to new frame.  Replace and label all heater wiring.

 

Install and adjust spare Robot EOAT for fan housing on MP8

 

Replaced  (4)  2” load system hose sections up in mezzanine area with what hose we had on hand.  More hose is coming.  Replaced 2.5” material hose on top of surge bins.  Installed elbows and partially hard piped some drops.  We are trying to eliminate all vacuum leaks.

 

Install sand paper to the bottom of rework fixture for orbiter disks and realign.

 

 

 

 

 

 

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

 

5.27.10 D shift

Replaced wiring to purge sheilds on presses #6 and #12, tied them up neatly and repaired sheilds with new screws and fasteners, etc.

Checked all of the presses that were down for loose safety circuit switches and door latches, fixed whatever I found. Replaced screws as needed.
Checked the lube lines for broken fittings.

MP#8 -Finshed where Ronnie left off on oil pan clean-up.

I left a paper for Mark to see about ordering those vacuum drainage reservoirs for the 500 Cincinatti's clamp drain line. They might give us one as a sample since you order them 48 to a case.?

Mark and I went over the procedure for HMI programming for the AEC robot displays.

Call if there are any questions...have a great weekend. I will be working Tuesday-Friday or Saturday nights next week or until? I sent Darryl an email.

Sean

" C " SHIFT

MP-19-22-23-25   Filled lube reservoirs.

 

MP-19 & 22   Replaced broken tie bar & skate lube fittings

 

MP-21  Robot crashed into mold. All of the gripper mounts were either bent or broken off. Replaced all mounts, tightened the gripper posts, chased

      threads & replaced bolts on eoat mount.

 

MP-6 Vacuumed out oil pan.

 

 

 

R. Upchurch

Molding Maint.

5.26.10 D shift

Mp#260 Changed out the temperature contoller. It quit reading actual temp. Auto-tuned the new one. Checked operation, O.K. to run.

#11-Robot
Would not reference the Z-axis. Went thru the whole z-circuit, found loose connection on break relay module.

Call if there are any questions.
Thanks.
Sean

Molding Support Tracking Spreadsheet

Hey Guys,

I put together a To-Do spreadsheet today and put it on the server.  Attached is a shortcut. 

The spreadsheet has multiple page tabs at the bottom for Issues, Parts, Projects, and ShutDown Projects.

Some of the cells have drop down boxes for your convenience. 

Collin- Don’t let your feelings get hurt because I left your name out of the “Assigned To” drop down box.

 

Thanks

 

  Joshua Ledbetter

  Molding Maintenance Manager

  Manufacturing Engineer

  Oreck Manufacturing Company

  931-239-3235

 

5.23.10 Weekend D-shift

Worked on conveyors repairing broken parts and generally looking them over to see if they need anything. There is still one that is going to need the Baldor drive repaired or replaced, but it is working for now.

#3 has a busted reservoir basin for the drain line that draws from the clamp seal. It is mounted under the automatic lube greaser. The words respiratory health care are printed on it so maybe it is something we can get cheaply at a hospital supply place?

#10- Had issues with the ultrasonic welder. The thermolator had been off and the positive stop was adjusted too far down. It was giving an error some of the time that would require you to press the reset button. It is working fine now.

Cal if there are any questions.

" C " Shift Weekend

 

MP-22  Broken glass on control panel—Ordered new one for Saturday delivery

 

MP-2  Tech had core problems--  checked & found sequence was set wrong.  Also DME hooked up wrong; heater was plugged in to zone 1 – TC was plugged in to

            Zone 2.  After correcting it, found it had a bad heater. Tooling to change it out.

 

MP-13  Tech said when sled was run in, the nozzle heat would drop out. When I went to check on it, Bill had started it up & it was OK. He said to let it run.

           ( For future reference )

 

I called Nissei about oiler fittings—They said they would send the right ones & for us to just keep the other fittings.

 

MP-22   The control panel glass & sheet came in---  Installed & checked out.  Also made a cover for it.  I need more hinges to make covers for the other ones.

 

MP-24  Installed a plug for the mold cores to the machine.

 

MP-17 Cleaned up oil jug overflow on clamp end.

 

MP-23  Weak vacuum on eoat suction cups--- tightened up all the fittings—OK

 

MP-23 Replaced the nozzle heater band.

 

MP-22  Could not change the screw back position.  I had to reset the injection scale. ( Press & hold the alarm reset while running the screw all the way back, then all the

           way forward, release reset button, then you can change the setting ).        

           

 

MP- 22  Getting a lot of color swirls in natural bag stiffener.  It wouldn’t purge out. I pulled the nozzle tip & the adapter. The adapter wasn’t seating, so I cleaned it out &  

             had tooling reface it. I reinstalled it & they were starting it up on “ D “ shift.

 

5.18.10 D shift

Mp#1-Put together a water manifold sheild to help direct any future leaks.

Mp#23 robot- Made a sprue gripper extension to pick offset runners (work order request). Helped them get it going.

Mp#21 robot- Replaced a section of tubing that had blown out.

Used 10x6.5mm metric tubing.

Put the new molds in the tool room.

Call if there any questions.

Sean

" C " Shift

  MP-23   Control power kept kicking off.  Mark and I checked it out; found the 3 amp control breaker was bad – replaced.

 

 MP-5 Installed  “T”  for gauge @ pressure transducer port.

 

MP-8  Made a fixture to check for bad ends on fan housings.

 

MP-1 Cleaned up water under clamp. Cleaned & checked operation of cabinet fan.

 

 

R. Upchurch

Molding Maint.

Tuesday

MP01 is still down with the servo drive alarm.  Mark is still doing some investigating before we send the thing in for repair.

 

  Joshua Ledbetter

  Molding Maintenance Manager

  Manufacturing Engineer

  Oreck Manufacturing Company

  931-239-3235

 

5.17.10 D shift

Mp#1- Motor power goes off after 1 second, then alarms "5E33" Clamp axis driver error (regeneration abnorm).

Checked it out, found wires burnt open from what appeared to have gotten wet. Repaired regen circuit wiring. Alarm on servo amp cleared but alarm on machine display still comes up as before.

I downloaded the Yaskawa manual for that particular servo amp and motor, it indicated that there were maybe a few solutions to this error.
1. Replace the servo pak
2. Replace the regenerative pak (it could be defective I suspect).
3. Repair wiring to regenerative pak.

After making the repairs and reading further, I found that resistance specs for that servo pak model was 2.4 ohms. We have 3.4 actual now.

This is why I suspect a faulty regen pak.

There is reference to an incorrect pulse count vs. pulse set value, this is supposedly a result of this cause, which may be cleared (with the host controller)if I knew how to do that.

We would likely need that digital operator that we just now ordered to do that?

I turned over everything I had to Mark when he came in and I think he is going to see about making sure that any internal faults get cleared and seeing what else can be done aside from ordering new expensive parts.

Call me if you have any specific questions.

Also worked on the Hot stamp press on #20. It was not reading the down switch and had to be set-up correctly.

Sean

5.13.10 D shift

Mp#4-conveyor quit. Reinstalled chain and readjusted belt tracking.
Working fine now.

Mp#5-overtravelled once and had to be rehomed, problem was a loose cable connection in panel where someone had moved the cabinet.

Mp#6- techs couldn't get the conveyor to work, jumper was not connected.

Mp#19- Nozzle was not working, found loose wiring connection, no further problems.

SB#2- Ran out of material, cap was off of header on catwalk.

Hot stamp press on #21- showing "eater control error". Found bad connection on thermocouple. Replaced the thermocouple (Type J) no further problems.

Call if there are any questions. I did check out the manual on the new star and on behalf of this shift, thanks for the new robot!~

Sean

" C " Shift

 Built & installed three more conveyor trays; only need one more to complete all.

 

MP-22  Checked & set torque on screw gun.

 

MP-1  thru  MP-12   Checked & lubed tie bars—blew out cabinet filters.  (  MP-6 & 8  need new cabinet fans )

 

MP-11  Cleaned up oil under clamp unit – Clamp seal needs to be replaced.

 

MP-17  Discharge line came off of our recirculating pump—blew oil on floor--  cleaned up & replaced hose.

 

 

 

  R.Upchurch

 Molding Maint.

" C " Shift

 MP-24  Oil leaking from tank hatch, where the parts bin track is mounted. Replaced mounting bracket & tightened back down.

 

Surge bin 2 was clogged. Took line apart outside where it 90’s up. Vacuumed out line all the way back to silo. Readjusted flow tube. OK  for now.

 

MP-4  Set up the timer for core 2 & installed a new bolt for one missing from the bottom core 2 cylinder.

 

Trying to locate & tighten some of the fitting leaks.

 

 

 R.Upchurch

 Molding Maint.

The week of May 3rd, 2010

Got Hopper w/ sensor and Jet Loader installed for MP26

 

Added the color port for MP26

 

Installed stainless 90s, new hose, and clamps above the surge bins for plastic load lines

 

Freed up valve under surge bin 1

 

Ordered wands for grinders, short and long.  Will be ready for pick up May 7, 2010

 

Installed the ladder for the feeder bowl on MP10

 

Replaced busted 480VAC plug on grinder on MP2

 

Ordered the mistakeproofing sensors for hole in baseplates (Wheel Press)

 

Ordered 3” Round Black Delrin

 

Picked up 5/8-11 X 4”  SHCS for mold setter

 

 

 

 

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

 

5/1/10

Put the barrel shroud back on MP1 after a bleed off

Core 2 pull quit reading in MP4. the bottom sensor wasn't working. I found another used sensor which would work with a magnet but not on the cylinder. The original senor started working again after I put a magnet to it. It quit one more during the shift so I removed it and stuck the magnet to it again to get it working. I don't know if there are any of these sensors it stock somewhere.

Cleaned the filters in the loader on MP23

Collin

4/30/10

Core 1 wouldn't read the pull switch on MP5. Found a loose connection in the core plug.

When DR18 was started it would index then trip the main breaker to MP25. The process heaters were shorted. I replaced them and started it back up.

The robot on MP25 crashed in the core dummy plug. Straighten the robot arm and set it to rotate above the belt instead of the mold.

Collin Miller

Friday MP05

I finally fixed the problem on MP05 where the screw would drift forward when the pump loaded for Clamp Open/Close and Injection Unit Forward/Retract. Fixing that problem also dramatically made Screw Recover better.
Sent From My Verizon Blackberry

4/29/10

Press 10 ran all night without stopping

Fixed core wiring on MP22

Worked on MP8 robot

Replaced right side push button on fan housing press on MP8

Collin Miller

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