Ronnie Upchurch

               Weekend    !/14 – 1/16/11

 

MP-8  Replaced  mixer loader hoses with the copper wire lined hoses to cut down on the static that affects the controller.

MP-5  The zone 2 barrel heats dropped out; the mercury contactor went out. Replaced it.

          Also the “Y” axis encoder was acting up. It was loose at the shaft coupler.

MP-19  One of the bolts on the rear screw flange broke off, & the other two were loose. Removed the broken one & replaced all three with new bolts & “anti-seize”

MP-16  Large blow back; I cleaned it all off & disassembled the nozzle. I had tooling resurface the end cap & nozzle adapter. Had to do some body work on the covers

      & align the sled.

MP-12  The right side palm button on the welder came loose. The mounting nut inside the box was broke, also the guard was missing. Replaced.

MP-7  Blow back-  Mark caught it when it happened, but it was still packed & hard. ( Nylon )  Cleaned it out & replaced the nozzle band.

Assembled a work table for Potter.

New Sonitek Heat Stake

FYI-

 

The Password for the new Sonitek Heat Stake is 84.

 

Thanks

 

Joshua Ledbetter

Molding Maintenance Manager &

Manufacturing Engineer

Oreck Manufacturing Company

(C) 931-239-3235

(F) 931-646-7615

 

1.16.11 weekend D shift - Sean

Worked on Pm's all weekend.

MP#13-Friday replaced the nozzle. The Nozzle was the cause of the bleed-offs. It was not seating off where the nozzle tip attached.

Mp#19- Wired in the ejector back limit switch and checked operation. Good to go. They ran the production out on that tool and because there were no more male core plug inserts, Ronnie used the adapter to temporarily jumper it out to run with out cores.

Mp#10- Replaced a broken sensor on the nutpress, and removed a piece of foreign hardware from one of the nut channels.

There are 3 dryers in the shop at this time. The 2 Conairs have bad boards. The Milacron dryer has an Overtemp problem to which the cause has not been identified yet.

The 230 VAC Matsui has been shrink wrapped and indentified "NOT FOR USE". It is located in the Trailor out back.

Worked on End of Arm Tools off and on all weekend. When Josh gets better we need to get him to put on a training seminar for all the techs on how to run parts with more than one cup! Just kidding...their pros!

Anyway call if you have any questions. Have a great day.

Sean

MP26 TC

Mike had to Jerry Rig the Zone 1 Thermocouple on MP26 the other night because of a blow back.  I have a new one with the TC Well ordered but there is a two week lead time.  Also ordered end caps for 25 and 26- should be here any day.

 

Joshua Ledbetter

Molding Maintenance Manager &

Manufacturing Engineer

Oreck Manufacturing Company

(C) 931-239-3235

(F) 931-646-7615

 

Jan 11, 2011

Tuesday, January 11, 2011,

 

Square nuts on MP10 are contaminated again with a sticky goo.  Remove track covers and nut from bowl, clean with mold cleaner, scotchbrite and Potter washed and dried nuts.

 

Current sensor fault on MP14, on nozzle.  Tightened screws on nozzle contactor.  Contactor could be going bad.

 

Order more components for new fan housing test station.  Sketched up station frame and layout for station. 

 

Getting organized with files for projects, cleaning up some.

 

Mark McKee

Technical Specialist

Oreck Manufacturing Company

1400 Salem Rd

Cookeville,  TN  38506

mmckee@oreck.com

PH      931.646.7856

CELL  931.644.5289

FAX    931.646.7615

 

MP05

The Core Problem on MP05 ended up being in the Output Card Plug itself.  J1 on the plug is the +24VDC for the first four outputs.  If you took the plug off and looked at it, the pins in the socket were broke on one side and bent back on the other.  Gary replaced the plug and so far it is OK.

 

Thanks

 

Joshua Ledbetter

Molding Maintenance Manager &

Manufacturing Engineer

Oreck Manufacturing Company

(C) 931-239-3235

(F) 931-646-7615

 

1.6.11 D-shift...Sean

Mp#5- had problems with cores again off/on all night (4 times).

I swapped out cards, solenoid coils, checked power supplies (except under load when problem occurs), ohmed out each contact on card 6's terminal strip back to common strip.

Checked the 235 contactor contacts and voltages (safety gate relay). The last thing I did to get it running again was to spray out from behind the backplane with dustoff.

Also checked for loose wires in the core switch boxes...although signals were present anyway.

When it malfunctions, it simply does not indicate on the board that it is outputting a signal. It is running now but thats where I was with it.

DR 23- The Milacron dryer was overtemp1 alarming. I went through the normal checklist and the only thing I noticed was that the cabinet fans were not working due to the faulty temp switch that controlled them. I jumpered the switch and it seemed to have fixed it.

Call if you have any questions. Good weekend to all!

Sean

Jan 6, 2011

Thursday, January 06, 2011,

 

Finished conveyor docking on IML automation cell.

 

Worked w/ Randy Russell on new Bag Dock Heat Staker station design.  Gathered materials for job.

 

Worked on materials for new Fan Housing Tester.

 

8 and skate 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    931.646.7615

 

1.5.11- Dshift...Sean

Mp#5- Cores quit working again. I went through and rang everything out from the #57 common wire, through to the output card's terminal strip at A233. It ohmed out fine. I looked at the backplane with the card out and some of the prongs that hold the card in position may have been spread out more than the others so I used a pin to push them back and help grip the board better. Put it back together and they started working again.

I pretty much went over everything looking for a loose connection and really didn't find anything...so it made me ask if the output card had something getting hot and cutting out? Then after awhile, it was cooling down and working again? We'll see?

Mp#23- was giving an 32036 alarm involving the ejectors possibly "timing out too soon?"
we put some cycle start time on it and slowed down the ejectors and it seemed to have went away.

I sent a molding support workorder regarding sled skate strips coming out. FYI. Need to find a way to keep that brass under there...open for suggestions.

Worked on PM #9- press and robot.

Have a good day.

Sean

January 5, 2011

Wednesday, Jan 5, 2011

 

Put MP13 back together, broken butterfly bolts, had to extract one screw.  Knockout bars were different lengths.  I noticed that the butterfly plate has been welded on and the bolt heads have to be turned down to enter the counterbore, so I think we should order a new one.

 

Wired the conveyor up for the automation cell for IML, working on the docking locators for it.  Received the locate and shuttle tooling from Star.

 

Made a list of tooling that needs to be made for Josh on the new fan housing tester.  Need to order the rest of the purchased item tomorrow.

 

8 and skate 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    931.646.7615

 

1.2.11 - D-shift Sean

Worked on PM's.

Robot and Press#5 tonight. The Y-axis lower pulley was bent and scraping the arm. I tried straightening it and using longer screws and nuts behind them. It didn't seem to help much so I added a right angle bracket to help brace it better.

It repair works... but... the drawback is that it shortened up the distance the Y-axis goes fully up by about 2cm. I had to adjust the Y-home switch for the repair also. It does clear the tiebars and door when traveling out the beam though.

Now we are getting ready to run it. Also used a hand grinder to clean the drag marks and burrs from the Y-arm.

Other than that, worked on regular start up stuff, nothing major.

Call if there are any questions. Have a nice day!

Sean

12.29.10 - D shift - Sean

Worked with Mike Daniels on PM's all night.

Nothing Major happening worth mentioning.

Hope next year goes as smoothly as tonight did!

Call if you need bailed out of jail! Happy new year team!

Sean

12.27.10 - D shift Sean

Mp#5- Cores not working...found loose terminal strip on Output card 6

MP#21- Bleedoff at Nozzle. Took out 3 heaterbands and thermocouple. Looked like the sled forward switch had worked loose causing the problem. Had no more trouble after we started it back up.

Mp #2- Zone 3 had a bad band. Replaced it. Replaced the fuses and checked operation...O.K. to run.

Continued with PM's. Worked on #10 press and robot tonight.

Call if you have any questions. Have a successful day!

Sean

12.19.10 D shift Sean

Mp#8- Replaced the ejector hydraulic hoses. They had been red tagged since 2008, so i replaced them and checked operation.

Continued working on PM's.

Need to order some cabinet fans again in 120VAC.

Have a great day!

Sean

12.18.10 D shift - Sean

Continued with PM's...Presses and robots #2 and #4 tonight.

Had an issue with #23 ejector encoder was not reading right after they set a mold in it.

I changed the offset on the VRE encoder offset and it started working correctly. I did check to see if anything was loose on the encoder first but it appeared tight.

Sean

Ronnie Upchurch

                   12/08/10

 

Worked on fascia hot stamp.

 

MP-13  Pulled barrel cover & cleaned off blow back – ¾ down the barrel. I was able to save heater band wiring & the covers , with some minor body work.

 

MP-19 The DME t.c. was reading low , but the mold heater was running away. I found that the t,c, wire had been pinched behind the mold clamp. Replaced.

 

 

                   12/09/10

 

MP-13  Pulled  the Conair heater to get the part #. There were two possible numbers for that model.  I ordered replacements .  There are only two heaters

       Per zone – 240 v.

 

MP-10   We cleaned out the nut feeder , Again , & cleaned a box of nuts. Mark adjusted the tracks.

 

MP-26  The center knock-out mounting stud on the eject. plate fell off.  Reinstalled.

 

I ordered a new adjustment screw & nut for MP-24 spacer adjustment.

 

I sent the top cover drill out for repair.

 

I ordered a new replacement motor for the small Solo grinder.

MP05 Robot

MP05 Robot has been stopping the last week or so randomly with a “Mold is not open- Robot in Unsafe Position error”. 

ANYTIME you get this error it means that the mold is not at it’s Open Limit and also the robot is not on either the Y-Up safety switch or Z-Out Safety Switch.

The Power Supply was low and what was happening was the 20 VDC that made it back to the coil on RYS or RZS would allow it to drop out one or both of them every now and again.

 

Mark adjusted the PS up to around 26VDC and fixed the problem.

 

Thanks

 

Joshua Ledbetter

Molding Maintenance Manager &

Manufacturing Engineer

Oreck Manufacturing Company

(C) 931-239-3235

(F) 931-646-7615

 

12.5.10- Dshift Sean

Mp#24- Made a new "bushing replacement part". Checked operation, O.K. to run.

Worked on PM's.

Replaced damed plugs on #10 connector mold from where it had been damaged before.

Made some adjustments to the nut press so nuts would slide down correctly.

Started making another component for the fan mold in #25, to grip instead of using the vacuum cup. (Requested by Darryl B.)

Call if you have any questions.

If you are reading this it is because I did post a blog...reciprocate the info!

Knowledge is power! Share the wealth!

Thanks,

Sean

Ronnie Upchurch

            12/03/10

 

MP-25   Replaced a broken air quick connect fitting on robot eoat.

 

MP-10   Added hydraulic fluid.

 

I helped Josh & Mark get old press 13 moved out.

 

I replaced the pneumatic drill on the top cover fixture. I will send the broken one out for repair.

 

            12/04/10

 

Moved the home sensor block over some for the single cavity connector mold.

 

Worked on the degate & lable fixture in shop.

 

MP-5   The tech said that core 2 on the top cover mold wasn’t pulling. I found the bottom core not hooked in to the cylinder.

 

            12/05/10

 

MP-22   PMed  the robot.

 

I  mounted  the motor on the polisher  test fixture table.  It’s the one they test the brush pans on.

 

Cleaned up some in shop.

11.29.10- D shift Sean

PM'd- MP#25 machine and robot.

Dryer DR#6 on mezzanine alarm for Regen Overload. reset OL's and had no further problems with it.

Hope everyone had a great Holiday. Call if there are any questions.

Sean

11.11.10 D-shift Sean

Mp#7- Robot PM. Had to use 2 of the spare air lines on the Y-axis arm, they were leaking. Inspected it thoroughly, cleaned and lubed. Ready to go.

Continued training on the robots with the techs on this shift.

I will continue touching up the presses with a little paint as they are down. I just need some roller pads and a roller handle if somebody happens to go to Lowes any this week or next.

Also, it should be noted that yesterday, before I left, Darryl had asked me to help him repair #24. Apparently they had tried to put two full width spacers on the clamp and it had worked loose and possibly damaged the threads? He got it started and reassembled, but thetre may still be some damage and further problems when the spacer needs to be changed out again. FYI.
The mold setter on D shift knows more about it.

Call if there are any questions.

Sean

11.10.10 D-shift Sean

Made a drive roller shaft for the small conveyor. Installed it and reassembled the conveyor and checked operation. O.K. to run, located it in the auxilliary equipment area.

Also moved the Milacron dryer to auxilliary equipment area as well. It ran most of the night without incident.

Mp#23- Darryl said that Bill and his techs were able to run the 2-cavity fan with the conveyor turned out away from the press and unload the parts 4 across the belt.? He asked me to set it up to do that but I was not able to make the crosswise move during Pack 1 or Pack 2. When I changed the modes, it changed on both Packs. Any idea how they did this? I would like to know.

Continued working on Pm's.

Painted the angle iron brackets Yellow with spray paint. It is a light coat but all I could find.
There was some driveway marking paint that was very flat and I didn't think it was a good idea to use that.

What was the story with 17? I heard it went down for maintenance? That we are shopping for a replacement?

Call if there are any questions! Have a great day!

Sean

Ronnie Upchurch

   MP-5  Replaced the nozzle heater band & fuse. The wire broke off & shorted out.

 

  MP-17  Cleaned up – changed out pads- emptied jug.

 

  Sean fabricated a motor-mount belt tension bracket & a safety switch block. I tapped out the 10 mm holes & mounted the bracket & block. I also installed the blades.

          We still need the key for the safety switch & knobs for the block handles. I sent Mark the part numbers.

 

 

Ronnie Upchurch

                         11/01/10

 

MP-13  Blow back – tightened down sled & replaced 2 nozz. bands.

 

MP-15 Solid state relay on nozz. heaters was staying energized – rebooted press & is working fine.

 

MP-9  Need to look at building new eoat for handle mold. The small cups don’t hold good on textured parts.

 

Brought grinder in from trailer. The repair parts came in.

 

                        11/02/10

 

MP-14  The timer relay on the thermolator went out. Replaced & Mark ordered more.

 

MP-11  Mold hanger broke a switch & a fitting on the core cylinder .  Mold # 75033.  Mark repaired.

 

MP-3  The Z axis contactor went out. Mark installed a new contactor & overload.

 

MP-21  A water pipe broke in the stripper plate – fan mold. Tooling  removed the broken threads.

 

MP-5  The wheel press staying down after pressing the wheels in.  Someone had turned the pressure up too high & the over stroke switch was making.

          Readjusted to 100 psi.

11.2.10 D shift Sean

Mp#2- had some problems with the core pull switch not reading. I went through it several times and it will read for awhile then quit again. We put it on timers til it comes out again.

MP#5- the base plate press needs a block to support the spring, and another spring detangler made up so they can run them both. Not urgent at this time.

MP#4- had to modify the gate cutter fixture to accomodate the change to the runner location on the tool. Works fine now.

MP#10- Nut Press. Cleaned out the vibratory bowl, tracks, and rails. Stoned the scratches out as good as I could. Noticed that the upper metal rails are magnetized and caused my screwdriver to become magnetized as well. I think an option to help prevent them from hanging up so bad would be to created new upper rails from a different material such as aluminum or plastic?

Helped the technicians and mold setter, set-up the mold and robot on #1,(at their request). They were not sure how to hook up the core hydraulic unit, etc. and we got the robot programmed in and going good. Also showed them how to save programs in all of the star robots again.

Mp#9- Robot is stopping intermittently above the conveyor, either going up or down. I slowed down the speeds and it seemed to reduce the frequency. I tried to watch it as much as I could but got called away. The vacuum switch is adjusted correctly so it is not that. I watched the brake modules and they were working correctly when it stopped once. I think it is probably a loose connection, but they did not want to shut it down completely for me to look at it.?

Went over the access receivers in the mezzanine. Several had loose screws and were loosing suction, etc. In general I looked around for anything else that might need repaired, etc.

Call if you have any questions.

Sean

Ronnie Upchurch

                 10/27/10

 

MP-12   Blow back -  the mold wasn’t centered in the check ring. I replaced one nozz. adapter  heater band.

 

MP-17 Cleaned up oil.

 

                10/28/10

 

MP-10  Cleaned oil from nut feeder. I gave them some alcohol & a bucket to clean nuts. Mark emailed engineering so they can contact vender.

 

D-32  Alarm  11  -   The turntable switch was out of adjustment.

 

MP-6   They changed to polycarb on the base plate. Mark turned the pressure up on the wheel press.

 

MP- 25 Set up chute for hokey handle water cooling tank.

 

10.28.10 D shift Sean

The robot on #6 has been dropping the parts into the grinder off/on all night. The cause is that the press will often mold baseplates with too much flash on the runner. This causes the gate cutters not to completely cut through the gate. This in turn causes the runner gripper to hold onto everything until it drops all of it into the grinder. FYI- ?

Replaced the regen heaters and the regen blower on DR#5. It is in the shop looped out until the cans have cycled enough to run on the floor.

Mostly had problems related to people not understanding how things operate correctly.

Did PM on 21, press and robot.

Also, the water bath operation for the Hokey handle was requiring them to hand dry each part with an air blow-off tool. I put up a cart with a wire frame basket and a fan blowing down on it so they could spread them out and most of the water could dry off before they got to the drying stage. We may want to look at that operation again for improvements?

I will probably come in sometime this weekend to discuss PM's with Mike. Likely on Sunday night early.

Call if you need something. have a good weekend.

Sean

10.27.10 D shift Sean

The Square nut press on #10 has problems with sticking due to the unusually oily nuts. I cleaned the entire vibrator bowl out and wiped out the slide tracks, but, until the nuts are degreased better, they will continue to get stuck.

I asked Darryl to speak with Wayne McConnel about looking into this oil issue with the vendors possibly? I do not remember having this problem when this began, do you?

Darryl said they had always been that way and there was nothing he could do, it would cost Oreck more forthe supplier to degrease them.?

Anyway, there it is.

Mark and I arrived at a PM program draft proposal which should be implemented soon for our team.

Other than that I continued with PM's.

The Robot riser has been painted and should be dry.

Call if I can help in any way!

Sean

Ronnie Upchurch

              10/22/10

 

MP-16   Installed a flow control valve on the eject. retract line.

 

MP-21  They changed the nozzle tip from a button tip to a  2”.  I installed a tip heater band and replaced the adapter band that was burned out.

 

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

 

MP-4  At 5pm the tech told me the robot crashed. I checked & the “Y” axis had extended to the mold & hit the stationary side. It broke the “C” air

          cylinder, two vacuum fittings, & bent two suction cup brackets. I removed the eoat & cylinder & turned it over to Sean Man.

 

              10/23/10

 

MP-9  The “Z” axis set point was drifting. I checked the encoder – everything was tight. I tightened the “Z” axis belt & rebooted the robot. It looks

          consistent now.

 

MP-22  The hotstamp heats kept going off. I checked all the heater connections. I reseated the T.C. plug on the board. It’s running & hasn’t cut off

            in four hours.

 

MP-11  The PS-2 pressure switch on the injection unit quit working. I replaced it.

10.22.10 D-shift Sean

Mp#4 Robot- repaired the C-axis wrist cylinder. The threads had snapped on the cylinder shaft when it crashed on Friday. Drilled out the end of the shaft and tapped it for set screw. Reassembled and tested operations. Replaced 2 broken fittings on the vacuum cups. It will run for now until we can get a replacement cylinder on order within the next few days.

Mp#9 Robot- The Y-axis was not homing in the same place and eventually would not home, although it was still referencing. Found the Y-home switch "flag" had loosened and slipped down. It took several attempts to locate it correectly until it would operate correctly. Also inspected the encoder, bolts, and belts while up there.


Had another water leak on MP#1- broke some of the same water lines on the fan mold (same reason as before on 21).

Luckily there was not any water spray to cause damage to the robot or injection molding machine.!

Call if there are any questions. I will not be in tonight for PTO time. Have a great day!

Sean

Week of October 18, 2010

Made program changes to the PLC and Quickpanel on MP5 Robot for an I/O Monitoring Screen.  The new screen can be accessed from the main menu.  Please try to check it out and use it as much as possible, we need to see if everything works correctly and if we want any more changes.  If you have any questions or suggestions please let me know. 

 

Picked up an inline, directional control valve for the eject retract on MP16 to slow down breakage of butterfly bolts.  Ronnie installed and set it to smooth out the banging on the retract.

 

We received the replacement seals for the Novatec Proportional Valves.  They are in MRO.

 

Small ice cube relays were ordered for the AEC Robot control cabinets, RB, RYS, and RZS.

 

The new butterfly plate, guide rod, and knockout rods for MP20 were finished and Gary installed.

 

Helped Mitch set the welder outputs in MP12.

 

Tightened and realigned clamp cylinder on MP10 connector welder.

 

Ordered the steel for Robot Riser spacers.  Josh got the prints for the machine mounts.  The steel should be here this Saturday.  We can start making them next week.

 

Started working on In Mold Labeling Project

 

Changed out more of the 3 pin color pumps connectors to 2 pin.

 

Mark McKee

Technical Specialist

Oreck Manufacturing Company

1400 Salem Rd

Cookeville,  TN  38506

mmckee@oreck.com

PH      931.646.7856

CELL  931.644.5289

FAX    931.646.7615

 

10-18-2010,

Good Morning Gents,

 

Lots of little stuff last night like plug it up turn it on.

Had issue with mp5 the cores not always working reseat I/O boards and they seemed to work for a sort while. Finally found a very loose wire on board in #6 slot in control rack.

 Hasn’t missed a lick since.       

 

Not really anything else major to speak of.

 

Have Great Day

Mike

10.19.10- D shift

Mp#9- Robot kept stopping, It was stopping over the conveyor every time. I noticed the speeds on the axis were all maxed out. I slowed them down to around 9800 each and it did not stop anymore afterwards.

Mp#10- Robot did not stop any at all tonight. Good Job guys!
Vacuumed oil out from under 10 also.

Mp#2- replaced nozzle heater band and fuse from bleedoff. Had to burn out the sprue plastic with oxy/acetylene torch.

Mp#16, Mp#19- PM'd.

Mp#8- Fan Housing press had problems with the nut press die magnet/ locating pin getting stuck inside the recess orifice. Took the one off the spare press and replaced it.

Left the damaged one in the shop for Gary or Mike to make a new one by...maybe?

Call if there are any questions.

Have a great day!

Sean

10.14.10 D shift-Sean

Mp#11- Sled would not go back. removed the V26 solenoid valve assy. and cleaned out the check valve and orifices with solvent and air nozzle. It appeared to be clogged and dirty. Reassembled, checked operation, O.K. to run.
Also refilled with about 20 gallons of Rando 46 hydraulic fluid.

Mp#23- Nozzle was not heating (according to the tech). Found band clamp broken and the other one missing. He still wanted to change the band out anyway, so we did.

The ink pad printer nest assy appears to be loose but all the screws are tight on it. Mostly looks like slop in the xy table, except too much ? I also could not locate the manuals for it. The last time I knew where they were was inside the pad printer. Now no idea? I was going to see what kind of pm inspection it needed?

Call if there are any questions, have a great weekend.

Sean

10.14.10 D shift

Mp#15- Zone 1 overtemp.

Found the problem to be an incorrect thermocouple type. It had a "j" type and it should have been a "k" type.

There were 2 more J type in the MRO location where the K's were supposed to be and I almost made the same mistake that someone else had made, of putting one on. Instead I used a nozzle band K type and put it under the band on the first zone.

It is running good and staying exactly on temperature now.

Fixed the leak on MP#2.

Refilled 17 with oil and cleaned up the oil dry.

Checked out the milacron dryer DR17 and it is fine.

Checked out DR2, looped it out for a few hours and checked the beds, it is fine too.

Sent an email to one metal supplier to see if they can get us some brass peices for the sled shims the right dimensions that I measured tonight.

Be back at 2pm today.

Don't call, I won't answer....lol.

Sean

thermocouple calibrator

This is the lowest priced calibrator I found on the web at $195.00

http://www.omega.com/pptst/CL3512A.html

Omega's are a good brand and this tool will allow us to read the output from a thermocouple or send a signal to a temperature controller for comparison or tuning.

With as much machinery we use with temperature related controls, this tool is a must for any professional maintenance department such as Oreck's.

Check it out!

10.10.10 D shift weekend Sean

Mp#1- was making a squeaking sound when the screw was almost complete with building a shot. I greased the extruder bearing assembly but that did not appear to be the source of the sound. Then I actually put a little grease on the screw itself at the back of where it entered the barrel and it seamed to help. It did not run long enough to know for sure though and likely needs to be inspected further when it starts back up.





Mp#3- Had an E00240 error. Had to reboot from the boot card. Then we had to reload a set-up in it. Ran good the rest of the day.



Mp#5-had leaks from where someone just left a hose dragging beside the clamp.



Mp#2- Has a leak on the core/ejector hose valve block we installed for the steamer molds. When it goes down we can re-do it. Put it on a shared tasks outlook item.



DR#6- Finished what Ronnie was working on and replaced the desiccant in all of the canisters. Checked it out with the Dew point meter @-40. Tagged it and located it in the mezz room.



We have been seeing quite a few dryer issues lately. I followed the email suggestions for testing the touch pad on that Cincinnati dryer/hopper and it appeared that the display board is likely defective as jumpering the touch pad pins gave no response.



Checked out several DME cards, replaced fuses and tested them on a mold. They all worked fine. Tagged them and put them back out on the shelf.



Worked on PM's all weekend. Finding many issues with loose components on the loading system. Also finding robot Y-axis are getting loosened. Tightening them up, and other wrist components are getting loose.



One issue that we need to start getting into is the sled shims on these Nissei machines. Many are working out from under the sleds. I think we can get some brass the full length of the guides and secure it with screws? The problem is that we will have to schedule them down and figure out how to get them elevated enough to install them. Shouldn't be too much of a problem. I will measure all of them that need repaired now and come up with a parts list on Thursday morning.



Since Ronnie is going to be out on the

Ronnie Upchurch

I emptied all the overflow jugs on the presses, cleaned up the oil on MP-17, & vacuumed the pan on MP-6.

 

MP-4   I made an eoat for the rear steemer handle mold & installed it.

           Somebody left the air poppet fittings out of the mold. We found them in tooling & installed them.

       

 

D-6  ran in the maint. shop for nearly 24 hrs. & the beds never did dry. I started pulling the desiccant cans to change them out.

Ronnie Upchurch

 10/8/10

 

MP-16  The touch pad on the Milacron dryer wasn’t working. I called & requested a quote from Uni-Dyn.

 

MP-11  The core pull hydraulic hose came loose at the threads behind the quick-connect. It was never tightened. I cleaned up an oil pond around the press.It ran all night

     & nobody saw it leaking.

 

Dryer- D-7 on the mezzanine had a bad regin. contactor. Replaced

 

 

10/9/10

 

Mezzanine -  I played musical dryers all day to get one that worked.  I pulled D-6 off station 2  & took it to the shop. I replaced it with D-32 from floor. I looped out

      D-7 on station 4, to try & dry the beds. I also loop out D-6 in the shop to see if it would dry out. After several hours, D-7 came down to – 40, so I put it on station 2.

      D-32 wasn’t drying, so I looped it out.  D-32 & D-6 , after  6 to 8 hours, the dewpoint is finally starting to drop somewhat.

 

MP-3 Installed core plug on the steemer handle mold.

 

MP-1 Die height alarm- The position had to be moved manually before the auto die height function would work.It was too close to the end of the threads to lock in.

         After that, it was getting an eject alarm----- I found the knock-outs weren’t tied in. OK  now.

 

MP-3  Robot was alarming out – not seeing eject. forward.  Found the multi-eject. on the special option page was not turned on. OK now.

 

Ronnie Upchurch

MP-23  I worked with Mark M. setting up the new eoat for the 2 cav. fan  mold 74022.

 

MP- 6  The mold wouldn’t close. I checked all the limit switches & found the operator side gate switch wasn’t making. I adjusted the jam-

      bar  flag.

 

MP- 1  It was getting a lube alarm. Josh reset the manual lube count to the maximum setting.

 

Two molds fell off the pallet while being transported.  We got them stood up & checked them out for damage. Mold 76003 cav.1 had a broke strap bolt.

       76003 cav. 2 had a pinched wire & cracked mounting brackets on the heater junction box. All is repaired except the box. We can fix it when they

       Finish the run on MP-6.

 

MP-17 Cleaned up oil .

 

MP- 6  Vacuumed out oil pan. Oil vac. is still behind the press.

10.5.10 Sean D-shift

Mp#5- Put the EOAT w/gate cutter back on and set values into the controller from the set-up sheet. Should be ready to start up.

Re-did some hydraulic core 2 fittings that were leaking and had been red tagged for repair. No further leaking.

Mp#3- Put the new EOAT w/gate cutter on and set it in as close as possible w/out running parts. I dry cycled it several times to check operation and get it timed close. May need to adjust the clamp position and ejectors, or the Y-axis up or down.

CAUTION!- The cutters are very SHARP. I bumped into them and punctured by hand!

Set the dryer temp correctly on the stainless cincinatti dryer on the mezzanine. It went down for wet material mid-shift, and after looking at it, it had been set to 32 F..?
Set it at 180 and it has been running fine.

Call if you have any questions. Be back Friday.

Josh-I submitted the rest of my PTO for the year, on your desk.

Thanks,

Sean

9.30.10 Sean

Mp#2- Smashed core wires twice. They have been tied up as neatly as possible to prevent further problems.

Got called into the assembly area to assist with helping the girl get the programming software working for the stepper drivers in the lab. ?

Mp#1- baseplate press stopped operating. Found sensor loose on the shuttle forward position.

Mp#21- while doing the PM I found the press had no control power. Looking further, it seems that the power from the disconnect on the bus was 100 volts short on the brown leg?
Mark and Gary are investigating that further now.

Have a portable hopper loader receptacle that is broken, may need to either order a replacement receptacle or rewire with something else on both ends.

Worked on PM's the rest of the time in between activities.

Call if there are any questions. have a great weekend.

Sean

9.29.10 Sean

Mp#5- They had a problem with the cores not working at all.
I went through replacing hoses and checking with the test cylinder and still was not working. Put gages on and had pressure at valve, but not at cylinders.
They would work when i probed valve m,anually.
Then I checked voltages at coils and had none on the set side.
At this point neither core 1 or core 2 were working but I was focusing on #1 for now.
Then I noticed that the output menu 41 slot 6 would energize 2 outputs when trying core 1, but the card was only lighting up the led for pressure and not the set output.
I tried swapping the card and then both sets of cores started working.
I suspected that there was a problem with the output card that I had moved to slot 8 so I left it down until we could find another one.
Ronnie mentioned that they had worked on it today but was not real sure what was done to get it going again.
I would like to know what you found?

Also had the problem with the Chilled water supply being dirty, in which I discovered, after speaking with Ronnie colson, that there is no filtration on the Chilled water system.? I temporarily bypassed the pressure switches on the Thermolators pumping chilled water until the problem is resolved and we have taken the corrective actions.

Call if there are any questions. Enjoy your evening!

Sean.

Ronnie Upchurch

MP-15  Oil leak.  I am ordering a new pump seal for this one.

 

We were having problems with thermolators cutting off on MP-2 & 3. ( chiller supply )  The flow & temp looked OK.  In tooling the EDM was over heating.

     they bled the line & got quite a bit of air & rusty water out. After that, the thermolators straightened out. There must have been an air lock.

     Ronnie Coleson was notified.

 

I installed the new overload on MP-5. They will hang the base plate back in.

 

If the hydraulic oil doesn’t come in today, I’ll call them in the morning.   

Mike Daniels-B Shift

Good morning Gents,

 

Typical night in molding no major problems. Mp2 has a issue with the core switches, the i/o page shows they are set when they are and pulled when they are but when put in cycle clamp moves about 6in. then stops and reads core 1 not pulled when it is. We ran it on timers  with no problems.

Repaired 3 more trollies

Replaced prox switch on fixture on mp10

Replaced blown nozzle heat fuse on mp2

 

Have a great day

Gone Fishin

 Mike

Sept 28, 2010

MP5 keeps tripping overload on pump.  A complete contactor and overload should be here Wed. UPS Red.

They moved the baseplate mold to #1.

 

Lexan sheets came in today.  Been trying to replace broken panels in trolleys as I can, if you pick up where I left off, measure each one individually as there are slight differences between them.

 

 

Mark McKee

Technical Specialist

Oreck Manufacturing Company

1400 Salem Rd

Cookeville,  TN  38506

mmckee@oreck.com

PH      931.646.7856

CELL  931.644.5289

FAX    931.646.7615

 

9.26.10 D-shift Weekend

Stripped equipment Friday. Reassembled the grinder on Saturday.
Worked on PM's Sunday. Turned in some work orders for some of the issues we had.
There was a problem with #4 that had to do with frayed core wire and a blown fuse.
We cleaned out all the water strainers on all the presses this morning.
I have noticed that the moisture in the air system seems to have been resolved.

I will be coming in on Wednesday at 10a.m. for Forklift refresher training. Afterwards I will see whats going on with our PM program. call if there are any questions.

Have a great day!

Sean

Ronnie Upchurch

One of the bucket tumblers quit working. I just had to tighten the belt. I asked Elaine to order two more motors for the two spare tumblers. I put them

       in the trailer for now.

 

MP-7  The bolts vibrated loose & the deflector fell in the grinder. I cleaned it out & restarted it. It still needs a new deflector.

 

MP-2  I hooked up the cores to the eject circuit for them. Also replaced a broken core switch on the stationary side. One of the mold heater plug pins was pushed in

        & not making contact; repaired.

 

MP-6  The clamp wouldn’t close. I tried probing the valve, no luck. When I opened the cabinet to check the input & restarted the pump, it started working.

 

I worked on stripping & scrapping equipment in shop. I cleaned out the cabinet in the bone yard.

 

I finished up on the grinder that Sean put back together. We put it back in service Sunday.

 

Cleaned up oil on 17 & 21.

 

I put the gaylord of spare parts in the trailer.

 

Ronnie Upchurch

MP-2  Nozzle heaters quit working. Found blown fuse & shorted wire on front band. The blown fuse was 20amp -  should be 15amp -  Replaced

          with correct fuse.

 

MP-15  The chuck was closing before it reached the sprue. Changing the timer or mode didn’t work. I found that when I removed the air exhaust

       muffler, It worked fine. I tried to clean it & reinstall it, but didn’t work, so I left it off.

 

MP-4  We still have a leak at the top of the eject. pump. It looks to be coming from the bottom of the block where the boss fitting ties in. If they  don’t

       shut it down in the next two days, I’ll get it when I get back Friday.

 

I’ve been bleeding a lot of water out of the air lines today; loaders, robots, & support equip.

 

I started vacuuming oil pans – MP-4 -6 & 7.

 

The chiller temp. started climbing again. 70 degrees in the shop. The temp. was set at 48, but actual was 57. I called Ronnie C. & he said he would

      come out & start the other chiller.

Ronnie Upchurch

I worked with Mark some in MRO, sorting parts that were stored in gaylords.

 

Mezzanine – DR-1 had two bad regin. heaters. Replaced.

 

Mezzanine -  DR-32  The turntable got in a bind because the limit switch was adjusted too tight against it. One of the motor gears stripped out &

              two teeth on the bed gear broke off. I replaced the motor. We had to order another bed gear. I swapped the dryer out on the mezzanine.

 

Mark replaced the nozzle heater on MP-13.

 

MP-17  Oil on the floor & the jug was full “ Again .“  Cleaned up.

 

New  hydraulic fluid has been ordered.

9.20.10 D-Shift

Matsui dryer not heating up to process temp.

The control does not appear to be outputting any contactor signal.

I am going to look at it again this evening to try and be sure that everything other than the controller is working alright. I suspect that there could be an input such as a switch or sensor causing the control not to output.?

I organized the machine and equipment manuals and labelled everything as well as possible. Maybe we can keep it this way?

Next problem is Brelands' encroaching desk area!

I could have made some mistakes in identifying presses with particular manuals so if anyone finds something wrong let me know or pencil it in and we can have some form to our function! I followed the asset list by serial number and old press number before labelling them. They are separated by machine brand, (i.e. Nissei, Milacron, and Toshiba, etc.)

Call if you have any questions, have a great day!

Sean

Mike Daniels-B Shift

Good morning,

Just a few issues last night

Replaced 4 nozzle bands on mp20 due to bleed off. Apparently it ripped wires from bands when sled was backed off.

Replace lexan in 2 buggys from junk yard and placed them in molding

Replaced a e-stop switch on grinder at mp6.ginder wouldn’t run

A core wire on mp2 got cut and shorted out blowing a fuse.

Swept the shop.

 

Have a Great Day

Mike