Ronnie Upchurch

                   2/25/11

 

Worked on the “Randy Russell” hot stamp project.

 

Ordered a large assortment set of metric o-rings from IR-G.

 

MP-13  Started getting material together to replace the section between the hopper & feed throat that keeps clogging up.

 

MP-6&7  Vacuumed out oil pans & emptied the oil vac.

 

                 2/26/11

 

MP-13  Made a new adapter plate for the hopper & remounted.

 

MP-24  Fabricated a temporary knock-off tool on the eoat for the wheel mold.

 

MP-16 Replaced the timer relay in thermolater – T-4.

 

                 2/27/11

 

MP-2  Core 2 pull not making.  The switch wasn’t working, but when I removed it from the cylinder, it checked OK. I changed it out. Working OK.

 

MP-6  I got the numbers off the pump to order a pump seal.

 

MP-15  Need to order a PS1 pressure switch. It build tonnage -2000psi- but bleeds off to about 1650psi.

 

MP-5  The nozzle heat wasn’t consistent. The contactor coil was weak. Replaced.

 

MP-2  The male quick connect on core 1 was leaking. Removed, put on Teflon tape, & reinstalled.

Ronnie Upchurch

MP_7  Alarm 5111 – The clamp close control switch got twisted around & the neutral position was actually the close position.

 

DR-32  Alarm 11 -  Index time too long. The index limit switch was bad.

 

MP-6  The conveyor wasn’t indexing. The relay in the robot cabinet burned out. Replaced

 

MP-21  The zone 2 heat dropped out. The contactor coil was weak. Replaced

 

Mark & I worked on the “Randy Russell”  hot stamp project. He’s satisfied, ( For Now )

2.22.11 - Sean

Mp#24- Butterfly bolts broke, replaced them and cleaned and lubricated the guide bar. There is a place for a guide bar on the opposite side, but it is not there. Not sure if it was ever there, but , I will try to make one or at least get some measure ments from it when it is down again.

Also wired up the cores and checked the sequence and operation for them. The mold setters are always asking about which sequence is what on the Nissei's so I provided them a cheat sheet and tied it to their cart.

Also, need some O-rings to continue beating down these leaks. I would just get a few kits of metric and a few kits of square cut. Or whatever? Thanks.

Also, out of the Orange degreaser from Prochem. It is a very good product, cuts grease and liquid color very well. Need to re-order or try to get it as a stock item, possibly? Thanks.

Cleaned up in the shop. I will try to 5-S more this weekend.

Continued with PM's.

Have a great day!

Sean

2.21.11- Sean

No immediate maintenance issues going on right now.

Mp#8- Worked on Machine and Robot PM. Painted some parts of the press.

Made a fixture for Bill Potter to rework the C-handle overmolds. Drill press was tore up when I went to set it up. Had to replace the switch on it. Everything good to go now.

Have a great day!

Sean

2-19-11 Mike Daniels

Mp21 replaced nozzle band and thermocouple also had a bracket from the y axis fall off. Replaced with new hardware                      

 

Mp11 cleaned and put end cap back on. Rewired nozzle bands and installed the guards good to go and was running shortly after.

 

Worked on PMs

 

Mike Daniels

Technical Specialist

Oreck Manufacturing

1400 Salem Rd

Cookeville,  TN  38506

Cell 931.287.6252

 

Eat. Sleep. Fish.

 

2.16/17.11 Sean

Mp#16- replaced o-rings on the sled valve. Checked operation.

Mp#14- pulled the ejector stack off and replaced the o-rings. Checked operation. Looks like I will have to do it again, it is still seeping some.

Mp#2-Replaced the mercury contactor. It had failed. I put the date/press# on the box of the old one and placed it in recycling as required.

Mp#13- Question: So, if all of the process technicians say they have been having problems with the screw on 13, who actually filled out a work request or told someone in maintenance?
Ronnie and I pulled it out. I extracted the broken tip and scrubbed the barrel prior to measuring the bore. Could not locate a bore gage to do a measurement for 32mm (1.2598"). Someone in quality may have something on days, or tooling. (No tooling person on this shift.)

Tagged it out at disconnect, not locked.

Continued with PM's. Trying to gain a little each week on the leaks.

Waiting on seal kit for #14 and #25 sled, (on order).

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

Sean

Ronnie Upchurch

MP-10  Robot part grip not working. It was getting a signal, but no air was going through the valve. I took the solenoid valve apart & cleaned it out. OK now.

 

MP-23  No nozzle heat—Jason changed the tip heater out; it must have grounded out. I reset the breaker. Working OK.

 

DR-27  The loader had no vacuum. I found the flapper valve had broken off. I made a new one & installed it.

 

DR- 10  ( The 100# dryer in the shop )  I checked the power supply control voltage, cleaned the edge connectors on the I.O. & mother boards, found the regin. temp

            probe plugged into the wrong spot, & installed a new control door cover. Test ran it in the shop for 3 or 4 hours. Ran good.

 

The hose reducer for the new Novatec dryer came in. I installed it. They can have it back now.

 

I made up a purchase req. for another Novatec loader.

 

  

2-15-11

Good morning All,

 

Nothing major to report. Worked on PMs.

 

Mike Daniels

Technical Specialist

Oreck Manufacturing

1400 Salem Rd

Cookeville,  TN  38506

Cell 931.287.6252

 

Eat. Sleep. Fish.

 

2-14-11

Good morning gents,

 

Mp24 core not working was the words the setup man gave me. Further inspection of the problem revealed a bad eject back switch bad. I bypassed switch and all worked. I then checked switch independently and it doesn’t change states. Let the team lead know what I found. So they can decide whether to run or pull.

 

Worked on PMs and house cleaning

 

Mike Daniels

Technical Specialist

Oreck Manufacturing

1400 Salem Rd

Cookeville,  TN  38506

Cell 931.287.6252

 

Eat. Sleep. Fish.

 

2.13.11 sean

Mp#16- Ronnie replaced the nozzle contactor.

Mp#15- Had some issues with the pressure switch PS1 for high pressure lockover on the clamp not making. We tried a new pressure switch, but it must have been the wrong type because it did not work. I cleaned out the old one and re-installed it and it worked again after setting the mold thickness, etc.

Mp#20- Sled and injection unit would not work. I re-adjusted the purge sheild switch. O.K.to run.

Continued with P.M.'s.

Have a great day!

Sean

Ronnie Upchurch

T-21  Hooked it up & ran it to check for leaks. OK

 

MP-21  Replaced one of the t.c. wires on the DME. It had a K t.c. on it.

 

Vacuumed out oil pans on MP-6-7-8-9-10-11-& 12.

 

Emptied oil vac.

 

Milacron dryer still over heating occasionally.

2.12.11 Sean

Mp#23 was making a squeaking noise. Turned out it was the mold that needed some grease.

Worked on the Milacron dryer tonight. I replaced the process heater thermocouple because I kept getting a "sensr error1" . Also set the dewpoint trigger to -10 like the dryer upstairs in the mezzanine. Also set the dew point extend feature "on". So far it seems to be working, but everyone has seen that scenario with this thing already too. I was leaning at the dewpoint sensor needing replaced, but after I set the heat time too low on it, the dewpoint did drop to -08. So that is why I opted to use the dewpoint extend. When it is doing it, it will display like: 175 * -40 to indicate that it is extending the time in the bed. We'll keep an eye on it.

Continued with PM's.

Sean

2.11.11 Sean Kearns

Mp#15- Rebuilt the sled cylinder that was leaking. The pistons seal were pretty torn up as well.
There were problems getting the shaft yoke off because it was made with a set screw which had mashed the threads and caused them to gall coming out and going in. There was no help for it and it may have already been that way.
If it comes out next time I will turn it down and drill through it and put a bolt in it.

Mp#14- Need to order a sled seal kit for it also.

Restocked the hydraulic oil spill kit with everything I could find to put in it. They need to post a list inside the lid of what it needs to contain.

Because of the recent safety alert, and the fact that I have seen so many people unsticking grinders with them still plugged up, I posted a copy of the alert on every grinder in molding. This way no one can say they did not know about it.

Call if there are any questions.

Sean

Ronnie Upchurch

MP-8  No screw function. The screw cold start prevent wasn’t working on the front zone controller. We replaced the controller & it’s working fine.

          I’ll take the old one to Craig & see if he can fix it.

 

New Novatec dryer – I installed the new motor & speed controller & set the speed at about 8 rph. I dry cycled it for 5 hours & gave it back to them.

 

MP-16  No nozzle heat. I checked the heater bands & power from the contactor. The only thing I saw was one heater wire that may not have had a good connection

       at the wire nut. OK now.

 

Matsui dryer on MP-14 was in high heat alarm. It wouldn’t clear so I powered it down. When it came back on I let the regen. heat come up before I hit the

       Dry button; the process heat came up & it’s running fine. I think they had just moved this dryer & didn’t let it cool down.

 

MP-15  The nozzle was freezing off & it blew out one time. “ Delrin”   They had a 1” band on a 2” nozzle tip & it was slid all the way back. I put a 2” band

       on it & cleaned up the t.c. wire.

February 11, 2011

Friday, February 11, 2011

 

Replaced hydraulic hose for core that blew out last night on MP5.  Tested OK.  Cleaned up, mopped floor.

 

Ordered spare static charger for MP22, IML.

 

Ordered new Novatech material loader for new to us Matsui Dryer.

 

Ordered, received photo eyes and valves for IML fixture to replace pneumatic proxes. Started on installation.

 

Debugged I/O on new F1 Lite Fan Housing Tester.

 

 

 

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

 

2.8.11 D-shift

Mp#19- Repaired leaking sled cylinder. Replaced piston and shaft seals. o.K. to run.

MP#10- Pm'd machine and robot, touched up with some paint.

Have a good day!

Sean

Ronnie Upchurch

MP-5  Core 2 set switch not making. The mold wasn’t repaired over the weekend, so they had to pull it again for repair. Both switches were bad. Tooling

          Replaced them.

 

MP-15  Lost all manual control function. I found that the mold hanger had over stroked clamp open while setting it up. Also the eject back switch wasn’t made.

      I just had to make the switch & go through the clamp position reset procedure.

 

MP-20  Pre dryer loader not coming on. The load level sensor was out of adjustment.

 

MP-2  The front zone heat dropped out. The mercury contacts stuck open. “ Tap & Go”

 

DR-17  Regin over temp alarm. I found out they had just shut it down & moved it to another press without letting it cool down. After it sat & cooled awhile,

          It started right up.

 

New Novatec dryer-  Still under warranty. They are sending a new drive motor & speed control. We have to send the old motor & speed control back.

 

I got a quote for a Novatec loader to go on the Matsui dryer hopper. Waiting for Jerome.  

2-6-11 Mike Daniels

Mp13    repaired water manifold. Had to weld 1 port up was messed up too bad to retap.

 

Mold# 74046 this had a tooling work order but it just had sensor issue which I replaced. And put back in rack.

 

Mp12 replaced bad slowdown sensor on mold open side. I robbed this switch from Mp17

 

Need to order sled cylinder rebuild kit for mp15

 

Worked on PMs rest of night

 

Mike Daniels

Technical Specialist

Oreck Manufacturing

1400 Salem Rd

Cookeville,  TN  38506

Cell 931.287.6252

 

Eat. Sleep. Fish.

 

2-5-11 Mike Daniels

MP25 adjusted the part verify switch

 

Worked on PMs

 

Overall good night

Ronnie Upchurch

MP20  Replaced the ejector cylinder, end cap, piston rings, and seals.

 

MP-25  Installed a relay on the robot up stroke; to prevent the cycle from stopping when the grippers drop the sprue.

 

MP-5  Core 2 not reading pull. The switch on the bottom cylinder wasn’t making.

 

MP-19  Ordered a seal kit for the sled cylinder.

Good Morning Gents,

 

Worked on dryers most of the night got 3 of them working and moved them to mezz room.

Spent of the night cleaning and putting things in there place.

 

Mike Daniels

Technical Specialist

Oreck Manufacturing

1400 Salem Rd

Cookeville,  TN  38506

Cell 931.287.6252

 

Eat. Sleep. Fish.

 

Ronnie Upchurch

          1/29/2011

 

MP-11  Replaced missing switch levers on control panel.

MP-10  Added two more quick connects on air manifold. One 3/8” & one ½”.

D-32  on mezzanine wouldn’t restart—Bad process blower contactor—out of stock. I was going to swap with D26, but the process blower motor was locked up

         & had two blown fuses. I put a 100# per hour dryer in to get by---- no spare 200# .Had to wait till Sunday to pull the two dryers down & take to the shop

         to repair – “ No Overtime”

 

 

          1/30/2011

 

D-32  Need to order a contactor for this one. Old one is on desk.

D-26  I replaced the process blower unit.

MP-13  The ejector lost it position. I found the collar that the transducer read position from had fallen off. Re installed.

 

I am leaving early today, because I stayed over an hour last night.

Ronnie Upchurch

MP-26  Installed new front zone T.C. probe.

MP-5 Top & bottom cores leaking. I tightened a fitting on the top core. The bottom core is leaking from the set switch seal. I tightened it; they were in a hurry to run samples, so I let them have it. I’ll check it out when it’s down again.

MP-2  The rear zone heats dropped out again so I replaced the contactor.

MP-22  I  re soldered the plug back on for the static charger. Josh & Jason had taken it loose to rig up a foot control switch to run some parts in manual.

1.29.11- D shift Sean

Mp#1- they had trouble with running the fans tonight. I was over there maybe 10 times working out familiarity issues with the machine and the robot. The techs were short handed tonight.

Mp#22- loaded the "takeout only" program for Darryl. Helped get it going and discussed how the robot works with them.

Worked on the dryer when I was not called away for other things tonight. Transformer is mounted and wired up. I wanted to use bigger SJO for the 480 plug cord but couldn't locate anything larger than 14/4. I can try it out to see if it works and maybe re-do it tonight.

There is no terminal identification on it other than: RST and UVW.? ( Jap stuff??) I am going with RST being the Primary side as it is reading higher resistance. Couldn't locate any info online, so if you got anything to add, please do. Thanks.

Sean

 

 

Mike Daniels

Technical Specialist

Oreck Manufacturing

1400 Salem Rd

Cookeville,  TN  38506

Cell 931.287.6252

 

Eat. Sleep. Fish.

 

 

1.26.11...D shift - Sean

Mp#26- Put the screw tip and barrel end cap on tonight.





SB#2- was not loading, found a leak in the suction line. Repaired it. O.K. to run.



Mp#2- Zone #3 quit heating. Unstuck the Mercury contactor .



Continued with Pm's.



Still looking into the Milacron dryer overheating problem.



Sean

Ronnie Upchurch

1/25/11

 

MP-6-7-8   Vacuumed oil pans.

 

MP-5  The bolt on the “C” axis pivot backed out & it wasn’t making the limit switch every time. Repaired.

 

MP-6 The robot kept stopping when “Y” axis started in mold. I found that the “Z” axis was loosing position. I tightened the encoder shaft coupler. OK now.

 

MP-12  Novatec dryer was running hot- not enough air flow on return from hopper. Bill didn’t want to shut it down to check for blockage in hopper. “Run it till

            The wheels fall off !! “

 

1/25/11

 

MP-10  The wheel press wouldn’t reset without switching the power off. Mark reassigned a reset in the program. Nuts are still oily, & they still want to run

      A faster cycle, & wonder why they have trouble pressing parts that are shrinking too much, & then blame us for the press not having enough pressure-

      Same old – same old !

 

MP-9  Vacuumed oil pan.

 

MP-2  The robot “X” axis position kept changing. The encoder shaft coupler was loose & the plug tie down only had one screw in it & plug was half way out. Repaired.

 

MP-3  The nozzle heat was unstable. The tip heater didn’t have a clamp & the T.C. was loose. Installed clamp.

 

MP-6  The gate cutter index cylinder slide broke. Mark made new mounting plates. Gary had already replaced the other side. The press will probably start

         up on night shift. Check for set up before it starts.

Ronnie Upchurch

MP-11  The core pull switch had a loose connection. Repaired.  About an hour later, the bottom core pin broke. I pulled the cylinder for tooling. They ended up

       having to pull the stationary side so they could burn the pin out.

 

MP-16  It was giving  2103 alarm code. LS-26  shot size limit alarm.

 

I emptied the oil vacuum & cleaned out the pan on MP-6. It was full.

 

MP-19  The core pull switch wires pulled apart when they opened the mold. I butt spliced them back together.

 

The main thing tonight is to make sure they get MP-22 running. The Star guy will be here first thing in the morning. The label people are coming in later in the morning

      to set it up after the programming is done.

 

 

1.24.11 D Shift Sean

Mp#25-Repaired broken stud in Hokey Handle Mold.
also repaired broken lube line on non-op skate.

Mp#1- Collar Mold, hooked up core switch plug on tool to standard style.

Still having many dryer issues.

Continued on PM's.

Sean

1.21.11 Dshift Sean

Worked on P.M.'s and cleaned some bleed-offs from the presses.

Worked with techs on programming #22 some more.

Cleaned up around the shop some.

Call if there any questions.

Good luck with the IML today!

Sean

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.