4.13.11 D-shift Sean

Mp#22- Pm'd machine and robot. Cleaned up conveyor belt and IML station.

Worked on minor support stuff off and on all night for techs, material handler, and moldsetter.

Assisted process techs some, we had one go home early tonight.

Have a great day. I will be back early today around 4pm.

Sean

4.13.11 D-shift Sean

4-11-11 Mike Daniels

Mp3 had some problems with nozzle heats running to 485 and the set point was 450. The contactor was good. Done some tweeking with the offset and gain. Still no good. I eliminated 2 bands as someone had crammed too many bands on a long nozzle extension and a long nozzle tip causing degradation of material causing splay That’s why I was called there for in first place. Heats are consistent now.

 

Worked on PMs

 

 

Mike Daniels

Technical Specialist

Oreck Manufacturing

1400 Salem Rd

Cookeville,  TN  38506

Cell 931.287.6252

 

Eat. Sleep. Fish.

 

4.9/10.11 D-shift Sean (Weekend)

Mp#7- replaced all the nozzle bands and thermocouple from a bleedoff. Mp#16- replaced the nozzle band and removed bleed off. Mp#12- Checked all of the heater bands on the barrel (at Potter's request). Also hooked up the dewpoint meter to see if dryer was working correctly. I did find some loose heaterbands on the nozzle, but all of the barrel bands were good. Mp#23- Replaced the conveyor drive belt on one of the small conveyors. Installed the lockouts on the E-stop pushbuttons until I ran out of them. I still need several more to have them installed on all presses. Repaired the heat guns that were in the shop. Both had bad heaters and one of them needed brushes. Checked operation and tagged them, located them in the auxilliary equipment area in molding. Mp#8- Verified the core sequence switch was right for the old fan mold (Potters's request). Replaced nozzle heater bands on this one also. Mp#5- rebuilt the core cylinder on non-operator side. Reinstalled only to find the pull switch was bad. Broke it off in the plate when I tried to remove it and had to pull the plate and core back off again. Got that fixed and then the machine started alarming prefill valve did not open in time. I zeroed the tonnage offset and checked comm vec values for that problem and it started working good after that. I did take some photos of the classic IML station and started putting the door latches on the R2 IML station but kept getting interupted. Call if you have any questions or just want to touch base. Sean

Ronnie Upchurch

MP-3  Replaced the mercury contactor on the front zone.

MP-6  Vacuumed oil pan – AGAIN -  We have another motor & pump in the bunker – just need the time & man power to put it in.

I’ve been checking the vacuum sensors on the phaser robots- found three of them adjusted too high. They need to be setting these up for each eoat.

MP-10  I tried out the prototype part for the nut press , it looks like it will work fine.

MP-2 They hung the main frame & the core plugs were missing again. Also one of the hydraulic quick-connects was broke off, and the eject. back safety

         switch wire was mashed between the mold & platen, other than that, it was in great shape.

MP-2  Small blowback- took out nozzle heater band & fuse.

MP-1 Blow back- Pulled nozzle wires apart. It had a ¾ tip on it & the mold was ½” . I thought they were going to make them all ¾ .

Power outage- Tripped the north buss breaker & shut down the compressor. Reset.

I put gear oil in MP-2,3,& 4.

MP-5 Core plugs on the mold were broken. I hard wired them in to get them going. Will change them out when they pull it.

MP-4 I had no signal from the input card for Y reference. I pulled one out of MP-3 & tried it, worked fine. I put the one I thought was bad in MP-3- It ran good.

         It must have been a bad edge connection.                                                                                                                                                                           MP-8  Core not moving—Had a bad quick connect.

MP-5  The core cylinder on the non-operator side blew a seal . I pulled the cylinder & put it in the shop. Sean was repairing it when I left.  

4.8.11 D-shift Sean

Robot on #11- stopped a few times. The x-axis was giving an error. I slowed the speed value down from 11000 to 8500 and that seemed to help as it did not stop anymore through the night. Press#16- Cleared a nozzle bleed-off. Press#14- replaced a nozzle heaterband. Installed the E-stop switch lock out devices on presses#2,4,6,7,8,9,10,18,and 22. I am keeping up with them on the PM board. Bill Potter requested that Ronnie get Gil to replace the worn out section of the 14mm allen socket they use for changing molds. It is worn out. Transfered the heat treat item as directions prescribed, left it laying on the table beside the oven. Swept the shop floor once over. I will continue with Pm's tomorrow and whatever else is available for repairs pending, projects, etc. Call or email if there are any questions. Have a great day. Sean

4.5.11 D-shift Sean

Mp#26- Worked on the robot interface some more tonight. I have it where it will run through one cycle completely but then I get an alarm for the X18 input "cycle start interlock signal not received". It doesn't appear that the cycle start signal is being received from the robot. It may just be a set-up thing. I got with Mark and he is going to look at it later. Meanwhile... Mp#21- D shift left the press down at 6 o'clock Thursday morning because the cable for the fan mold had broken and tooling was going to make up something more permanent to pull out the stripper plate. C shift left the Nylon in the barrel not purged. It stayed in there through day shift and into night shift when Bill let me know around 1:00 or 2:00 a.m. that it would not pull material through it. The material had turned into degraded hard plastic that resembled hard clay. After attempting to remove the material conventionally, maintenance began pulling the screw out of the barrel to unwrap it. Call if you have any questions. Have a nice day. Sean

4.4.11 D-shift Sean

Mp#11 Robot- X-axis encoder had a broken coupling. Replaced it and found a loose wire possibly. O.K. and running. Mp#26- Continued wiring interface. Ran into a problem locating the x51. The print called for a CS- Control switch for the "automatic signal". We have the HMI which has a bit that sets or something. Anyway, there was not a X51 on the terminal strip. Mark and I are looking at other possibilities for narrowing that input down. Had a power surge at around midnite and reset the compressor. Have a good day. Sean

3-3-11 Mike Daniels

Battled with robot on mp10 most of the weekend it would stop in random positions I checked power supplies the 12volt supply seemed a little hot but was working. Gary also checked all the connections it ran for a few more hrs then started stopping frequently again. Gary was working on it Sunday and discovered a relay that may have been bad, hasn’t missed a lick since.

 

Mp26 drilled and tapped platen and installed robot, plumbed the air in and ran cables. I believe Sean is going to finish the interfacing process.

 

Dr18 in shop. I finished putting process heaters in and installed new blower/motor there is a board lying in the rack not sure where it goes or if it’s bad as I didn’t remove it. And that’s where we are on that.

 

Worked some on PMs.

 

 

Mike Daniels

Technical Specialist

Oreck Manufacturing

1400 Salem Rd

Cookeville,  TN  38506

Cell 931.287.6252

 

Eat. Sleep. Fish.

 

3.31.11 D-shift Sean

Mp#26- Installed the box with SPI base and routed the cable for the sprue picker interface. Will Continue interfacing it in on Monday. DR#11- replaced the process heat contactor. Moved some of the equipment out of the shop that has been waiting on parts. Tagged the items with signs. Including the Hot Stamp press Randy Russell was working on. Cleaned up in shop to make room for the R2 Fascia IML project. Continued with PM's. Have a great weekend. Call if there is anything I can help with! Sean

R2 FACIA PROJECT

We are about to begin the new R2 Facia project which will involve 7 or 8 new part numbers for molding, these will be run on MP22.  A new station will be constructed with a shuttle mechanism to present individually formed labels using two nests (operator loaded) on a subplate that mimic the mold. Gary will head up the physical building (construction, tooling) of this station, but may ask any of us to help out as needed to complete in a timely manner.  Sean will work with me on the electrical.  If anyone signs out components for this project in MRO, please sign out to R2 Facia.

 

The new Star robot for MP26 should arrive anytime.  A robot interface will need to be installed and the top of the machine will need to be drilled and tapped.  I would like Mike to install the hole pattern for the robot on the top of the machine.

 

Ronnie is ordering parts for the Conair dryer in the shop.

 

Parts are on order for the Interroll Decline Conveyor in shop.

 

Branson came in on the welder for the Ultimate Canister Vacuum Inlet Assembly, the setting are as follows:

Weld Time         .350

Hold                  .5

Trigger              3.5

Air Pressure      25psi

AB                    OFF

Stroke               3.5 inches

Adjustable Leveling plate is level.

 

Parts should be here anytime for the new Pilot Destruction Mechanism.  This may replace the duck bill style.

 

 

 

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

 

Ronnie Upchurch

MP-25  Had to unwire the relay & gripper so they could use the “B” side eoat.  The input must be bad; it’s staying made.

 

MP-2  Core set wouldn’t work. I found some cut wires.

 

DR-29  Novatec – I changed the desiccant. It was discolored & contaminated.

 

MP-6  Vacuumed oil pan.

Parts

Gentlemen,

 

FYI

 

Conair 1250W regen heaters are on order,  ½-13 all thread is a stock item in MRO and is located in the extrusion rack.

 

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

 

3.27.11 Weekend D-shift Sean

Had several dryer problems this weekend. Seeing that many of them are related to dirty filters and worn out hoses, etc. Are the techs still doing dryer pm's? Some had other issues, bad heaters, desicant problems, etc. Waiting to hear more on the Calibration procedure for MP#21. It ran fine all night tonight but still leaking , maybe worse. The clamp seal is leaking worse than before. Pump is operating a little warmer than the other day, but not running hot. MP#12-The connector test fixture had some problems failing test and leaking pressure. I flipped the rubber peice around and reinstalled it and it worked fine but the indicator lamp bulb was missing. Found one in MRO and replaced it. Mp#2- replaced the Zone #2 thermocouple. It was reading off temp significantly. There is a short list of items to be ordered that Ronnie and I left on the desk in the shop. Items like a regen heater element for conair dryers,etc. I will be back on Wednesday. See you then. Have a good day! Sean

Ronnie Upchurch

MP-18  The machine disconnect & switch gear came apart. I turned the power on so they could do a mold change. The E-stop button on the control panel

            fell off, I reinstalled it.

 

DR-11 Mezzanine – Process alarm. I found the rotation backwards. Rewired.

 

DR-6  Mezzanine – Temp. wasn’t coming up. I found the bed motor drive gear had slipped down on the shaft & wasn’t contacting the bed gear. Readjusted.

 

MP-4  Had a small blowback. Had to replace the T.C. wire

 

MP-18  Had to replace the safety docking switch on the grinder.

 

MP-9  Replaced the robot conveyor relay.

 

MP-25 I don’t know why the relay isn’t bypassing the gripper switch. When they shut it down we’ll be able to tear into it.

Ronnie Upchurch

MP-24  Installed a relay to give a gripper signal when the arm is in the up position. MP-22 & 25 already have a relay.

 

I worked with Tony Cannon & Doug Mason setting up the Branson welder for the vacuum inlet assembly.

 

We got in eight different sizes of rubber plugs to use on hydraulic lines & valves. I put them under the hose crimp bench.

 

MP-10 is to stay down all weekend. The nut press fixture has to be changed to work with the engineering change made to the part. Mark & Gary will

          finish it on Monday.

3.23.11 B-shift Sean

MP#21- I adjusted on it for a long time last night and finally got it to where it responds and is shooting good parts. It is still not responding like it should be though. The extruder is working at a functional level but could be better, it is a little slower than it ought to be. Josh mentioned that we may try to get a calibration procedure for it on Thursday.
I ran it on the robot for 2 hours and then shut it down because Marty did not have an operator for it. I posted a note on the door to let techs know that it has had the pump rebuilt and system pressures may be different than before.

Robot on #25 needs a new runner gripper sensor. We could not use it because it is reading "on" all the time and alarming LS4S alarm the robot when you put it into auto. I checked it out and found the wires had pulled back into the conduit and may have shorted. I tried to leave them disconnected but the alarm still would not clear. So I borrowed the sensor from #24 and it did not work either. May have a problem with the board. I left it disconnected until we get a new sensor. The wiring will need to be double checked before installing the sensor.
The robot works, just not the sprue grip arm because of the sensor alarm LS4S.

Have a great day,

Sean

3.22.11 D-shift Sean

MP#2-Mounted R2 topcover belt door fixture onto the other fixtures table so they could use it. Evidently we took the table to use on another project. I drilled the table so either fixture can be swapped out with the same table. When they are not using it, we can make something more permanent.

Mp#21- Hooked up the ASL filtration cart and let it run on it for a month. Try to watch that the pressure gage does not go over 35. If it does, we will need to backflush it. Procedure for that is on the cart. We can move it around every month to each of the presses we think may need it.

Continued with PM's.

Have a great day.

Sean

Ronnie Upchurch

MP-21  Got info from Toshiba tech. to check pump pressure – Press is ready to run.

 

MP-4  Replaced two hydraulic hoses & adjusted the angle of the fittings to keep the hoses off the deck.

 

Wiring cores & eject. switches on new molds.

Ronnie Upchurch

MP-12  They had some more trouble with the injection encoder rail gear. I found a new gear in the L-1 cabinet. Mark installed it. I put some grease on the extruder

            follower  arm – it was squealin !  I’ll order some more of the rail gears.

 

MP-24  I hooked up an eject. back safety switch.

 

MP-21  I drained the oil tank & pulled the tank inlet strainers. They were both 90% clogged. I cleaned them in the parts washer & reinstalled. Josh wants to run

            the static filter on it for awhile; because there’s still some sediment in the bottom. I cleaned out what I could reach with the oil vac.

 

MP-25  Cinn. Milacron dryer kept going into high temp. alarm. First I thought it was the mercury contactor sticking. It turned out to be a loose connection – the

            process temp. probe at the board.

3.21.11 D-shift Sean

Mp#21- Filled it all the way up with oil. Ronnie and I found the Suction line gage missing and reinstalled it on the pump. It would not load up with any pressure. I noticed the suction gage was not indicating any suction so I removed the gage and tried to prime oil into the pump, then replaced the gage and tried it again. Still not building any pressure. The nozzle will move and the ejectors did briefly but then quit. I tried to probe several valves (M1,M7, 102,104,gatevalve, etc.) in an effort to possibly "unstick" anything but no luck. Left it down to let air settle out of it and because I am afraid it may be damaged from running with the gage missing.





Mp#22- IML was running and the "low Label" light was staying on. He thought it was a sensor but it just turned out to be low of labels.





Mp#8- The operator they call "The Crow" fell asleep on the fans and crashed the robot. I have a picture for you.





















Continued with PM's.

Have a good day.

Sean

Ronnie Upchurch

MP-21  Mark & I installed the pump. I started it up & it ran quiet, but after a short time, it started heating up & it is still pumping air into the tank. I believe the

           tank inlet screen is stopped up & the only way to get to it is to drain the tank. I locked it out again & we can get back on it Monday.

 

I helped Henry get the new molds off the truck. The three smaller molds had fallen off the pallet – no damage – just a pain to get to.

3-20-11 B shift

Mp12 the strip gear on injection position sensor broke not sure how. Its just glued on so I cleaned reglued so if you have issues with screw position check this first.

 

Worked on PMs            

 

 

 

Mike Daniels

Technical Specialist

Oreck Manufacturing

1400 Salem Rd

Cookeville,  TN  38506

Cell 931.287.6252

 

Eat. Sleep. Fish.

 

Ronnie Upchurch

MP- 1   Installed a cover on the touch screen control.

 

MP- 10   The nut press wasn’t working. The nuts weren’t sliding down the left side track; cleaned it – working now.

 

MP- 24   Replaced a broken roller on the operator side gate.

 

I didn’t see the pump for 21 yet. If it comes in tomorrow we’ll have plenty of time to install it since molding is down for two days.

 

                                                                                                                                   Later………………………………

Update 03-16-11

Hey Guys,

I just ordered a new Star Sprue Picker for MP26.  I also ordered a new 5/16” screen for the green small grinder on MP22 (GR21).  It has 3/16” screen and is grinding Santoprene and getting clogged up frequently.

I finally convinced Ken that we need to order 2 of the Special AEC grinders that I had spec’ed out to especially grind warm rubbery materials.  He is turning in a CER for it today.

The pump for MP21 is due back in by the end of day today.  Mark is out today and I have to leave at noon, so I told Ronnie just to prep it for tomorrow.

 

Thanks and keep up the hard work.

 

 

Joshua Ledbetter

Molding Maintenance Manager &

Manufacturing Engineer

Oreck Manufacturing Company

(C) 931-239-3235

(F) 931-646-7615

 

Ronnie Upchurch

MP-6  Adjusted the gate cutters; one side wasn’t cutting close enough.

 

MP-7  The portable hopper loader motor burned out. Replaced.

 

GR-4  I flipped the stationary blades & removed the rotating blades; no more blades in MRO. Also one of the adjustment set screws is missing from the front

           stationary blade ; it’s metric.

 

I vacuumed out the oil pans on MP-6 -7 & 8

3-14-11 Mike Daniels

Worked on PMs

 

Made a core plug for mold in mp5           

 

Swept shop

 

Mike Daniels

Technical Specialist

Oreck Manufacturing

1400 Salem Rd

Cookeville,  TN  38506

Cell 931.287.6252

 

Eat. Sleep. Fish.

 

3.13.11 - Sean D-shift

Mp#25- Has been stopping for core bwd limit sensor. I found the core cylinder was loose. It has stopped a few more times infrequently. I have checked the wires on the switches and plugs. At this point I think the mold cores may be getting caught up and not pulling after it shoots parts.
It occurs about once every half hour, and always at the same place in the cycle, right before it starts to open and cores are pulling. I added some time before opening to it and it seemed to help.

Mp#14- The machine would shoot parts and then stop before building a shot again. Then the clamp would not open up in manual. Checked many switches, etc. Finally found the mold touch switch (LS2) was flickering. I re-adjusted it and checked operation, no further problems.

Continued with PM's..

Sean

Ronnie Upchurch

MP-2  Cores not working – The hydraulics were hooked to core 1 & the switches were hooked to core 2. I moved the plug to # 1 side. It still wasn’t shifting.

         I found one of the male quick connects was bad.

 

I emptied all the Nissei over flow jugs & the oil vac.

 

I moved the grinder from MP-12 to the shop. I cleaned it out. We need to order new blades for it.

 

 MP-1       I changed out the grease tube on the lube system.

 

They brought 3 scales to the shop for repair. I  cleaned them up & adjusted the level.  2 of them work fine, the other one I’ll take to Craig to check out. It

       wouldn’t hold the zero or the tare setting.

 

3.11.11 Sean Kearns

Mp#12- The Grinder was found completely full. I cleaned it out and set it back up to load material again.

Continued with PM's

Sean

3.8.11 Sean Kearns D- shift

Finished Packing up the pump and weighed it @139lbs.

We had a power failure at 11:02 pm last night. It tripped the #3 panel which fed the North Bus. I was able to reset it and the air compressor and we were going agin shortly after 12:00.

Mp#9- The Z-at part drop maximum limit needs changed in the HMI's. It would not hurt to set them all that way, or make the value accessible from the touch screen. Maybe add it to the speed control page.

Continued with PM.'s!

Call if there are any questions.

Sean

3.7.11 Sean D-shift

Mp#23- Potter asked me to look at the mold heater circuit. It checked out alright without taking the tool apart. It just appears they are not getting good heat transfer inside the mold. Heaters checked out and T/C's did too. They will need to pull it ouit and take it apart.

Mp#18- Had trouble with zone #1. Could not get the controller to output a signal. Found a relay with a bad set of contacts, moved wires over to a spare set on the same relay. Never could get the controller to send a signal. Changed it out 4 times and finally got one of the very older analog types to work correctly. I only had used stuff to try out, so we may need to order a new one to put on the shelf...when the money returns?

Mp#15- Did not get very far with it. I pulled the M1 valve of and cleaned it, it was very clean and solenoids ohmed out good. Reset mold thickness, etc. and bled out the air, problem remains.
Will proceed some more tonight.

Sean

Ronnie Upchurch

MP-21  Worked with Josh & Mark trying to figure out why it’s generating so much air in the oil. Mark is checking into having the pump rebuilt. It’s down

            until we get a response on the pump.

 

MP-15  I replaced the C-7 check valve, still no go. The Toshiba tech. said we’re in the right area; sounds like something isn’t shifting fast enough. I did all

           the system pressure tests they told me to try, & it checks out OK, so at least we know it isn’t one of the pumps. The next step is to start pulling the

            clamp valve stack apart & check for sticking spools etc.

B shift 3-4-11 thru 3-6-11

Worked on PHs

 

Cleaned a pithead from nozzle on mp16 and rewired.

 

Vacuumed excess oil from presses

 

Mp12 broke ejector cylinder bolts. Repaired

 

Replaced a broke belt on grinder behind mp10. Nobody knows how or when this happened.

 

Have a Great Week

  GONE FISHIN

 

 

Mike Daniels

Technical Specialist

Oreck Manufacturing

1400 Salem Rd

Cookeville,  TN  38506

Cell 931.287.6252

 

Eat. Sleep. Fish.

 

3.3.11 - Sean

Continued with PM's.

MP#16-Replaced the sled forward switch.

Have a great weekend. Call if there are any questions!

Sean

Ronnie Upchurch

Dryer in the shop – over temp. alarm.  I had to adjust the bed switch.

 

DR-4 In the mezzanine – Alarm 11. The top of the drive motor housing was loose & the gear was slipping. Tightened .

 

Chuck w/ Nissei is faxing us some better copies of the valve driver set up.

 

MP- 15  I ordered a new clamp check valve – ( C-7 on the hydraulic print )

 

I made a purchase req. for some more Citra-Solv degreaser & Litho- Lube grease.

 

I got a quote for new Spenser Vortex blower- 906.00.  Cookeville Elect. wants 1000.00 to repair the old one. We still have a spare in MRO.

 

We got everything cleaned up & picked up in the shop, but didn’t see anyone walk through today.

March 2, 2011

March 2, 2011

 

Ordered a hardened screw, barrel, and tip for MP13.  Right now it is a 4WK lead time.

 

Labeled steemer tank EOAT.

 

Worked with Ronnie on MP11 Cal.

 

 

 

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

 

2-28-11 3-1-11

2-28-11

 

Worked on dryer issues all night. Dryer11 replaced overload contacts on blower motor then it lost a process heater contactor do we see a pattern these things are ending there life and are in need of replacement. Dryer was brought to shop looped out and running so far so good.

 

Mp2 had issues with Mold and cores not set up to run on cores read Josh’s blog about it.

 

 

 

Mike Daniels

Technical Specialist

Oreck Manufacturing

1400 Salem Rd

Cookeville,  TN  38506

Cell 931.287.6252

 

Eat. Sleep. Fish.

 

March 1, 2011

March 1, 2011

 

Work with F1 Fan Housings and new tester.  Fan Housings that had a .7 weld time proved to be leakers and could be destroyed at about 5psi.  Housings with .9 weld time had a small leak but passed the tester and were able to be destroyed at 10psi.  Housings with 1.0 – 1.1 seemed to be sealed / welded very well with destruction around 12-14 psi.  All new housing halves passed the drop tester at 30inches.

 

Wired mold #52926 (Steemer Tank)  for cores.  Swapped hydraulic fittings on the mold and connected to core 1 on MP2.  Adjusted switches and cores worked on A1 and B1.  Gary made EOAT for Tanks and we adjusted in. 

 

Talked to Josh about MP21, he showed me the valve to increase speed of functions, worked with Rick to get fan runners to drop.  Repaired pull cable for plates on mold.

 

Set up ban saw in molding shop for techs.

 

Helped Gary button up MP15, he replaced screw and tip.

 

Worked on MP11 Robot,  Robot would grab parts and stop above mold, say in unsafe position.  Ended up being no time in cycle start timer  on mold machine.

 

Ronnie and I will  try to calibrate MP11 and MP21 tomorrow.

 

 

 

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

 

Recovery Tank MP02

Hello All,

Gary Gore and Mark McKee built a new EOAT today to enable the Recovery Tank to run in MP02 off of the cores.

In the past we have used the Ejectors to control the stripper plate on this mold because when not using the robot multiple strokes were needed to clear the part.  It is a lot safer to use the Core circuit because when using the Ejectors the set-up parameters were just “tricking” the machine and everything was based on time with no part removal verification.  When using the Core circuit in combination with the robot, part removal is verified.

Just remember that on the “Special Options” menu of the robot that “Cores Logic” needs to be turned ON.

Any questions regarding this can be directed to me or any member of the Molding Maintenance Department.

Thanks

 

 

Joshua Ledbetter

Molding Maintenance Manager &

Manufacturing Engineer

Oreck Manufacturing Company

(C) 931-239-3235

(F) 931-646-7615

 

2.26.11 (Weekend of) Sean

Mp#23- changed nozzle band.

Mp#3- replaced 1-1/4" hose on the op side clamp assist cylinder that was leaking bad. Cleaned up the oil.

Mp#1- installed air pressure regulator on the EOAT so it would not damage fans. They had turned down the regulator on the robot to where the system pressure switch would no longer make, faulting out the robot.

Mp#21-Sole Plate wheel press, replaced one of the two hand air switches.

Mp#2- Replaced the wire on the ejector back switch of steemer tank mold. It got smashed.

Mp#24- Wheel/Tire Press Tool. Made a hand tool so they could rework the cold tires that were molded. This item needs to be revisited by one of our manufacturing engineers involved with it. The normal automatic operation is damaging the parts when used.

Mp#10- The nut press is still having problems when the nuts are not cleaned, the track will not load up correctly. Wev put some in a 5 gallon bucket with degreaser and tumbled it for an hour. Then cleaned them off with rags and air. No one can give me an answer as to what is the procedure with this situation. Who makes the decision? Communication has been poor lately on some of these problems that keep lingering around.? Thanks for any support you can get.

Continued with PM's and other support functions.


Have a very nice day.

Sean

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