Today 12/17/09

Replaced pneumatic drill motor on top cover drill station.  Replaced bit.  Replaced shock absorber.  Repaired e-stop circuit.  Repaired air leaks on drill.

Set up and run parts to verify.  Cleaned up and returned to equipment storage area.

 

Wired eject back switch on MP15

 

Replaced (2) batteries in MP23 pc boards.  Machine has lost program.  Nissei to send procedure by email.  We have discs for machine in office in storage box.  I will program load tomorrow.

 

I haven’t had a chance to look at robot on MP24. 

 

Mark McKee

Technical Specialist

Oreck Manufacturing Company

1400 Salem Rd

Cookeville,  TN  38506

mmckee@oreck.com

PH      931.646.7856

CELL  931.644.5289

FAX    931.646.7851

 

RE:

Worked on number 22 robot tonight. It alarms while stacking the parts on the belt during the down stroke at random pack numbers. The alarm is displayed as a Y inverter fault and it states the Y speed cannot be controlled. I changed out the y-axis encoder, switched the Y and Z inverter cards, and checked all the connections to the circuit board under the x-axis cover. I checked the different voltages on the main transformer to make sure they were within tolerance and monitored the inverter power supply voltage while the robot was operating and everything seemed ok. I tried changing the y-axis pack speed to different values also.

Collin

8.15.09 night shift---Sean

Put a tool arm and program on the Wittman tonight. I worked with the techs so they could do hands on with it so they could understand how to make changes to positions and speeds or call up existing programs.(at their request).

Should be ready to go. We also added commentary to the program and saved it by mold number.

Had a bad locator ring in #23. I pressed it back straight and turned the I.D. back so it would work again.

The robot on #5 had some incidents of stopping over the conveyor after dropping parts.

It would simply reset and rehome.

I am guessing a potential encoder error. Has not stopped since 11 pm so ???

I'll be back on saturday, Call if you need me.

Sean Kearns
931-239-7671

12.14.09 night shift...Sean

Worked on moving stuff out of repair area. Green-tagged 3 or 4 color pumps after checking them out.

I Re-did the float switch on the leak reservoir on MP#17 and put cover back on.

Marty had asked me about the "transfer velocity" setpoint that shows up on press#3 but not on #2. I looked through both control books to see if there was a convec to turn on that would make it appear on screen but did not find anything. Both books never made mention of that setting. The 486C control has it but the 486 does not so I am guessing that it is simply in the screenware program?

I called the Milacron after hours number to see what the deal was but the guy acted like he didn't know what I was talking about.

I am not sure that it is even needed but would like to know.

Sean

" C " Shift

 

   MP- 20      Thermolator not cooling down; inlet clogged at solenoid.

 

   MP-21     Robot pivot cylinder blowing air ; removed fitting, chased threads, & replaced.

 

   Cleaned out all tower water inlet screens.

 

   Started  repair on liquid color pumps.

 

 

 

   R. Upchurch

   C  Shift Maint.

12/13/09

The screw on MP3 was wrapped with plastic but it was only near the back so we didn't have to pull it. The robot on MP4 lost communication error twice and the screen would freeze up. In order to reset it we had to power down the robot. The nozzle on MP5 caught on fire due to the sled being misaligned ,plastic bleeding off, and shorting some wires out. I replaced the nozzle band, thermocouple, and realigned the sled.

Collin

Sunday 12-13-09 A Shift

Saturday we kept getting a Y inverter fault again on the Wittman, so today I jumped out the Y Inverter Fault Monitoring Input to the control in the cabinet.  After that I dry cycled the robot for 4 hours with no problem.
If there is a minor problem still, the control will not know it and it should continue to run. If there is a real major problem, the robot will hopefully run long enough for us to get more clues to fixing the problem.
Call with any questions.
Josh
Sent From My Verizon Blackberry

Surge bins

The surge bins ran out of material tonight which was due to bin #1 material hose having holes all in it. We replaced the hose and checked the others which were all ok. Also dryer 11 on MP16 blew a fuse around 6 p.m. Day shift said it blew one on them too. It ran the rest of the night with no more problems.

Collin

Worked on number 22 robot tonight. It alarms while stacking the parts on the belt during the down stroke at random pack numbers. The alarm is displayed as a Y inverter fault and it states the Y speed cannot be controlled. I changed out the y-axis encoder, switched the Y and Z inverter cards, and checked all the connections to the circuit board under the x-axis cover. I checked the different voltages on the main transformer to make sure they were within tolerance and monitored the inverter power supply voltage while the robot was operating and everything seemed ok. I tried changing the y-axis pack speed to different values also.

12.11.09 night shift

We built another EOAT for the 4 cavity bag dock running in 22. This time we are getting the runner and delivering it to the grinder. Next program we will try to do more with part stacking, subroutines, etc.

Also, need to order some airline for tieing in those hose reels. I looked and we did not have any 1/2" hardline. (60)ft.

Sean Kearns

Inverter Fault

Anytime the Wittman gives an inverter fault, try and recognize which axis the fault occurs on (x, y, or z).
Thanks.
Josh
Sent From My Verizon Blackberry

12.09.09-night shift

Put the switch back in the reservoir pan on #17. I left the cover off to check on it again this evening.

#22-robot stopped once at 1:30 a.m. for a "inverter fault". We powered it down and re-homed it and there were no more incidents.?

Did thorough PM's on robots on presses #7 and #11. They were in definite need of cleaning and lubrication.Also cleaned the control cabinets very well.

Give me a call if there are any questions. I plan on taking Friday the 18th off (last 12hrs PTO).

Sean

Wednesday C Shift

Mark extended the y axis up roller switch on the Wittman today so that it could approach closer to the mold before the clamp opens.  This switch controls the secondary mold close interlock.
I didn't do anything on the floor.
We did schedule Branson welding training for next Tuesday. I also got a PO cut for training on the Star robots. It will be scheduled for after the first of the year.
Sent From My Verizon Blackberry

" C " Shift

   MP- 1 thru 8 -   Vacuumed oil pans, checked & lubed tie bars, & blew out control cabinet filters.

 

  MP- 17-   The oil pan ran over. The oil recovery pump clogged & oil went over the float switch; pump runs continuously. I could’nt find anymore switches;

                I’ll check w/ Collin & see if he has one.

 

 

                 Ronnie U.

              “ C “ Shift  Molding Maint.

#22 Robot

 There wasn't enough operators to run the hoky top covers tonight but Charlie and I went ahead and syncronized the robot on 22 with the ejectors. With the robot running at 100% global speed, the ejectors need to be set at 28%. We moved the cups and also dropped the EOAT positive stop bar down to keep from hitting the runner.

Also while setting up number #5 robot the CPU faulted out and had to be cleared. I noticed the pentant light is almost out. I'm not sure if we have any hid away anywhere. If not it I can order some and make them a stocked item.

Collin

Tuesday A Shift Part B

Before I left I programmed the Wittman for the Hoky “Top Cover” (80083) that they hung in MP22 today.  There was not a set up in the Nissei, so the only thing that cannot be changed on the machine is the clamp full open position and the eject forward position.  The only thing on the Wittman that needs to be changed is the cup position on the EOAT.  Also, the way the teach program is written right now, you have to time your eject speed so that the ejectors get all the way out just before the robot gets to the mold face (When robot is at full speed.  First cycle, the robot will only run 30% speed.  To change, in Auto, from the main Wittman screen, hit F6 to increase overall speed and F1 to decrease).  First cycle the eject speed needs to be ran REAL slow so that the robot can get there before the part falls off, and as you increase the robot overall speed, you need to increase the eject forward speed.

 

Thanks

 

  Joshua Ledbetter

  Manufacturing Engineer

  Oreck Manufacturing Company

  931-239-3235

 

Tuesday A Shift Days

Hello All,

Not much going on today with me.  I was watching an auction most all morning and in meetings most all afternoon while Mark covered the floor.

I did have to jump out the hydraulic filter clogged switch on MP4 today, and last weekend I had to jump it out on MP5.  I know you get this alarm sometimes when the oil is cold, but we may also have some legitimate filter clogging.

 

Thanks

 

  Joshua Ledbetter

  Manufacturing Engineer

  Oreck Manufacturing Company

  931-239-3235

 

Dec.7th A Shift

We ran the Wittman today on the Hoky Chassis in MP22.  Runs well, but some of the lights on the sub-pendant still do not work (Manual, Operate with/without Robot, Auto-Cycle Pause).  Swapped the bulb on the Operate with Robot light, and it still did not work.  Outputs for lights coming from Card A22 in the Cabinet (Operate with Robot light is Output A5).  I didn’t troubleshoot it much past that so someone still needs to figure this one out because it confuses everyone not knowing which button(s) are engaged.

 

Also got MP 5 tuned in today and dry cycled.  It is ready to run.  They are going to try and run the baseplate in it this afternoon.

 

  Joshua Ledbetter

  Manufacturing Engineer

  Oreck Manufacturing Company

  931-239-3235

 

12.06.09 nights

Wittman is running. Worked with Josh last night on programming it. I like it, and think it has potential. Attached is a video of what we had last night.

Worked on PM's and cleaned this weekend.

I wired the Dummy plug attached to 22 just like the one Josh was using so it should be O.K.

The only ones that do not have dummy plugs attached to the machines at this point are #2, and #3 presses.

Sean

" C " Shift

  MP 8 – robot touch screen display – “ waiting for download “ – Thought I would have to reload the program; I unplugged the interface cable & plugged it back in

              & it came back up.

            After the press was started, the left side palm button on the fan housing press broke. I robbed one off the spare press & installed it.

              I found two new ones in the assembly maint. cabinet – installed them on the spare press. There is one new palm button in MRO. I put the old one I had

            left, in MRO molding spare parts.