2. 27/28 .10 nights Sean

Mp#25-
It is down and needs an encoder for the ejectors. They had problems with it after changing the mold and it would not read, I worked on it and got it to read but it would never close the clamp and it would give an alarm like: "confirm setting for ejector bwd limit." I wanted to eliminate that it was n't the limit switch cicuit so I checked the door switch, and ejector back limit switch jumper and cable.(was fine). I spoke with Mark and gave him the Encoder information and model number.

Made EOAT for the Edge top cover on #11.

Got the signs turned around for the Machine Disconnect locations.

I am sending an email to Jerome asking for some time to get leaks fixed on press# 17.

Call if there are any questions.

Sean

" C " SHIFT

MP-16  Tech said barrel heats were running too high.  I checked heaters, contacts, T.C. connections,& cables. Everything checked OK.  The heat profile was 500 to

       535. ( Nylon )   For some reason, we had to run the heats 50 to 55 degrees under & parts ran fine.

 

MP- 17  Mold 74005-01 broke a pin “ again “.  I found the thin switch had been wired N/C.  I changed it & Gill repaired the mold. It should be back in & running

       Before the end of the shift.

 

MP-21   I vacuumed up oil & cleaned around press.

 

DR-23  I put this dryer on the mezz. In place of  DR-19 . We need to order large bed gear for DR-19    Conair part #  183875

 

 

 

         R. Upchurch

         Molding Maint.  

" C " Shift

 MP- 13 Eject. cylinder bolts broke. Replaced.

 

Dryer- 19  Turntable motor mounts broke & large drive gear stripped. No new gears in stock. Will order more gears Monday.

 

MP- 1  Mark finished pulling valves – we put the frame & covers back on. I should be ready to go .

 

MP- 25  Ejector not working -  Tech said he wiggled the plug on the eject. transducer & it broke off. I was able to straighten the pins enough to plug it back in &

         tape it up. The end that broke off was on transducer. We will have to order a new one to fix it properly.

 

We checked the oil storage building, & the drums had not been emptied, so we loaded four empty drums on a spill pallet & brought them inside.

 

 

 

      R.Upchurch

      Molding Maint.

2.26.10 nights D shift.

DR26- repaired the carousel position switch with new screws, no further problems with it.

Gr13- repaired hinge pin, made a new one.

Mp#3- screw was wrapped with plastic and it would not build consistent shot.(kept stopping). Jacked up the barrel heats to 550 and let it soak for about 45 minutes then ran a bunch of clear PC regrind purge and compound through it until it was shiny clean. Ran great the rest of the night.

Mp#2- was down so I checked the core 2 circuit, at first it would not work, then I moved the pressure line to the P1 circuit and it had 2000 psi. Checked it with the test rig that was in the shop and it worked fine. O.K. to run.
Also on 2, I cleaned up the oil that was in the floor there, I couldn't really tell where it was coming from, but it was under the mold area mostly and appeared to have dripped down... was there a leaky mold on A or B shift?

Started swapping orientation of the U-bolts on the disconnect signs, should be finished by this weekend.
Did we decide what to do with the 200volt conveyors in the shop? I can put them back in the trailer? Let me know.

Sean

2/24/10

I removed the adapter heater band from MP22 to put on 23 so it could start up. It's wired into the same terminals as the nozzle (R1 and S1)

MP20 broke all the ejector plates bolts and had to be replaced. Also the plate guide bar was badly bend. Darryl and I straightened it in the shop press enough to be useable.

MP21 stopped working while in production. Nothing would move but the sled. Also the clamp and screw position wouldn't read. We powered it down about 3 times and it allowed us to move the clamp so we could reset the mold thickness. Everything started working then. I've seen it do this once before a while back with the same problem and solution.

Collin

2.24.10 night shift D

Mp#5- fhd current input #1 exceeds limits alarm.
Changed the fhd current index for extruder max out value to 12000 from 16000. Per Josh's advice. No further issues this shift.

Mp#16- Used the heater band from #1 to get the heaters going on it. Noticed the sprue-break limit switch adjustment ring was slid back a little more than all the way up. This may have contributed to some bleeding off that occurred. Put a note on the press for operators to remind the techs each hour to check for bleed off.

Found a 400 ton FN7000 1999 model online last night. It had a 575volt.
http://www.usedplasticinjectionmoldingmachines.com/2010/02/04/1999-398-ton-used-nissei-injection-molding-machine/

Another one:
http://www.kitmondo.com/ViewListing.aspx?lid=242651&prodName=Nissei_FN7000

This is the 575 volt one:http://www.elitemachinerysystems.com/machine_details.php?prod_id=645

" C " Shift

 Still working on stripping MP-1.  We drained the hydraulic suction lines, & water from the heat exchanger. Mark removed the conduit & recepticles.

    I  removed the rear frame to access the pump & motor.

 

All the waste oil drums were full , so I moved them to the oil storage building for pick up. Walter said it would probably be Thursday before they could pick

     It up.  If we need an empty drum before then, there are two in oil storage.

 

 

 

 

 

 

           R.Upchurch

           Molding Maint.

2.23.10 night shift D

Mp#5- had lots of metal in the nozzle. Typical baseplates? Grind it till we find it?

Mp#2- Nozzle has been running away somewhat. I noticed first zone was 5o degrees hotter than the nozzle the way setpoints were set. I checked the mercury relay and noticed it was not plumb, straightened it back up and tightened the screw on it. Compared pg 96 values with those of #5 press and set the PID for then nozzle the same. Also increased the scan time from 5 secs to 2 secs. (#5 was set at 1 sec). Next move is to change out from mercury to solid state relay, but I think much of the heat is coming from the process.

Started pulling more stuff from #1. Also made progress on the Yushin 900. I need to change out some sensors and replace missing parts and it should be O.K. to go.

Call if there are any questions.

Sean

Monday Feb 22, 2010

Tagged out power on MP1.  Started stripping parts of value from MP1

 

Received New Motor Starter Parts for MP3.  Assembled and Installed in MP3.

 

Received additional seal nuts for 3/8-24 Go Switches.  Put in MRO in Go Switch Tray.

 

Received new clamp on Reed Switches for magnet piston type cylinders.

 

We have the Nissei Gas Springs for Display controllers that need to be installed.  They are on the table.

 

Ordered new Machine moving skates.  Salesman will pick up the old ones tomorrow.  RMA #’s on my desk.

 

We should receive the motor for MP3 sometime Wednesday.

 

Ordered the core stack for MP19.

 

Put connectors on new Encoder for AEC Robots and put in MRO.

 

Mark

 

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

 

#16 heater bands

MP 16 had a bad blow-back which cover all the bands but three and destroyed all the insulation from the barrel shroud. I was able to reuse most of the bands but we are missing or out of stock one of the nozzle bands. It's a 240V (2.5" X 1.5"). I left the old one laying on the press. The nozzle thermocouple is wired in and the tip band is on the press also.

Collin

2.18.10 nights Sean

#10 robot was stopping over the conveyor and screen was displaying
"robot not on". It would not power up at all. Got in the cabinet and traced down the mcr circuit to one of the NC switches on the y or z axis. Replaced the Y axis reference switch and had no further trouble from it.

Pulled hoses from eagle top cover tool that is going out today for engineering changes. I made a detailed drawing of hoses but they are still together in one bunch and is fairly self explained when looking at them. They are in a blue tote.

Finished putting up the signs for the disconnect locations at machines.
If there are any problems with them we'll be glad to make changes as needed.

GR-20 : Replaced start push button. Replaced broken caster with a used salvaged one. Put the panel screws back on it. Green tagged it after starting it and checking operation.

The conveyors in the shop are 200vac. They are rated at 25watts. The star robots have a maximum requirement of 500va (or.55%x500=roughly 275 watts) and the transformer is only rated for 500va...so they could only use them if they do not run the robot at the same time.

Call if there are any questions.

Sean

2.17.10 nights Sean

Mp#22- set it up on the robot, made some program changes and modified EOAT.
Mp#21- After resetting clamp by the book instructions it worked alright.

Did some minor mold repair work for moldsetter.

Hung about half of the disconnect signs. Will finish tonight.

Mp#3- someone ran the extruder with the sled forward and created a nozzle mess. Replaced both bands and thermocouple.

Also 3, the motor keeps stopping, about 30 times last night.

Need to layout a plan for that, it has become a production problem now.

Call if there are any questions.

Sean

" C " Shift

   MP-17   Vacuumed oil off of clamp end deck; will try & get back to this one later. Needs “ O “ rings changed on directional valves.

 

  MP-5   Made new belt for extruder rpm meter so Josh could recalibrate.

 

  MP-7   No clamp movement – One of the input plugs was pulled out in robot cabinet.

 

  MP-22   Made new end of arm tool for the bag stiffener.

 

  MP-7   Machine stopped in cycle- error code 5202 – back door came open.

Tuesday A Shift

Got MP2 running today, but the eject option I tried to add never did work.  The software did not want to cooperate.  How it is running now is that I have the ball valves cracked a little and I’m just reading the butterfly position, not the switches on the mold.  I also turned on the core 2 option, but I never tried it out.  They needed parts and we’ll just deal with it later.

Robot on MP7 is ready.  X axis was not reading position.  Gary swapped out the encoder with the new style and also ran a new cable down to the plug on the beam.  It still would not work and we ended up finding pin 1 loose in the plug.  The plastic is wore out and the pin does not want to stay, so right now we just forced it in there and wire tied it good.  If you have problems with X axis in the future, check pin 1 on the encoder plug first.

MP10 bowl feeder still needs a little work.  Gary is going to come in for a bit tomorrow and work on it.

 

Thanks

 

 

 

  Joshua Ledbetter

  Manufacturing Engineer

  Oreck Manufacturing Company

  931-239-3235

 

2.14.10 Weekends on nights Sean

Mp#10- parts were not welding the deflector. Double checked the process before i began working on it. It was running at 56 seconds cycle time. Water was partailly shut off, but not all the way. To cut it short, Marty and I adjusted the fixture and just kept working with it until they were welding good again.

Worked on the 900 Yushin sprue picker. I wired up the other interface box using the 200vac transformer because the print was calling for that circuit box. It came up but indicated E-stop faults which were from a blown fuse. Changed fuse out, got it up to a "kick cyclinder input error" .
It probably has a short in either the sensor or the pendant because it keeps blowing the fuse. If it turns out to be the pendant then I can still change out the board/pendant with one of the others.

Mp#2- I attempted to plumb in the hydraulics on Core #2 . The pressure line is tapped into MX2 feeding off P1/P3 circuit. It has NOT been checked yet, still need to turn on the Core 2 convecs/ options etc. and set up pressures and flow controls etc. I have some questions for Josh about this when I come in next or can call me, etc.

Went through the trailor and tried to straighten up etc. Moved the 3 small conveyors into the shop and let the process techs know that they can use them to draw runners out from under presses where needed. No takers yet.

The Pump motor on #3 is limping along for now. I understand that Josh is checking on getting it rewound, etc.

Call if i am needed. Next week is my short week and will be glad to come in and assist at short notice. Thanks.

Sean

" C " Shift

 MP-13   Nozzle heater not working; T.C. was loose. Tightened ba                                                                                                                                                                                                                    

                                                                                                                                                                                                                                                           

 MP-1   Finished vacuuming out tanks.  Emptied oil vac.

 

 Potter  wants more of the trays made for the tall conveyors. I need to order material to complete these.

 

 At 12:30  the security guard told me one of the units in life test had fallen & was hung up between the test platforms. I shut it down , unplugged & unbolted  the unit ,

     & set it on the floor. I restarted the tester.

 

   

2.13.10 nights Sean

#3- press stopped about 8 0r more times with several different alarms such as injection valve off etc. Routine was powering it down then back up again. Then motor overloads began tripping about every hour. Marty stopped it because we were short a technician last night and it was becoming too much trouble.

Collin and I checked it with the ammeter , ohmed out the motor and compared it with the readings of #5. Amps were way higher and two of the legs on #3 were reading 8 ohms vs. 0.2/0.3 ohms on the other motor. Also checked the page 42 board and compared output voltages for everything and they were comparable to #5.

We suspected the motor is the cause, in addition to it tripping OL's so much lately. While inspecting the press, noticed the top oper. side tiebar bushing had came out again. I cleaned and put it back in, made a new retainer bracket for the one that was missing. Also, cleaned and lubed tiebars real well.

Put the machine into "dry cycle" without the injection unit and let it run continuous to see if there was any improvement. Has run half an hour and has not stopped, so it might be alright?? Other than changing the motor out? That is where we are with it.

Call if there are any questions.

Sean

2/11/10

MP20 Ejector plate bolts broke. Found one of the knock out rods threads were stripped. I fixed the knock out rod and replaced the broken bolts.

Tried to start up MP2 but couldn't put the machine in manual mode. Josh guided me through cold starting the press to get it running and said he would work on it tomorrow.

Set the welder and belt back up but they were out of y plates so they didn't run it.

The tape sensor on the heat stamp on MP20 stopped working. I adjusted on it and finally found the light/dark switch on the main panel was flipped in the wrong direction.

I was going to paint the new robot riser on MP2 but couldn't locate any brushes or rollers. Darryl and I looked in the shop, MRO, and the tech's shop but could find any.

Collin

2.8.10 nights Sean

Worked on grinders and loading system on 24. Collin said that the breaker was tripping frequently for #5 grinder. It was making a loud rumble so I pulled it apart and reset the stationary blade where it was rubbing. It has been O.K. since.



#6 robot- ran a new airline because I had already spliced the line once and it was leaking again so I put a new tubing in it. Also replaced the cabinet fan on it and checked it out for preventative maintenance.



#22 robot- painted the support column. Was going to paint the riser that Collin built but Mark talked like it was going on this morning. I can paint it after it goes on.



Need a new wire feed motor for the "Cricket" Miller wire welder in the shop. We do not need it right now but if we do in the future, it is not working.



Let me know if there are specific things you need me to start on tonight Josh. Thanks.



Call if there are any questions.



Sean

B Shift

One of the new Eagle molds with cores was put in MP17 this weekend. To the best of my knowledge, 17 has never ran cores before. Gary wired up the pull and set switches and everything worked fine. The sequence is different than the other presses. Sequence 1 is set and pull before close, 3 is set and pull after close and I'm not sure what 2 is. I'll try to put some indicator lights on the panel when it's down.

MP5 has a pre-fill valve not open in time alarm. If you probe the open side then the close side of the valve while someone is pressing clamp open it will shift and the mold will open. I checked the voltage to the valve then switched the coils out. I removed the valve and the check valve behind it cleaned and inspected them. The value seems to move smoothly. The press is still down. If number 3 is down tomorrow night I want to trade the valves out.

Collin