Mould-Tek Dryer on SB#1- The dyer has stopped in cycle due to the failed gear motor that burned out likely from the mechanical apparatus that ratchets the desiccant beds around. We need to order another gear motor for it. I found them in grainger for about $100. Also, the linkage in the ratchet apparatus needs to be checked out for corrct function, it was sloppy loose so I tightened it up and tried to manipulate it by hand but I was not certain about it. When the motor comes in we can check alignment and operation in further detail.
Mp#15- The mold setter evidently put too long of a screw in the platen holes that I recently tapped to 3/4". I asked Roger to get with him and decide what size screws we needed to accomodate setting molds correctly. Now it has a bolt stuck in it, they did not want to repair it, only set the new tool and run the press. So?
Give me a call if there are any questions.
Sean
Thursday, March 15, 2012
Tuesday, March 13, 2012
3.13.12 Sean
Mp#1- Checked the fans on the cabinet, they are working. replaced cabinet filters and vacuumed inside the cabinet. Cleaned and inspected the machine and core pump.
There were no other alarms on my shift for anything on this press last night.
O.K. to run. I don't know how they continue to get so much liquid color all over the place??
Mp#2- The robot arm looked really bent like it had been crashed. Upon further inspection, found the bearings on the C-axis were mostly destroyed and one of the support arms looked bent really bad. The screws that held the C-axis assembly together were stripped out also. I put 5/16-18 keenserts in the screw holes and had Gil make some inside bushings from Delrin material and I replaced the outside bearings and shoulder bolts. I used permanent strength loctite on all of the screws and checked the operation. Nice and smooth now! There are probably some more C-axis that need repaired but for now we are out of those bearings from MRO (noted on the sign out sheet).
Have a nice day.
Sean
There were no other alarms on my shift for anything on this press last night.
O.K. to run. I don't know how they continue to get so much liquid color all over the place??
Mp#2- The robot arm looked really bent like it had been crashed. Upon further inspection, found the bearings on the C-axis were mostly destroyed and one of the support arms looked bent really bad. The screws that held the C-axis assembly together were stripped out also. I put 5/16-18 keenserts in the screw holes and had Gil make some inside bushings from Delrin material and I replaced the outside bearings and shoulder bolts. I used permanent strength loctite on all of the screws and checked the operation. Nice and smooth now! There are probably some more C-axis that need repaired but for now we are out of those bearings from MRO (noted on the sign out sheet).
Have a nice day.
Sean
Monday, March 12, 2012
3.12.12 Sean
Mp#10-Replaced the sled cylinder seals. Checked operation, O.K. to run.
Mp#14- Made some new matching ejector bars.
Mp#11- Repaired waterlines on mold at Techncian Roy's request.
Continued with PM program.
Have a great day.
Sean
Mp#14- Made some new matching ejector bars.
Mp#11- Repaired waterlines on mold at Techncian Roy's request.
Continued with PM program.
Have a great day.
Sean
Thursday, March 8, 2012
3.8.11 Sean Kearns
The nut feeder vibratory bowl is not working all the time it comes on from time to time with no LED indicators lit. It is outputting a voltage but no current. The LED's are showing both red and green off. When the nuts are loaded to the sensors, the green comes on indicating the sensors detect presence. I tried adjusting the sensitivity but it still cycles infrequently. I am going to look at testing the triac again. The vibration adjustment knob was maxxed out at 10 again also.
Mp#15- Drilled and tapped out 4 holes on the moving platen at Roger's request. Need to several others when the press is available.
Talk to you tomorrow!
Sean
Mp#15- Drilled and tapped out 4 holes on the moving platen at Roger's request. Need to several others when the press is available.
Talk to you tomorrow!
Sean
Sunday, March 4, 2012
3.2.12 Sean
MP#21- Is locked out. The key for my lock is on my toolbox. The ejectors were not working. I put a mold in it and clamped it up to set the clamp readout, etc. The ejectors worked once and started leaking from the hose I made. I replaced the fittings and the hose end and it did not leak anymore, but I still couldn't get them to move on their own. Probing the valve, it worked fine.It still needs zeroed out though.
I was looking for the procedure when I got the call to come home, my wife had spotted a tornado. Of course by now, everyone has likely seen the news about our area.
I came back in on Sunday and set the dryers and left them a note for start up.
Call if you have any questions.
Sean
I was looking for the procedure when I got the call to come home, my wife had spotted a tornado. Of course by now, everyone has likely seen the news about our area.
I came back in on Sunday and set the dryers and left them a note for start up.
Call if you have any questions.
Sean
Friday, March 2, 2012
3.1.12 Sean-
Mp#6- The technician Charlie Pack indicated that the press was stopping because the ejectors kept "bouncing" off the rear limit switch. He asked me to replace the switch and it did appear busted so I did. The problems still remained. I then attempted to adjust the EV2 potentiometer to "slow ejectors backs speed". Charlie also indicated that no control over ejector back speed was the problem. The EV2 pot changes did allow control over eject back speed, but the "bounce" problem remained still yet.
Next, I discussed this with the supervisor Roger who thought the mold needed to have return springs in it. I mentioned that if I could find one, I could install a flow control with one way check valve in line with the hose and that would probably remedy this situation, but, I could not locate one anywhere. He also wanted to change the seals in the ejector cylinder.
The rod seal was not visibly leaking, but to be sure, I went ahead and tore it down and replaced the inside o-rings, rod seal, and both the piston seals. The problem of "ejector plate "bouncing" after retract still remains. The valve was my next choice, as I suspected drifting. It appears to still have the original valve on it. It was 12:00a.m. at this point so I went ahead and left. I will resume on it tomorrow when I come in.
Additionally, I would like to add that we could use some more seal kits for 360 ton Nissei presses as I had to re-use the external wiper rod seal because there was not one in the kit I found in MRO.
MP#8- The fan housing press was over-pressing the push-nut rivet assembly on the service parts they were running. I adjusted the positive stop to meet quality approval. I found out later that the process techs came back and adjusted it several more times. I think there may be some operator error being introduced to this operation. Check it out if anyone gets a chance. There could also be problems that have been overlooked with this process. Thanks.
Give me a call if you have any questions.
Sean Kearns
Next, I discussed this with the supervisor Roger who thought the mold needed to have return springs in it. I mentioned that if I could find one, I could install a flow control with one way check valve in line with the hose and that would probably remedy this situation, but, I could not locate one anywhere. He also wanted to change the seals in the ejector cylinder.
The rod seal was not visibly leaking, but to be sure, I went ahead and tore it down and replaced the inside o-rings, rod seal, and both the piston seals. The problem of "ejector plate "bouncing" after retract still remains. The valve was my next choice, as I suspected drifting. It appears to still have the original valve on it. It was 12:00a.m. at this point so I went ahead and left. I will resume on it tomorrow when I come in.
Additionally, I would like to add that we could use some more seal kits for 360 ton Nissei presses as I had to re-use the external wiper rod seal because there was not one in the kit I found in MRO.
MP#8- The fan housing press was over-pressing the push-nut rivet assembly on the service parts they were running. I adjusted the positive stop to meet quality approval. I found out later that the process techs came back and adjusted it several more times. I think there may be some operator error being introduced to this operation. Check it out if anyone gets a chance. There could also be problems that have been overlooked with this process. Thanks.
Give me a call if you have any questions.
Sean Kearns
Tuesday, February 28, 2012
2.28.12 Sean
Worked on MP#18- seal is ready to remove. Press is locked out, I will get Mike to put his lock on it today when he comes in.
I had Henry put his lock on MP #8 until Ronnie comes in Wednesday morning.
Here are some images of MP#8 for future reference.
I had Henry put his lock on MP #8 until Ronnie comes in Wednesday morning.
Here are some images of MP#8 for future reference.
 |
| Extruder Motor with fittings taped off and tachometer removed to prevent damage. |
Friday, February 17, 2012
2.17.12 Sean
Dryers all set that could be set for auto-start. I left a start up sheet for Marty and 3rd shift that indicated which dryers needed to be turned on and which ones were off and not in use.
We had another hydraulic leak on MP#2 core cyclinder hose. I replaced the hose and we cleaned up most of the oil.
Mp#26- Replaced the nozzle heater bands due to a bleedoff. Checked back on it later and there were no further problems with it.
Sean
We had another hydraulic leak on MP#2 core cyclinder hose. I replaced the hose and we cleaned up most of the oil.
Mp#26- Replaced the nozzle heater bands due to a bleedoff. Checked back on it later and there were no further problems with it.
Sean
Thursday, February 16, 2012
2.16.12 Sean
Mp#6- Had more trouble with the gate cutter on the baseplate EOAT scratching the parts. The back stop had loosened again. Tightened it up, no further problems.
Mp#20- Has been having bleedoffs around the nozzle tip. It needs to be changed out to a new nozzle, or the old one re-surfaced when it goes down for a mold change. Keep an eye on it.
Repaired the DME in the shop. The clip in the 3rd spot down inside the terminal connector must have a clip in it regardless of whether it is wired to anything (it is not usually). If it does not, cards will not work correctly in it. In this case, it had one missing.
Finished up the conveyor roller covers in the shop and rolled it back out of the shop.
Cleaned up in the shop, took out the trash and cardboard.
Have a nice day.
Mp#20- Has been having bleedoffs around the nozzle tip. It needs to be changed out to a new nozzle, or the old one re-surfaced when it goes down for a mold change. Keep an eye on it.
Repaired the DME in the shop. The clip in the 3rd spot down inside the terminal connector must have a clip in it regardless of whether it is wired to anything (it is not usually). If it does not, cards will not work correctly in it. In this case, it had one missing.
Finished up the conveyor roller covers in the shop and rolled it back out of the shop.
Cleaned up in the shop, took out the trash and cardboard.
Have a nice day.
Tuesday, February 14, 2012
2.14.12 B-shift Sean
Mp#1- Robot is down until pendant is available.
Nut Press on #10- Replaced a sensor on LH side square nut fixture. Cleaned and inspected it. O.K. to run.
Pm'd Press #5. We are putting loctite on the screws on all the loading receivers on the presses and in the mezzanine to prevent screws from loosening. I am also trying to get around and refill all of the FRL's with oil where needed on robots, etc.
Mp#6- Replaced the rpm tach for the extruder that was busted off. Used the one from MRO.
Have a nice day.
Sean
Nut Press on #10- Replaced a sensor on LH side square nut fixture. Cleaned and inspected it. O.K. to run.
Pm'd Press #5. We are putting loctite on the screws on all the loading receivers on the presses and in the mezzanine to prevent screws from loosening. I am also trying to get around and refill all of the FRL's with oil where needed on robots, etc.
Mp#6- Replaced the rpm tach for the extruder that was busted off. Used the one from MRO.
Have a nice day.
Sean
Friday, February 10, 2012
2.10.12 Sean
Mp#12- Replaced the mercury contactor on zone #3 with a solid state contactor 25 amp. Checked all heater bands. O.K. to run.
Mp#4- Core problems. After determining hydraulics were working, and set to correct pressures and flow rates, had electrical signal dropping out on both core sets. Found they had same card in rack in common and found what appeared to be a bad socket on the terminal connector. I gently bent the top pin enough to where it would make a tight contact. No further problems.
Worked with Roy Smith and Charles Pack on understanding the robot on press #22 better. I strongly emnphasized the need to improve their habits of saving mold set-ups in the robot memory. I showed them how they could change or save set-ups in regards to different conveyors (tall or short).
Worked on the trolley/platform for the new hydraulic power pack unit.
Cleaned up in the shop.
Note about shutdown.
Bill Potter informed the team leader and the process techs that there was no need to set dryer timers since he was coming in early on Monday morning for start up since 3rd shift was not going to start on Sunday.
I did not get any other information since that so I did NOT set the dryer timers at Rogers' request.
I will call and confirm with him sometime on Sunday.
Mp#4- Core problems. After determining hydraulics were working, and set to correct pressures and flow rates, had electrical signal dropping out on both core sets. Found they had same card in rack in common and found what appeared to be a bad socket on the terminal connector. I gently bent the top pin enough to where it would make a tight contact. No further problems.
Worked with Roy Smith and Charles Pack on understanding the robot on press #22 better. I strongly emnphasized the need to improve their habits of saving mold set-ups in the robot memory. I showed them how they could change or save set-ups in regards to different conveyors (tall or short).
Worked on the trolley/platform for the new hydraulic power pack unit.
Cleaned up in the shop.
Note about shutdown.
Bill Potter informed the team leader and the process techs that there was no need to set dryer timers since he was coming in early on Monday morning for start up since 3rd shift was not going to start on Sunday.
I did not get any other information since that so I did NOT set the dryer timers at Rogers' request.
I will call and confirm with him sometime on Sunday.
Friday, February 3, 2012
2.2.12 D-shift Sean
MP#16- Needs a pressure hose on the pump replaced soon. It is bubbled up at the crimp.
I think it is a 16- female compression on both ends approx 48 inches in length, but want to double check. I let Gary know when I came in today.
Mp#9- Replaced the sled seals.
MP#12- fixed the door bar and put together a paddle for the mixer.
Have a good day.
I think it is a 16- female compression on both ends approx 48 inches in length, but want to double check. I let Gary know when I came in today.
Mp#9- Replaced the sled seals.
MP#12- fixed the door bar and put together a paddle for the mixer.
Have a good day.
Thursday, February 2, 2012
2.1.12 D-shift Sean
Mold#80251-Built another EOAT, they were using the one I had already built for it on another tool.
I did not see anymore of the short stroke cylinders we use for grabbing runners or the jaws for them in the blue drawers. I will look in MRO for some items to restock with.
Mp#4- We need to order a new hose for the core valve pressure line. It is leaking at the crimp. We don't stock those size fittings for it, or the hose, so may have to get one made.
Mp#11Robot- Need to get Elaine to order another belt for the Z-axis. It is a stock item and I used the last one several weeks ago. I signed it out from MRO and indicated that we were out, so it may be order already. The belt on #11 is chewed up pretty bad.
Mp#13- Needs a new lube oiler, or just the reservoir container housing if available. It was damaged a long time ago when we first got it in and I tried to build a support to hold it up. In any case, the oil keeps leaking out or they are bumping into it somehow. Needs replaced or repaired, I can engineer something more permanent if we are strapped for funds?
PM'd on #11 and fixed the air leak on the fan tester behind 12.
Have a great day.
Sean
I did not see anymore of the short stroke cylinders we use for grabbing runners or the jaws for them in the blue drawers. I will look in MRO for some items to restock with.
Mp#4- We need to order a new hose for the core valve pressure line. It is leaking at the crimp. We don't stock those size fittings for it, or the hose, so may have to get one made.
Mp#11Robot- Need to get Elaine to order another belt for the Z-axis. It is a stock item and I used the last one several weeks ago. I signed it out from MRO and indicated that we were out, so it may be order already. The belt on #11 is chewed up pretty bad.
Mp#13- Needs a new lube oiler, or just the reservoir container housing if available. It was damaged a long time ago when we first got it in and I tried to build a support to hold it up. In any case, the oil keeps leaking out or they are bumping into it somehow. Needs replaced or repaired, I can engineer something more permanent if we are strapped for funds?
PM'd on #11 and fixed the air leak on the fan tester behind 12.
Have a great day.
Sean
Monday, January 30, 2012
1.27/28/29.12 Weekend D-shift Sean
Tried to work on PM's as much as possible, we were short the tech they let go and didn't really have anyone come in until Sunday night. So, I helped them with processing some.
Mp#22-built an eoat for mold#80135 haven't logged it on the sheet yet, but it is stamped with the number.
Mp#6- Had some trouble with the EOAT gate cutting on the base plates. It is sporadically missing the cut on the op.side part. When I say sporadic, I mean every 10th-30th shot it may miss the cut. At this point, I suspect the ejector timer may be messing up because I have caught it once and it looked like the ejectors went back too fast, or the compact cylinders delayed too much before moving the nippers.
Mp#17- The door was causing a "5200: Confirm stopper plate position" alarm and would cause servo control to loose power. I removed the back door and bent the flag slightly so that it would pass a little closer to the prox. It seemed to help. I noticed that press #1 has a magnetic catch on the door to keep bounce to a minimum. I think we should get one for 17 also.
Give me a call if you have any questions.
Have a great day.
Sean
Mp#22-built an eoat for mold#80135 haven't logged it on the sheet yet, but it is stamped with the number.
Mp#6- Had some trouble with the EOAT gate cutting on the base plates. It is sporadically missing the cut on the op.side part. When I say sporadic, I mean every 10th-30th shot it may miss the cut. At this point, I suspect the ejector timer may be messing up because I have caught it once and it looked like the ejectors went back too fast, or the compact cylinders delayed too much before moving the nippers.
Mp#17- The door was causing a "5200: Confirm stopper plate position" alarm and would cause servo control to loose power. I removed the back door and bent the flag slightly so that it would pass a little closer to the prox. It seemed to help. I noticed that press #1 has a magnetic catch on the door to keep bounce to a minimum. I think we should get one for 17 also.
Give me a call if you have any questions.
Have a great day.
Sean
Wednesday, January 25, 2012
1.24.12 D-shift Sean
MP#6- Still trying to get the kinks worked out of it. Ronnie and I worked with the pressure and flow valves on the pump as well as adjusting the trim pots on the controller. We couldn't ever get it to a point where operation would be acceptable.
After he left, I changed out the pressure/flow valve on the pump and again went thru adjusting the trim pots. In the process, I was able to get most operations functioning within reason except for the clamp speed CV3. I think the trim pot may actually be bad. When Ronnit and I tried to adjust it on the first valve, there was no response on the mA meter. The same is true with this new valve as well. I pulled another controller from MRO that was aved for parts and will look at the measured value ranges to see what they are averaging so that we may compare it with the one that is in it now, (check the variable resistor).
Note: When I installed this valve, I made no changes at all to it, so it should still be where it was set from the factory.
Ronnie said he would come in today to call Nissei and get some suggestions from their technical support group. Give me a call if there are any questions, I may come in later to see what he found out.
Have a nice day.
Sean
After he left, I changed out the pressure/flow valve on the pump and again went thru adjusting the trim pots. In the process, I was able to get most operations functioning within reason except for the clamp speed CV3. I think the trim pot may actually be bad. When Ronnit and I tried to adjust it on the first valve, there was no response on the mA meter. The same is true with this new valve as well. I pulled another controller from MRO that was aved for parts and will look at the measured value ranges to see what they are averaging so that we may compare it with the one that is in it now, (check the variable resistor).
Note: When I installed this valve, I made no changes at all to it, so it should still be where it was set from the factory.
Ronnie said he would come in today to call Nissei and get some suggestions from their technical support group. Give me a call if there are any questions, I may come in later to see what he found out.
Have a nice day.
Sean
Tuesday, January 24, 2012
1.23.12 D-shift Sean
Mp#24- Pm'd press. Found some leaks on the core lines and fixed them, also found the pump seal was leaking. It shouldn't be difficult to get to if they are not running it. I will get with Ronnie to see if we have a seal kit.
Mp#21- Emptied the oil vacuum barrel and cleaned up under the clamp again.
Mp#22- Worked with Roy Smith some more making some position adjustments to the robot and helping him get the labels to run good. We made some changes to the posture position on arm #2. After homing, it was not plumb at label insert position, and it was not level at label pick up. We also slowed down the injection velocity because it seemed like the labels were shifting some after insertion.
Tried to mop up around some of the presses where oil has seeped out, etc. Will continue more tomorrow.
Have a great day.
Sean
Mp#21- Emptied the oil vacuum barrel and cleaned up under the clamp again.
Mp#22- Worked with Roy Smith some more making some position adjustments to the robot and helping him get the labels to run good. We made some changes to the posture position on arm #2. After homing, it was not plumb at label insert position, and it was not level at label pick up. We also slowed down the injection velocity because it seemed like the labels were shifting some after insertion.
Tried to mop up around some of the presses where oil has seeped out, etc. Will continue more tomorrow.
Have a great day.
Sean
Thursday, January 19, 2012
1.18.12 D-shift Sean
Dr#9- had some fuse blown and bad contactor. Removed the dryer from the mezzanine and put a 200lb dryer in its place. Dryer is in the shop now, work has been done, it just needs to be checked out. I will finish it tonight.
MP#4- 8:00pm -Nozzle heaterband was left with a bleed off on the nozzle tip. I replaced the heater band and thermocouple at Roy Smiths' request. Then at 11:45 Roger asked me to check out the mold heaters which were showing OPi on all of them. I found that the plug at the top of the mold had been smashed down and was not making contact. Replaced it and labelled all the wires inside, then checked operation. At 5:00 they informed me it had filled up the sprue with plastic and had run no parts on it yet. It was the number one priority on the schedule. I did not receive any work orders from any of them. I will write some tonight.
Mp#7- chased out some holes in the bag dock tool, installed new screws with loctite per rogers request. Assisted Roy Smith in getting the Robot going at his request.
See ya tonight. Have a very safe and productive day.
Sean
Sunday, January 15, 2012
1.13/14.12 D-shift Sean
Mp#20- Changed nozzle band, aligned sled after removing the shims that were messed up.
the clamp position switches got raked when the mold setter left some clamps near them and closed the mold up. I replaced 2 and fixed the others. Also cleaned and pm's the press.
Mp#24- wired up 2 heater bands on the nozzle at Roy's request.
Mp#1-Conveyor started messing up, it appears to be the gearbox or roller, I'll check it out more tomorrow. I swappped out conveyors for now.
Mp#9- robot relay contacts for conveyor was burned up. Replaced 24vdc relay.
Word on the floor was that one of the operators was throwing scales around.?? They asked me to find another scale for them, Roger and I located one in MRO. The broken one is back in the shop again.
Mp#3- blew a 2" flange hose. Ronnie got it replaced Saturday.
It is really cold this weekend!
Sean
the clamp position switches got raked when the mold setter left some clamps near them and closed the mold up. I replaced 2 and fixed the others. Also cleaned and pm's the press.
Mp#24- wired up 2 heater bands on the nozzle at Roy's request.
Mp#1-Conveyor started messing up, it appears to be the gearbox or roller, I'll check it out more tomorrow. I swappped out conveyors for now.
Mp#9- robot relay contacts for conveyor was burned up. Replaced 24vdc relay.
Word on the floor was that one of the operators was throwing scales around.?? They asked me to find another scale for them, Roger and I located one in MRO. The broken one is back in the shop again.
Mp#3- blew a 2" flange hose. Ronnie got it replaced Saturday.
It is really cold this weekend!
Sean
Saturday, December 31, 2011
12.30.11- D-shift Sean
Mp#15- Motor coupling had a catastrphic failure and will need replaced. I removed the coupling and inspected the motor shaft and the pump shaft. Both are in good shape, pump is not locked up and moves freely. It simply appears that the coupling has worn out over time. It is laying in the shop on next to the vise. We need to order one when you read this Josh, Mark or Ronnie. They are running part number 09-79048-03 (Fascia w/ pad print) and the mold is closed up. I advised Roger that the clamp could be opened with a portapower if he needed to pull out the tool to run else where, but he said it was not necessary. I looked it MRO and did not locate another Coupling.
Have a happy new year. Keep it between the lines!
Sean
Have a happy new year. Keep it between the lines!
Sean
Wednesday, December 28, 2011
12.27.11 D-shift Sean
Dryer DR-10 on the mezzanine had low regen temp alarm. Found bad heaters and replaced them.
Mp#-24 had a leaking hydraulic hose on the core line fitting. Tightened it up, stopped the leak.
The Fan housing press with fan seal verification is ready to be cheked out and make the final adjustments to it. It should be ready to use on Friday.
Give me a call if there are any questions, Thanks.
Sean
Mp#-24 had a leaking hydraulic hose on the core line fitting. Tightened it up, stopped the leak.
The Fan housing press with fan seal verification is ready to be cheked out and make the final adjustments to it. It should be ready to use on Friday.
Give me a call if there are any questions, Thanks.
Sean
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