Monday

Me and Mark worked on Wittman most of the day today.  Found a few problems, but we think that now there is a problem with the X-axis encoder.  We’re going to order a new one in the morning.

Thanks

 

 

  Joshua Ledbetter

  Manufacturing Engineer

  Oreck Manufacturing Company

  931-239-3235

 

11.22.09 Nights

Worked with #6 robot checking it out etc.
I have it homing and have all the positions entered for the baseplate.

Ran into a snag when I tried it out in automatic with the ejectors not ejecting after opening.

I spoke with Mark and let him know where I was at with that. There may be some interface differences between the Star robots and the AEC's?

FYI-We also had an issue with #13's pump kicking out intermittently.
Found out that clamp position was off due to incorrect mold thickness data.
When the machine sees a problem with "abnormal clamp closing", it activates the motor stop circuit. It was apparent by the fact that it was kicking out upon lockover.

Have a great week.

Sean

" C " Shift

    MP-8    The core pull limit switch plug on the bottom cylinder had a broke wire. Ran a new wire/plug.

 

   Checked all tiebars & lubed dry ones.

 

    Grinder on MP-8 sqeeking loud. It has no zerk fittings on the shaft. I srayed TFE dry lube on inside shaft ends & blade edges; It lasts for awhile.

 

   I vacuumed more oil pans; I did’nt get to MP14.

" C " Shift

   Made e.o.a.t. for  bag dock on mp – 24

 

 Vacuumed out oil pans on MP – 1, 6, & 21.

 

 Removed broken safety glass from molding breakroom door ; I will e-mail facilities maint. to order new glass.

 

 Still having trouble with mp-13  occasionally ; checking for loose connections etc.

   MP-4    Tech could’nt get cores to operate;  Top cover mold 77041 requires core 2  to be on timer.

 

  I followed up on purchase reqs & ordered barrel heater bands for MP 22 & 23, barrel htr. bands for MP 2 thru 5, T.C. connectors for MP 5, &

 

      Mold locating rins for MP 22 & 23.

 

I have been troubleshooting MP 13. The pump shuts down during cycle – ( no alarm code ).  I will send another e-mail w/ info when I  figure it out.

This Week

We should have all the vertical conveyors wired now.  (Interroll)

 

The butterfly bolts broke out of MP20 on Thursday, on inspection the bushing was wore out, the steel has many stress cracks in it.  A new butterfly plate is $3K.  So we replaced the bushing and broken bolts, faced off the knock out rods and put it back into production.  The plan is to replace the press on the next go round.  This is the second time in 2 weeks that I know about.

 

The new CPU and FHD boards came in for MP5, also the FHD protection kit.  I set the jumpers on the boards like the old ones and installed them and the protection kit. 

 

The table for the new hydraulic hose crimper and cut saw is complete and located behind the flammables cabinet in the shop. 

 

Gary made (3) communication tables w/ boards.  We ran out of feet for the legs, so when more come in we will install.  Extra com board lexan sheets are located on top of the flammable cabinet in the shop.

 

When I came in Friday, Darrell said MP23 was down.  Nozzle zone wasn’t heating.  A 12A fuse was blown and it was an odd fuse, couldn’t find one so I temporarily installed a fuse block w/ fuse we had in stock.  I will order some additional fuse blocks because I think the other new machines have these odd fuses.  I will put them in the project cabinet.

 

Someone requested a new hydraulic hose and it is laying on the molding maintenance table.

 

I took inventory of the Dummy plugs we are missing for the robots that are installed and we need (4) more made.  I will try to do that today and get them attached to the corresponding press.

 

Fastenal has been in this week trying to fill in the voids on our fasteners.  They will consolidate all of the metric bolts to one area with the smaller ones (m3 and m4) in drawers.  They are going to leave a dry erase board back in the bolt bin area so we can write down items we need as we identify them.

Fastenal will organize all our bins for us.

 

We mounted the remaining Eagle nests on the nutrunner stations and rolled them to the molding equipment storage area by the racking.  Still need to do the electrical controls, plc, program for the sole plate press.  (It has guards in place and can be run pneumatically for now.)

 

I ordered new bolts for the end cap on the barrel on MP5.

 

 

 

 

 

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

 

8.17.09 night shift

#8- Changed the x-axis drive gear on the motor. Took the only one we had from MRO so we will be needing another.

PM'd robot on #5 press. It had about 15 broken screws that secure the rails on the z-axis. Cleaned and inspected everything else on it. Looks good now, wasn't sure about the encoder that got put on it yesterday, did anyone check it?

#6 robot- ran the pendant over to oper. side and made a hanging bracket for it. Still did not get the input tied in for clamp closed, we will look for a window to do that.

#21- Ronnie and I discussed that we need to take care of those leaks sometime. It will likely take awhile, I haven't done a clamp seal yet so we need to get with Jerome and set up a time to do that?

Call if there are any questions. Hank was in late last night looking for something?

8.16.09 night shift

#8 robot-Changed out y axis motor and encoder from #5 and put on #8 due to problems with position. Ok and running, but we do not have any available encoders for #5 or any spares in MRO at all.

#25- put the spacer plate on that tooling provided. Torqued all screws to 170 lbs and applied rust preventative to both sides before mounting it on. It fit well. We made new ejector bars (4) to accomodate the increased length.

#20 robot- did a thorough PM and built a eaot, went through and checked it out making preliminary adjustments as needed. It is running.

#24 robot- Did a "once over" PM on it. Marty did not want to shut it down.

#6 robot- did not get to do anything to it today as it ran all shift.

#12 welder- made some changes to the welder set-up due to parts failing leak test and welding poorly. I saved two parts after changes, then at 5am, I was asked to put the settings back to where they had it on days and I did.
The only things that I changes were hold time, forces 1,2,and 3.
I changed things one at a time on a basis as to whether it made it better same or worse.
I could not understand why they had hold time at .04 secs? I had ran it at 3 secs. With less force (700) instead of (1000).
FYI-The parts that were in the first peice bag did not pass leak test either and the primary problem area was where the bag dock slips over the connector.
Call if you have any questions.

Sean

Sean, If they will give you the machine, finish the interface on 6 tonight. We finished robot install on 20 and 24. Robot on 20 needs a good PM before start up.

11.12.09 nights

Worked on Preventive maintenance all night aside from some issues with #1 concerning the mold installation.

The moldsetter did not know how to hook up the steemer tank tool because it wasn't written in the SOP to reconfigure the cores as ejectors (switches and hoses).?? Go figure??

Good to hear that we are getting the hyd. hose crimper.

The worst leaks out there seem to be 21 and 17.
We should try to schedule some downtime to do those seals on 21 whenever 2 of us can double up on it. That clamp seal could be tedious.

Hope everyone has a great weekend. Call if you have any questions.

11.12.09

Robot interface on MP6 is ready to tie in to the I/O when the machine is down.  The wires are labeled and hanging in the cabinet.  It includes a Permit Eject Forward relay, so Y4C wire runs from the output of the controller to one side of the relay contact and from the other side of the contact back to the terminal strip where the valve wire is.

 

Added a chute to the convey on MP11 to run parts thru to MP12.

 

The Wittmann still has a problem with the Y axis.

 

Industrial Rubber will be in tomorrow to survey all the hydraulic fittings we will need for our new crimper.  I gave Gary Gore’s name as the contact for tomorrow.

 

Don’t forget I am off 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    931.646.7851

 

Sean Checking in.

MP#20 is tied in except for the permit forward Josh and I discussed. Dummy plug is in and it is working fine. I added the other relay for the permit forward but have not wired it in. They wanted to run the press again.

Worked on PM's and repaired some water leaks also. Need to review the to-do list again.

Sean

I sat on pc most of today. Do not run Wittman b/c Mark changed out encoder today. We will verify tomorrow. Thanks. Josh

Weekend.

"The MRO Key" is gone from its place. It was there Saturday Night.

#20 is ready to tie in the robot interlocks.

Ran wire and mounted junction box for interface on #6.

Mark and I got squared away on interface cable wire color issues concerning #20 .

The dummy plugs are all on (except for 6).

#2's core wiring is up to new standards, need to order more junction boxes to continue with that.

Had to modify the EOAT on the fans because they made some changes to the tool which shortened the daylight. It is running but they need to get the waterlines straightened out so they can apply the runner picker now.

Hope everyone has a great week, call if you have any questions. I may try to come in one of my off days this week and work on interfacing 20 or 6. I do not want to be excluded from that so please do call. Thanks.

Sean

   Replaced lightbulbs in Wittman pendant ; waiting for e-stop & encoder.

 

  Took empty oil tank to bone yard – needs to be returned to supplier.

 

  Brought empty waste oil drums on spill pllet back inside.

 

  Mp-10 connector assembly welder quit working ; had to realign & tighten booster & horn assembly. 

Transformers for Stars

Installed the robot trans. in #20 and checked voltage at receptacle. O.k. all it needs at this point is tieing in the machine interlocks with relays. Which I will cover with Josh soon.

Installed the robot transformer in #24 but did not attach primary power because Marty did not want the press to go down at all (too hot) same with #6.

Installed dummy plugs on #22 robot and #20 robot. Still need to do #6.

I was not sure about the pendant for #22 robot, it was left apart and I am guessing we are waiting on the E-stop switch?

Be back on it again this evening.

11.6.09

RONNIE AND I PUT BARREL AND SCREW FOR MP5 ON SKIDS AND SENT TO SHIPPING FOR DELIVERY MONDAY, 11/9 5AM

 

TRANSFORMERS FOR ROBOT POWER ON MP24, MP20, AND MP6(IF IT NEED A TRANS) ARE ON MAINT TABLE IN SHOP.  FUSE BLOCKS AND FUSES ARE ALSO ON TABLE.

 

REPLACEMENT LAMPS ARE ON MAINT TABLE FOR WITTMANN ROBOT PENDANT.

 

NO SIGN OF SPARE PARTS FOR WITTMAN.

 

HAVE A GREAT WEEKEND!!!!!!!!!!!

 

 

 

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

 

11.4.2009

Pulled screw out of MP5 this morning.  Screw has chunks of metal missing.

 

Sent MP5’s CPU and FHD boards to R and R Electronics for evaluation.

 

Ordered replacement lamps for Wittmann robot pendant for tomorrow.  Josh says we should receive other spares for Wittmann tomorrow as well.

Looked at swapping Y encoder with X.  Y cable too short to swap with any other axis.

 

Ordered additional heater connectors, boxes, and cables for incoming molds.

 

The push to disconnect fittings for the Star Robot cylinders are here and can be installed.

 

I worked on installing a shelf under the new multi-fan housing tester to store addition weld nest for MP12.

 

 

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

 

C shift

  I worked on PM’s today MP-6,11, & 19.

 

 I took the full waste oil drums on the spill pallet to the oil storage shed – will email Walter M. so he can have it picked up.

 

 I started vacuuming out the pan on press #1. The tank is low.

End of arm tooling cart.

Found an example of a good idea put to use. Why not keep components centralized?