Jan 7, 2010

 

Thursday, Jan 7, 2010

 

Started the day with problems at MP10, the connector nut insertion station.  The left side was jamming every 10 parts or so, with somehow feeding (2) black nuts and trying to press them.  It ends up that it was an inertia problem with the black nut slide, it traveled so fast outward and was bumping the track so that the first nut moved forward and allowed a second nut to feed down in place to be pressed.  We disassembled the left side, installed a directional flow control on the black nut slide cylinder and adjusted it about half way and reassembled.  The problem went away. 

 

There was an eight bank D-M-E heater controller and some cards that were burned up, probably from inserting or removing cards with the power on.  Ronnie and I gathered enough new components from MRO to put a new system together.  The problem was that who ever ordered the new D-M-E controllers a few years ago, ordered them wired 240V three phase.  So we had to rewire the controller for single phase 240VAC.  After checking everything out plugged in to a mold, I attached a label indicating not to move cards with power on. 

 

Helped set up robot on press 25 for brush roll end caps.

 

Snowing today, I heard the plant was closing at 4pm because of weather.

 

 

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

 

1/7/10

1/7/10  FYI

 

Stiffener and nut press station at MP10 would not seat the stiffeners consistently in the plastic connector.  Ronnie and myself checked the machine, it was OK.  Ronnie increased the supply air pressure to max line pressure.  Still problems.  We checked the parts and it looked like the opening in the parts for the stiffener was smaller than the print allowed.  On further examination of the inside of the pocket where the metal stiffener seats, we found additional plastic down in the hole about three-quarters of the way down that provided interference.  We checked the chiller temp, set at 53 degrees.

Checked the water and water flow.  Cores for the stiffener pocket were blazing hot.  We got the process tech to slow the machine down from 54 seconds to 59 and immediately the parts looked much better and we were pressing with no problems.  I believe the correct cycle time on paper is 60 seconds.

 

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

 

1.07.10 night shift

Mp#7-had to replace fuses in the 120/240 transformer. The DME box arced when they were changing out cards.
Marty asked me to put an EOAT together for the wheel cover they were running, its running good.

MP#11- replaced 2 hydraulic hoses to the ejectors, they were worn and looked like they were leaking in several places. Checked operation, good to go.

Worked on PM's on machines and robots most of the night with other odds and ends such as making mold lock straps etc.

If there actually is bad snow, I may not be able to come in, I will try anyway if the roads are clear though.

Sean

1.03.10 night shift

Cleaned up in preparation for the "QVC film crew" which is supposedly coming in this week.

I tried to get as much tagged equipment repaired as possible. The only thing left was that dryer DR20 which for some reason iss not providing a control output for the regen beds to kick in? We may have some spare parts somewhere or I can try to swap out parts with another dryer when possible.

Had a few minor issues this weekend, I turned in workorders for most of them. Have a good day call if there are any questions.

Sean

" C " Shift

   MP-11   I shut the press down & cleaned up oil on the clamp end. Found two leaks on eject. Manifold ,  tightened , & restarted press.

 

  MP-16   Mold not closing – error 122 – not making eject. back switch .   The eject. back jumper had a broken wire.

 

  MP-17   Hose on eject. manifold sprung a leak. Made up a hose & replaced. I made a hose for the other side too, but I couldn”t  find

              any ½”  boss fittings.

 

  MP 6,7,8,10,11,& 12    Vacuumed oil pans Then emptied oil vac.  I started on # 1 ;  The vac .  will probably need to be emptied again.

" C " Shift

   MP-7     Loader not pulling material --- Hopper feed at mezzanine not opened all the way.

 

   Vibratory welder -  Had filter clog alarm ;   Installed new filter .  cleaned up all the parts & oil under welder & on top of tank.

                            I let the oil heat up & cycled it several times ;  found one leak at press. gauge fitting & another at tank lid mounting bolt.

                             After it runs awhile , I’ll check it again.

 

  MP- 25    I emptied the oil jug @ injection end of press;  this was the second time in two weeks it has over flowed . It looks like it is coming from

                 the  injection cylinder . Will need to order parts & schedule down time for repair.

 

 

         R.Upchurch

         Molding Maint.

#5 Had a fault FHD1 analog input 5 exceeds limits.Took pressure transducer off #3 injection unit and put it on #5 clamp. parts will be monday for #3.
Replaced belts on grinder #19.Put a new gripper on #22

12.29.09 night shift

Changed several heater bands on #3 at Bill Potters request. Also repaired some of the wires and re-did the paint on the barrel shroud. Checked it and it came up to temp fine.
While it was down went over some of the leaks and cleaned it up in general.

#16- had a problem with ejector back limit switch...it needed adjusting, it was making the clamp sound really awful when it closed up, and also would not lockover and build tonnage.

#4- made a new core cylinder hydraulic hose.

#5- replaced a core line quick connect and tightened all the lines up. It looked like the two fittings on that block really needed those o-ring/washer sealed types of fittings but I didn't find any to replace them with.

#11- has several leaks but is #1 priority on the schedule, so I attached work orders to the machine...1 for the tool and one to let the techs know to notify us when it is down so we can fix those lines above the clamp cylinder (ejector line fittings).

Call me if there are any questions!

Sean

12.28.09 night shift

MP#5- Mark and I put the pump in and I started it up. I ran around 40 shots of baseplates through it and shut it down. It is working fine. I then put the tool arm back on the robot and referenced it. Had to locate the loose plug connection in the controller first though because it would not power on at the pendant. It should be ready to start up this morning if they want to run it.

#11- has stopped a few times (4 or 5) throughout the night from 3217 alarm...which I think is the core switch signal...but when checking it out further, the signal IS made... so?? It starts right back so we have been keeping it going.

#2- The sled cylinder coupling was ran out too far and loose...I adjusted it and tightened. It was causing the frame to twist very badly when the sled was ran back all the way.

#25- Initially Mitch had made me aware that Zone #2 was over heating by 30 or 40 degrees. We found later that the feedthroat was partially blocked from old Nylon and liquid color residue. It kept slipping while building up a shot and taking much longer. While it was not running the barrel temps maintained and stabilized. After we cleaned it out it was fine. I also helped them process out the splay problem...they were short handed.

I came in early at 3pm so I am leaving at 4 am. Mark said he must leave early today so I may also come in early today.

I put the straps for Bill Potter in a box with his name on it in the Molding Office so he would find them.

Call if there are any questions.

Sean

12.23.09 Nights ...Sean

Mostly cleaned up in the shop and helped the process tech do a mold change etc.

Worked on the dryer in the shop, found a loose wire connection on a relay block terminal.

There is an oil line leaking on #11 (ejectors) but it was running and they did not want to stop production.

I talked to Mark last night and he is going to call me when the pump for #5 comes in on Monday so I can come in early and we can both work on it.

I wish all of our team a very Happy Holiday!

Sean

12/23/09

Worked on Star Robot on MP24.  Display was dead on power up.  Disconnected all I/O connectors on the main power board with the power off, powered up controller, and the pendant came back to life with errors.  Started plugging in connectors one at a time with the power on and CNA made the pendant lose power.  Looking at the prints, connector CNA has limit switches that are around the EOAT, on inspection of this area I found that a cable labeled LS4 that had bare wires that had got together.  I insulated the wires from each other and everything powered up no problem.  I was able to move the robot around and send it home.  So evidently a short with the 24VDC will not allow the system to power up.

 

Changed over the Z axis encoder on MP5 to a BEI encoder.  On power up the robot could not find itself, so I swapped the A+ and A- with the B+ and B- channels.  On power up this time, the robot referenced fine and homed itself.  There is a box on my desk with (1) new BEI encoder, connectors, pins and sockets, and a print.  Since we are out of the old encoder again, we should start changing over to the new encoder on a failure.  We only have (1) new encoder right now but more are on the way.

 

I replaced, dated the PCB backup battery in MP25.  It has an NC9000G controller and only has (1) back up battery.  They are supposed to be good for 5yrs.

 

I replaced, dated the PCB backup batteries in MP22.  It has (2) batteries like MP24, (1) on the back panel and (1) under a cover on the back side of the main cabinet door.

 

Called Milacron to track the pump for MP5.  They said it didn’t go out till today and wouldn’t be here until Monday, the 28^th.  I feel goobed.

 

I believe I heard that new GO switches are here and are in MRO, I think several have been robbed.

 

That is all I have for today, have a very Merry Christmas and we will see you next week.

 

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

 

I took the inverter out of #22 robot the other night because it kept tripping the breaker. It had a bad 3-phase full bridge rectifier and I found one online for $34. Mark ordered it and I put it in and tested it out and everything seems fine. They haven't ran the press so I'm not sure what program is in it.

The insert press on MP10 quit working. I found a loose bolt that the sensor has to see in order to start.

The z-axis encoder went out on MP4 robot and I think we are out of them. I switched it with the MP5 since it's waiting on a pump.

The robot on MP24 will not power up the pendant. I tried the pendant from 25 but no luck. The control board does have power but the board's lights will not come on. I planned to switch boards with another similar robot but none were down.

Collin

12.20.09 weekend Sean

MP#17-refilled with Hydraulic oil. It had ran a little low and would not lockover.

Sped up the flow controls (at Marty's request) to the ultrasonic welder on Press#4- because the operator could not keep up with the machine due to having to wipe color from the parts. I adjusted down speed of press head and operator door speed.

Remade an broken bracket for the connector press on #10.

Also helped the technicians set-ups some of the star robots to pack parts on belt better, and hook up regrind onto the matsui dryers,etc.

Cleaned up in the shop, especially around the welding area.

As far as #22, and #24 robots...I don't know what is going on with them, no info?

Call me if needed, I will be glad to come in and help with anything. See ya Wednesday evening at 6p.m.

Sean

" C " Shift

 

    MP-6   Added oil to tank.

 

    MP-4   Had to adjust core 1  pull switches.  The core 2 cylinders were leaking; tightened them, but couldn’t get the top one to stop leaking, so I

               just put one of the sensors in to plug it.

 

    I emptied the waste oil vac.

 

   MP-8   I made & installed leg pins for the robot cage.

 

   Dryer -  D 24 -  They were having trouble with this one last week.  Breland was using it to dry polycarb @ 250 degrees.  This dryer is one of the older CS101’s

                         & it struggles to run at that temp. It works great up to 200 degrees so I  put a label on it ---  set point  not to exceed  200 degrees .   If  they

                         don’t  like it , they can purchase an after cooler for it.

 

 

 

 

         R. UPCHURCH

         Molding Maint. “ C “ Shift

" C " Shift

  MP5    Installed  new 21/15 gal. pump ;  still not working. The variable volume pump is bad – no pressure @ test port & no sled movement.

            They are going to hang the other base plate mold in MP6, so we’re OK on parts.

 

MP21    The DME on the nozzle was left on , ( no mold in press )  & material blew out on moving platen. Not sure when this happened- wasn”t  today.

            I turned DME off & cleaned the platen.

 

I checked , cleaned & lubed tie bars – MP13 thru 25

More from " C " Shift - ( Friday )

       MP -13      Just before shift change , 5:30 pm,  they found a blow-back ¾  of the barrel was covered on the top side ( DELRIN )

                      I cleaned it off ,replaced 3 nozzle bands, & rewired 2 barrel bands. Luckily the connectors for the barrel heaters were on the bottom & weren’t

                      covered  up  with plastic.

                      The nozzle was loose, I turned it by hand.

" C " Shift

 MP-8      They crashed the robot on top of the cage last night; Mark repaired the eoat. The touch screen lost it’s program again, this time for good.

 

              Had one more Quick Panel in MRO,  we installed it & down-loaded program.

 

 We sent out the spare top cover drill for repair.

 

MP-5     Lost the low volume pump;  ordered a new one from Servtek. ( Saturday Delivery ) 

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