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

" C " Shift

  I used up the rest of the hydraulic fluid ; there was enough to finish filling the tanks.

 

 I got all the tie bars lubricated & the Nissei overflow jugs emptied.

 

 I started pumping the oil out off MP-1; I’m trying not to pull from the bottom of the tank because it’s so dirty. We can use the oil vac on the bottom. Both the

   front & rear tanks have to be pumped out.  I filled up one of the 250 gal. plastic tanks; I brought the other empty one to the press.

 

 

 

      R.Upchurch

      Molding Maint.

Friday

I straightened out the robot interface on MP13 today.  It is running but there is still one little thing not right on it.  The Auto signal does not appear on the robot screen (MA), but the robot will go into auto anyway.  Problem is that it will also go into auto when the mold machine is in manual or semi-auto too.

I plan on working tomorrow and will fix it then if Collin doesn’t tonight.

 

  Joshua Ledbetter

  Manufacturing Engineer

  Oreck Manufacturing Company

  931-239-3235

 

2.4.10 night shift Sean

I was looking at the star website for info on the new robot and stumbled on a spin off idea for the robot riser we are about to construct for running the steemer mainframe tool. It is riser that swings back out of the way: here is the link> http://www.starautomation.com/images/Pivot%20Base%20~%20L1%20~%206-14-04.pdf
It looks like all we would need to do is use a larger bottom plate with some gussets for support? Just an idea?

I was going down Ronnies List of Machines low on oil.
Refilled Presses 6,11,12,and 14 with hydraulic oil, there is maybe enough to top off the others if they are not too low and the spare oil vat will be out. #11 was the lowest. There is still #18,#19,#20, and #24 to do.

#13- tied in power to robot receptacle and powered it up. The mold safety gate alarm is present on the picker and the machine is saying E-stop circuit activated. They wanted to go ahead and run without it for now so I will check it out further when it is down next.

There was an Assembly issue with the fan housing pressure tester . Had a bad fiber optic receiver on the "part sense" input 6. There were no more in MRO so I informed Rich about it this morning. He (Gary) was asked to but did not provide a work order.

FYI- I have seen an influx of small tool room work since Chris left and they did not replace him. Mostly repairs such as making ejector bar spacers and broken stud extractions. I have also noticed many locator rings for the sprues are getting smashed up lately. We have pressed a few out and turned out the I.D.'s so the molds would fit center. We may need to order some extra locator rings so they can be replaced if needed.?

2.3.10 night shift

Robot Support Column: I cut it and welded it. I still need to check that the riser that comes in will match up to the drawings that I had to go by.

Installed both color pump signal receptacles in #13 and #19...checked them both with color pumps, good to go.

#19- The techs on my shift were saying that it was down because Collin needed to work on the heaters? I looked at them and noticed that the actual temps were off about 20 degrees from setpoint. I compared the PID settings with those of #22 (same control and on tempersture) and changed them to match 22. Came back an hour later and changed the Middle zone's Integral setting to 150 because it was over about 20. Mark and I checked it at 6am and it was right on so they should be fine now.

#3- had a "Fatal Error" "Communication Error 39 Variable Readkey".
Powered it down and re-referenced robot...seemed to be O.K. afterward.
We'll keep an eye on it.

Sean

#19 cores

I looked at the core problem on MP19. It seems the core pull output (166) isn't supplying enough current to even energize the core valve relay. When the load is removed, the output works. But if either the wire going to the relay coil or wire 929, which should power the core, is hooked up to the output, then the voltage drops out. The amperage reading to the 24VDC relay coil is 1.6mA. The set side, which is working, is conducting around 44mA. Both are powered from the same 60mA source. I think the NPN transistor may be bad on the output board. They were going to start the machine back up so I didn't have time to find the actual transistor itself. If we had access to reprogram the controller, we could use output 165 which is free.

Collin

Nozzle Band Wire Nuts

Hey Guys,

In the future, when changing nozzle heater bands, do not use the non-insulated high temp crimp connectors.  Use insulated wire nuts- just make sure you tape them well enough so the plastic will not melt. 

We are getting into situations where the non-insulated high temp crimp connectors are being used, but not taped up very well, and they are shorting out.

I do not want anyone to get hurt over something stupid.

 

Thanks

 

  Joshua Ledbetter

  Manufacturing Engineer

  Oreck Manufacturing Company

  931-239-3235

 

Weekend _night shift D _1.31.10

Mp#13- I got it leveled up, still needs the power tied into the robot and checked out for correct operation.
There are two primary side transformer fuses inside the cabinet that need to be pulled out!
I wasn't sure if we were going to add another 480 there also or not?

MP#19- Cores are still not working, looked at it and found tank/pressure lines were backward. I corrected that, still did not work. After looking at prints, it was apparent that we had the wrong style of solenoid valve. We were using a regular 24vdc, looked like what we needed was the 4 wire type the other newer nissei's have on them (with the circuit built in). I attempted to use small relays to isolate the signal from the load of the coils. One side is working but the other side(929) is not putting out a signal. Not sure if it is a program thing or exceeding the 60ma load may have caused a fault, etc.? Ronnie said that when he checked it out, one side works, then if you swap wires to coil, the other side works so it definitely looks like a signal problem at this point.

I tried to clean and organize the shop tonight and put away a bunch of items back into MRO, etc. The filter cart hasn't been checked out but Mark and I discussed getting it going...there was an issue with the motor coming in wired incorrectly and it looked like it had been very hot before. I printed off a ser vice manual and got some info on it.

Call if there are any questions.

Sean

" C " Shift

   MP-11    Core set not reading;   The wires had pulled out of the plug. Repaired.

 

  MP- 5   Getting “ prefill time out alarm “.      Changed offset.

 

   Got filter unit off trailer , cleaned, &  mounted on cart. Need to check on filters.

 

I  made some measurements on the main frame mold & MP – 2 . I measured  from the center of the sprue bushing  to the top of the mold.  While the mold was out of MP-2 , I was able to measure from the center of the platen . I marked the uprights . The marks are  one inch above the highest point on the

       mold .  We will need at least 10 inches between the uprights for clearance.

 

 

 

     R.Upchurch

     Molding Maint.

This Weekend

Hey Guys,

They are running 6 presses today and plan on running tonight.  Do not put yourself in danger to come in here.  If you can make it, plan on working.

For anyone working this weekend, here are some projects that need to be addressed-

 

1)     MP13 still needs to be leveled.  I still need to order two more feet to put under it, put it can be leveled with the four that it has.  The level is on MP19 with a magnetic V-Block to help stabilize it when placing on top of a tie bar.

2)     MP19 needs to be leveled also.  There are some minor things that still need to be done to 19 as well, including hanging material pipes, etc.

3)     MP19 cores do not work.  Pull works, but Set does not.  We’re still not sure if the pressure and tank lines are plumbed correctly.  Also, the solenoid could be wired wrong.  Input switches are wired correctly.

4)     MP01 pump still needs to be addressed.  New pump is $8K and 45 day lead time.  I want someone to take measurements of Mainframe mold to see what would have to be done to robot riser on MP02-MP05 to accommodate hanging this mold (Spreading the riser legs out).  That way we can run the mainframe somewhere else until we figure out what we are going to do with MP01.

5)     Someone can get the hydrostatic oil filer out of the storage trailer and put casters on it and see what it will take to get it functional.  We need to get that trailer cleaned out sometime to store extra stuff.

6)     Someone can also bring in those little conveyors and see what we can use them for.

 

Thanks

 

  Joshua Ledbetter

  Manufacturing Engineer

  Oreck Manufacturing Company

  931-239-3235

 

1/27/10

MP1 pump number two was making a loud noise. I took the coupling loose and the motor and coupling seem fine. It sounds like the pump bearing is out.

Robot number 10 alarmed only one time tonight with in the mold. It gave a "Mold not open. Robot in unsafe position." alarm

MP23 over stroked the ejector limit switch and had to be dialed back into zero.

Robot on #3 hit the conveyor belt and tripped the 220V breaker inside the press.

Worked on new MP19 tonight

" C " Shift

   MP – 16    Installed a plug for the eject. back safety switch.

 

  MP – 19   Pulling everything off the press that we may need later; scrapping the rest.

 

  MP – 25   Nozzle was blowing back,  Checked level of sled.  Breland said it’s been doing it on the last three molds. They’re suppose to be

                 trying a new tip on it & letting us know how it’s doing.

 

 

 

   R. Upchurch

   Molding Maint.

1.20.10 night shift

#23- finished putting screw back together. Set a mold in and made sure nozzle was aligned correctly. The machine had not used cores before so I put quick connects on. Also wired the core switches up on the mold and put QD fittings on it as well. When I tried it out, cores would not work. I remembered Collin saying that he had found a problem on the circuit board inside the valve on 22, so I swapped out boards to eliminate that. Still did not work. I swapped out hydraulic hoses. Still not working.

I was at the point of replacing the quick connect fittings I put on the machine but there are none left in MRO. You can manually probe the valves while someone energizes switch and the cores will move, they just do not seem like they are getting an output signal. I tried to bypass the switches and run it on timers but it still will not work.

I went through it all with Mark and Ronnie, we got to a point where we had isolated a problem with the valve.

Sean

1.18.10 nights shift D

Mp#15-had a bleedoff back about 3 bands. We cleaned it off and patched it up without replacing anything but the nozzle clamp. O.K. to run.



Mp#7- put a material loading sensor on the hopper sight glass at the request of Process Techs. Had to get one from the Turck vending machine. Used the number 00344.



Mp#23- put another 120vac receptacle at the rear of the machine per Mitch's work order request.



Robot on press # 2 - Did a pm on it. Mounted some brackets to hold the HMI touch panel securely to pendant. I still need to do one on #11 when it is down.

Robot on press#25- Also did pm. Cleaned, greased, inspected, tightened screws etc.



The single cavity topcover mold is leaking on press#11. It was pulled out with a workorder last time it ran, instead of moving it to a repair location, someone just put it back in the racks. Bill mentioned to me that it was back there with the work order, but by then it was already scheduled to go back in on our shift and run again. I asked Marty if he wanted to shut it down to fix the leak, he said no.



I did notice that many of the ISO work instructions on the Online Document website have not been revised since 2002, etc. Including the molding maintenance work order request instruction. We were looking for the procedure for mixing up the ink for the pad printer. It was not there or at the support site.

Need to order some cabinet fans like we use in the robot control panels and DME boxes. Need both 240 and 12oVAC. 3 are out in the robot panels, and I think one of the Cincinatti's has one out also. Then the DME's run on 240vac and we do not have any of those either.

Call if you need me to come in or have any questions.

Sean

" C " Shift

    Tightened up the pump drain plug on the vib. welder; It had a slow leak. I’ll check it again after they run it awhile.

 

 MP-21   Vacuumed oil under sled & on rear deck.

 

Installed eject. back switch on new mold # 74017.

 

Installed conveyor tray behind MP-25.  They can try it out---- see if they need to modify it.

 

Loader # 7 on mezzanine wasn’t pulling from Gaylord. I found  two other loaders leaking at the vacuum ports. I changed out the seals

 

 

 

          R.Upchurch

          “ C “ Shift  Maint..

1.17.10 night shift D

MP#10 - robot was stopping above conveyor after part delivery. Ronnie and I looked at it briefly,didn't see anything obvious. We adjusted tracking on Z-belt. I did a PM on it after they shut it down an hour later and dry cycled it for about 20 minutes, it did not stop anymore. Will keep an eye on it.

MP#2- Robot had no apparent alarms but would not give permission to close to machine, turned out that someone had left the robot in "DRY CYCLE" mode.

MP#7- looked at the baseplate tool, had open thermocouples, we checked boxes, cables, etc, turned out to be open TC's in the mold. They are running it in Manual.

I vacuumed out all the robot control cabinets and found 3 cooling fans bad.
I could not locate any in MRO so we need to order those. Also need a few other items to complete some workorders so I will leave Mark a list Monday morning.

I mounted a tray on the crane column behind the Welder on #12 to store nest screws so they will be 5-S compliant.

Worked on PM's and misc. oddball requests from the Moldsetter, process techs and team leader throughout the night. Call if there are any questions.

Sean.

" C" Shift

   MP-4  Robot not holding position & conveyor not working.  They had the “ Z” at home position set the same as “ Z “ at part drop. I changed

             The part drop setting & it homed .  The conveyor  relay  had no  incoming power---- someone had it unplugged..

 

   Hopper # 13 @ mezzanine wasn’t unloading material to MP – 5 .  The supply air to the valve wasn’t plugged in all the way  & the material line got

                  stopped up. I fixed the air line & opened the material line to clean it out.

 

  MP-16  New mold had two eject. back switches – I wired them in series & put a plug on it .

 

  MP-10  Robot stopping occasionally. Haven’t found the problem yet.

 

  MP-24  Mark worked on the cores on a new mold; both core set & pull lights were on at the same time. He found the  polarity  wrong at the plug wiring.

 

 

 

              R. Upchurch

              “ C” Shift Maint.