3.18.10 D shift

Mp#8- the robot had crashed when I came in and it had apparently only broke the center peice of the wrist assembly. We took the one from #6 off and replaced it. Had a little trouble getting it off and running smoothly, but it has been doing good.
Welded up the broken part and drilled and tapped it out, made some replacement bushing for it and put it back on #6 robot. Should be fine to run now.
Mp#23- Moldsetter was changing tool and said that after he opened it up it would not close back again. With ejectors back all the way it was reading 204.5 mm. It kept giving an Error 35- confirm ejector bwd position.
I checked that manually probing the valves (while actuating switches) would indeed work the clamp and the ejectors, so I knew it was not that. It behaved similar to the encoder problem on 25.
I tried swapping them out but it made no difference, so I put them back.
When I looked at the ejector bwck stop position there was an offset for the encoder sensor.
I added the difference that it was off by to the value that was already there and it started working. But we had to adjust the ranges some more to get it working like it should.
I cannot explain the problems root cause unless someone had changed the program by accident, but it is working now.
I also refilled #22 with oil because it was very low.

Sean

Week of March 15

Ronnie and I put pilot operated check valves for core on MP24

 

Ronnie, Sean, and I added core 2 and the new switch setup to MP22.  Gary, the manifold mount worked great.  Rewired the Eagle Top Cover mold with new switch system.

 

Investigated adding core 2 on MP23, talking to Nissei, needs another look.

 

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

 

3.14.10 Nights weekend D shift

Mp#23- Looked at Valve Block changeover situation.

Found all the fittings need to connect to hose out of the new valve block .

We will need a fitting to tie into Pressure port on Machine and Drain/Tank.

We may have something that will work, need to remove hard lines to verify.

Same goes for the lines going to Core A/B block where QD fittings attach.

I looked at how the existing valve block attaches and tried to determine the best possible retrofit.

I took measurements and completed a print for a bracket that will allow us to make a bolt on replacement.

There are notes on my desk and I discussed it with Mark also.

Yushin Picker , pulled another one from the trailor and parts needed to complete the build. Problem I ran into is that None of the pendants I have tried are working. I am going to try a few other pendant cables or sensor boards as time permits.

Did the PM on press#3- repaired the blown out grease fitting Bill Potter mentioned. Will keep an eye on it. We are trying to get back on top of these leaks and minor repairs.Keep me informed on any new policy changes or developments, thanks.

Call if there are any questions!

Sean

" C " Shift

   MP-23  Made a temporary separator for fans coming off belt.

 

  MP-23   Josh said we were going to put the new core valve on this press; they were running it this weekend. We probably need to get Jade in to

               look at it & see what fittings we need to tie it in.

 

  New top cover mold -  I tightened & double checked all the hydraulics; still need to check limit switches.

 

  Well, the new o-rings on MP-17 didn’t work ! 

 

  I worked on PM’s the last part of the shift.

 

 

 

    R.Upchurch

    Molding Maint.

" C " SHIFT

   Changed out the belt on the molding sander- the one they’re using for rework.

 

  MP-2   Installed a new bit in the belt door screw gun.

 

 Made up a new extension cord for the fan tester – don’t know were they all go !

 

 MP-17 They shut the press down for awhile, so I put new o-rings in all the directional valves on the block on the clamp end “ AGAIN “

 

 Still Troubleshooting the dryer in the shop – it seems to be cycling correctly, but it is still over heating when it shifts beds. I may need to call for

    tech. assistance  Monday.  

3.12.10 D shift

Mp#13- stopped and they were saying that the clamp was opening past its setpoint causing the ejectors to malfunction. After closer inspection, found that the ejector plate in the mold was bound up. We greased the plate and pins, and after coersion, we got it moving and up and running again. It did it one more time before the end of the shift.

Continued with P.M.'s

Sean

March 11, 2010

MP24 – Started up the machine and the top core cylinder would not pull with 2000psi.  Lowered the thermolator temp to 120 degrees.  Increased cycle time to 36 seconds.  Lowered the pack and hold pressure to 350psi.  Went from 12 sec on cooling time to 16 sec.  Fred came out and looked at the mold and saw the top core was dragging on its way out, he also noticed that it was very dry.  He sprayed a healthy dose of injector rod lube in and around both cores.  The cores have pulled ever since.  Something was binding in the top core tooling.  To Temporarily solve the core push back problem on injection we changed the sequence to # 3 and set the cores first to allow time for cores to fully pressurize, added a sprue break function, and used a relay to break the output to the core set, using the n/c contacts,.to capture full pressure against the cores.  The input for inject unit forward confirmed, 137, is used to energize the relay and remove power to the valve prior to inject.  Clamp high pressure might be a better choice if a mold can’t use a sprue break but n/o contacts would have to be utilized, I believe the high pressure switch is signal off when tonnage is achieved.

 

MP10 – Branson 910 Sonic Welder – Worked on it off and on last two days.  This is what I have learned.  Alignment is critical, the horn should push evenly around the part flange and bottom surface should be parallel with the part flange.  Adjusted the stroke so that it would travel far enough to weld but not far enough so the horn would bottom out on the lower part if the top part was missing.  Slowed the down speed so the other controls and settings had time to react.  Reduced the down pressure to 20psi.  Increased the trigger pressure setting to 6, to allow time for our flimsy top part to settle, before welding.  Tuned the Sonics by depressing the test push button for 5 seconds, then while holding the test button in, adjusted the trim pot above to read the lowest digital number on the read out.  Here’s where settings ended up:  Weld Time was at 2.000, Hold Time was at .300, AB Delay was at .050, AB Time was at .050.  We may have power supply issues since we can’t seem to get the settings back to original.  I was informed today, as of September of this year, Branson will no longer support this piece of equipment because of obsolescence. 

 

MP17 seems to be leaking from everywhere and sooner or later we will have to deal with it.

 

The Eagle baseplate mold is back and needs to be plumbed and wired.  I will start with the plumbing and see how far I can get.

 

Thanks and have nice day,  any questions please don’t hesitate to call.  3/11/10.

 

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

 

MP24

I worked on the core problem on the new cord dump mold in MP24 for a while last night. The problem we were having was with core pull in automatic sequence. After the cooling time, the cores would try to pull but only one would. We had to put the machine in manual cycle and wait. After about 30 to 45 seconds you could set the cores again then pull them. If you tried to just pull them, it wouldn't work. I checked the pressure on the set and pull side of the cores and it was reading around 2000psi. I verified that the set side pressure was dropping to zero before the pull side was energized. We then dry cycled the press without parts and the problem didn't occur. Since having parts in the mold was required to cause the problem, we tried decreasing the injection time. We had the injection time down fro 5 to 3.2 seconds. And even until the parts were short-shots and still no luck. We turned the front half of the mold down from 150 to 100 degrees and then tried increasing the cooling time from 12 to 30 seconds without any change.

Mark is going to try and turn the core pressure down to 1000psi to see if maybe the core or cylinder is sticking it the set position. The mold ran fine when it only had around 250 or 300psi on the cores but the core was being pushed back. I talked to Charlie on B shift and he said when he ran the sample run in MP17 he had the same problem with the core being pressed back but was able to process it out by decreasing his pack pressure. He said he only ran a couple hundred in single cycle though.

If turning the pressure down fixes the problem, we may have to take a closer look at the cylinders or whatever is causing the cores to stick so it will be able to run in other presses without modifying the pressure each time.

Collin

3.9.10 nights D shift

Mp#24- Gary, Collin, Ronnie, and myself looked at it. The problem communicated to me was that the cores were bleeding back and there was no core pressure in automatic cycle.

After looking at it further, we determined that the cores were locking into "system" pressure in automatic (as we compared test results from press #8) but not in manual.

In manual we were seeing "set system pressure" as what was set on the controller (85%) etc. 2000 psi. When watching it in automatic, parts were filling out at 400psi so that is all the cores were getting.

When Mark and I tricked out the machine this morning so that settings for inject were higher, we had 1800 inject prs and core prs likewise.

Because the only cavity with the "bledback" effect on it was Cav#2, I had to rule that there was probably an issue with the mold fit. Possibly in the core linkages for the affected cavity. Gil looked at it as well and agreed.

other than that, worked on P.M.'s the rest of the night. See work orders for details.

Submitted PTO for Thursday- April 29, 2010.

Going on California trip.

Sean

Sean

3.8.10 nights D shift

Mp#23- finished installing the remote E-stop disconnect. Checked it.

Also labelled 480 panel and receptacles on press#22.

MP#3- material hopper kept calling even though it was full, changed sensor and corrected problem.

Repaired both thermolators that were red tagged outside the shop.

Replaced the flex conduit on press#6 for the yellow alarm light. It was damaged and exposing wires.

Will continue with PM,s tomorrow as well.

Sean

" C " SHIFT

 MP-24  Made up adapter box for core plugs.

 

 MP-11  Single cav. top cover mold leaking @ core pull sensor – it was loose. The leak that is filling up the jug is coming from the clamp seal.

 

 MP-17  The oil recycle pump burned up; pan overflowed.  Replaced pump & left cover off until it fills up to see if it needs to be primed.

 

 Got part numbers & prices for clamp seals on MP-11 & inj. seals on MP-25 – filled out purchase req.

 

 

       R.UPCHURCH

       MOLDING MAINT.

3/7/10

DR17 on MP20 regen heaters were not working. Two of the three elements were bad. I took the last one from MRO and found one in the molding nonstock parts in MRO.

Replaced two broken DME heater connections on a mold pulled tonight.

Fixed the feed-throat water on MP13

Collin

Storage trailer roll up door

FYI-

 

Ronnie Colson and Jeremy fixed the roll up door to the storage trailer today.  I just wanted to make everyone aware of it before someone tried lifting it with a forklift again.

 

Thanks

 

 

  Joshua Ledbetter

  Manufacturing Engineer

  Oreck Manufacturing Company

  931-239-3235

 

3.3.10 nights D shift

MP#10 Robot- was stopping in mold and at part drop. Found a loose sensor connection on the C axis. Tightened it up. No further problems from that, but then an hour later it would stop over the part drop area with parts. I found that the Z position was not going all the way to set point. Noticed that the belt was off track and loose. Adjusted tracking and tightened it up and had no further problems with 10.

Mp#9 Robot- stopped once at 4am and would not home. Powered it down and reset. referenced it and it would try to home after reference but it could not go to Z at mold position (set at 30) because it was already against the back stop (reading 40 as actual value). We jogged it into the mold and aligned it with parts and it appeared that the Z in mold needed to be at 72 at that point. So we changed that value only to 72 and it started running fine until it went down an hour later. Mark and I discussed changing out to the new encoder style on that axis possibly. Also talked to Potter about that too.

Mp#13- Mold setter was having trouble removing mold from machine. we used die bars to pry it out, then next tool wouldn't fit without forcing so we went around the I.D. of locating ring with a die grinder and cleaned it up. Then tool fit good. O.K. to run.

Finished E-stop install on #22 and checked operation of it. Ran the box and flex for #23 but have not tied it in as they were still running the press. I will continue with that and signs tomorrow. Call if there are any questions, I'll be glad to help.

Sean

MP16

Gary and Mark changed out a bad heater band on MP16, and also found that the zone 1 TC was not pushed in all the way and was heating 70 degrees above set point.

 

 

  Joshua Ledbetter

  Manufacturing Engineer

  Oreck Manufacturing Company

  931-239-3235

 

Monday March 1st

Ordered a new rotary encoder for MP25- it should be here tomorrow.  Mark got the one on there to read somewhat, it may be good enough to limp through until the new one comes in.  We were waiting on them to put a mold in there so that we could really test it out.

 

Also, three “new” 2003 model Jet Loaders came in for MP23-MP25.  One of them has a busted up display and no filter, so I will need to order some parts for it.  Collin, see if you can get two of them ready to run.  I will try and get a good manual for them before I leave today.

 

Thanks

 

  Joshua Ledbetter

  Manufacturing Engineer

  Oreck Manufacturing Company

  931-239-3235

 

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