" C " SHIFT

  MP-19    Installed new glass & touch screen on controller.  It was ready to go at 9:30 am .

 

 MP-10   Mark & I worked with the Branson guy on the sonic welder. Mark has more details on his blog.

 

   Vacuumed out pan on MP-6 & emptied oil vac.

 

 

 

   R.Upchurch

April 10, 2010

This morning worked with Doug Mason to set-up an alternative ultrasonic welder for the connector on MP10.  After a fair amount of tweaking, this machine which is the old Air Ten Truman Cell Bracket welder, could work in a pinch with some modifications.  We finished with 30-40 parts in a row with no failures. 

 

About 10am, Keith Raiford with Branson Ultrasonics came in to work on the Branson Model 910IW welder on MP10.  After a thorough investigation we found the following problems with our old welder:  The main power supply for the welder was dead w/ no output, (A new power supply was installed) The upper exhaust fan in the cabinet had failed, (Both fans in the cabinet were replaced to protect the ps)  The horn cylinder was replaced, The trigger switch was replaced, The trim pot on the front of the machine was jacked up and we replace it,  Both air regulators on the front of the machine were broken and we replaced them.  We bummed a packed of mylar washers from him for the horn,  Went through the horn stack and serviced it,  Tuned the machine, aligned the horn and fixture and started welding parts.  Potter was happy with the parts.  The following set-up exists:

 

38psi air pressure

1.5 weld time

.050 on hold time

5.5 trigger

 

 

 

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

 

4.10.10 D shift

#4- had a problem with temp zone#2 it was a mercury relay stuck. Pecked on it and it started working again.

Continued working on new press 26 water and New press#1.

Sean

" C " Shift

 Leave MP-10 down ;   Branson tech will be here in the morning.

 

MP-2 – They hung the supply tank again. You have to crack the eject valves open so the machine & mold plates both move, so it can read limits.

 

MP-19  Someone broke the glass on the controller.  I ordered a new glass & touch pad . It will be here tomorrow.

 

MP-8   Cores not working--- after checking everything, it ended up being one of the hydraulic quick connects.

 

MP-25   Ran a new T.C. wire for the nozzle tip heater.

 

MP-17  Oil was running out on the floor AGAIN.  Cleaned up AGAIN. Needs oil added.

 

 

 

R.Upchurch

4/8/10

MP20 broke the ejector plate bolts. Replaced them and started back up.

Hooked up the cores and ejector hoses and switches for the tank mold in MP2 but we couldn't figure out the settings to make it read the ejector switches only

The Branson welder on MP10 stuck a couple of times like it was still trying to weld when the head came back up. The operator tapped on the side of it and it quit. Later on in the shift it quit welding altogether. I checked everything out and tried a new relay in it but still couldn't get it working.

Collin

4.6.10 D- shift

Mp #3-

Stopped during production with clamp closed. The machine acted like it had lost its pump and nothing was working at all. We tried probing the variable pump load valve and got 3000 pressure so we started looking at the electrical and found a fuse blown. We changed it and it blew as soon as we started the pump. After tracing out the short, we located the coil bad on the "Decrompress Hoses valve A156". We replaced the fuses and used the coil from the sled retract valve to open the clamp and check things out. When we took the coil back off the A156 valve we noticed that it was extremely hot.

After looking at the output card, I noticed the output for A156 (slot 5/#10) was staying on constantly. I wanted to isolate it to the output card so I swapped it out with the card from slot 8. Well, it was not the cards.

So I compared it with Press#5 to see what it was doing and 5 was not coming on at all in automatic cycle. So, I stopped it long enough to see if it came on in Manual or when the pump was off. It didn't come on in either case. So, at this point I went to the sequence chart and looked at when it should be on during the cycle. It does appear to be on throughout most of the cycle except for a short break between decompression and extruder run.

So the dilemma I am faced with now is why would the control be energizing this A156 output all the time? Is there something feeding back data to the control that would make it respond this way? Maybe a bad transducer or another input signal?Or a bit set in the control? Maybe needs reprogrammed?

Call if there are any specific questions about this or anything else.

Sean

3/2/10

Worked on core # 2 pull sensors on mold # 74046-01 in MP4. Two of the three hall effect sensors will not read up the magnets in the hydraulic cylinders. The top sensor works as long as you don't tighten down the hose clamp too much. I found two more sensors in the shop and tried them. They work with a strong hand-held magnet but not on the cylinders.

Robot #10 stopped 3 times within a 5 minute period and never messed up again. Two of the stops were in the mold accompanied with a "Mold not open. Robot in unsafe position" alarm.

Cleaned the two new presses and started painting them. I will try to finish tonight.

Collin Miller
"B" shift
3/2/10

" C " SHIFT

MP- 25  Changed  nozzle T.C. to “ J “ type so it would run in auto on DME.

 

MP- 23  Nozzle adapter heater band went out ;  replaced.

 

MP- 17  Chiseled Santoprene out of grinder. It had two different colors in it. I guess it had been running all night.

 

MP- 10 Robot only stopped one time. They wanted to let it run . I guess we’ll try & fix it on the next run.

 

 

 

 R. Upchurch

 Molding Maint.

4.1.10 D shift

Clear out the area for press#1 and capped off the heat exchanger lines.

Changed out a color mixer motor on #9.

Robot on MP#10- has been stopping every hour or so. It has been stopping over the conveyor after it has dropped the parts and goes up. It readily homes back and restarts. I mentioned stopping it to work on it but Marty did not want to leave it down for any length of time.

Call if there are any questions.

Sean

MP22 Star Robot Operational Update

We had a service tech from Star Automation in here yesterday on a courtesy call to help us out on some issues we have been seeing with the TW1200 robot on MP22.  Listed below are some corrections that were made that I wanted everyone to be aware of.

 

1)     Insert Arm L5 Home Limit Switch-

We were having an irritating problem with the robot not wanting to reference or return to the home position without the L5 Limit Switch being made.  Since we’re not currently using the Insert Arm, we corrected this by moving the L5 Limit Switch closer to the traverse beam and set the “Avoid Position” for the Insert Arm to 0.  Now the Insert Arm should never move off of the L5 Limit Switch and cause this problem.  Also because we moved the Insert Arm closer to the Traverse Beam, we were able to move the Product Arm Limit Switch closer to the Traverse Beam to give us more Crosswise stroke on the Product Arm.  Now we should not have to open the mold as far to remove parts.

2)     Part Grip Circuit-

The Part Grip circuit was not functioning because the robot’s previous owner had wired the valve output down to a plug at the EOAT.  The valve was rewired and now functions correctly.

 

Also, if you’re like me, then you have been having problems getting this thing to reference when you first power it up.  I would get an alarm saying “To make sure there is no interference with the Traverse Beam and to perform Posture/Rotate in Free Operation Mode”, or something like that.  What I learned yesterday about referencing the robot and homing the robot both is that it works a whole lot better to exit all the way out to the initial screen first before homing/referencing the robot.  There are two ways to home the robot-  First you can hold the “Dead Man” button until the bar at the top of the screen turns yellow and then hold the home button, or secondly you can turn the switch on the pedestal to “Origin” and then press the green “Start” button on the pedestal.  The light on the “Start” button will blink until homing operation is complete.

 

Call or email with any other questions.

Thanks

 

 

  Joshua Ledbetter

  Manufacturing Engineer

  Oreck Manufacturing Company

  931-239-3235

 

3.28.10 D shift weekend

Worked on Pm's most of the weekend.

Put the remote and blowback option on the 1 shot loader. Checked it, it works fine.

Looked at the Jet Loaders and Jet select valves. We really need the jet selects when using them for multi loading application. Talked with Mark about it and there may be a cheaper alternative to buying jet selectors? Might be able to use conair or off brand pocket valves to do the same things? Just a thought.

I need to obtain a Yushin pendant that works. I remember there were about 4 good ones from when I initially checked them all out, but now i cannot locate them. I am going to try to get the one on 16 going first.

Started putting SPI on #16. haven't tied it in, but have the box and wiring numbered and run already.

Had mostly minor issues since we were not running very much this weekend.(SLOW).

I will be out this Thursday, call if there are any questions. I will call back on Tuesday.

Sean

" C " SHIFT

   MP – 22   Mark & I  built eoat for new handle mold.

 

  MP – 4  Nozzle heat was running away; T.C.& tip heater were damaged, also the nozzle adapter heater was shorting out. Replaced all.

 

 Emptied oil jug on MP – 11; replaced oil pads on MP – 17

 

 Started cutting material & getting hardware together to assemble more catch trays for tall conveyors.

" C " Shift

  MP- 8  Mold hit the robot again. I reworked the end of arm, & shortened the “Y”  axis up flag.  I cleaned & lubed tie bars before they started press.

 

 MP-20   Realigned  the sled.

 

 MP- 5  Lost robot power  -  The grinder jammed & tripped the breaker.

 

 

 

 R. Upchurch

Molding Maint.

3.24.10 D shift

Robot 22- Constructed end of arm tooling and programmed robot for production. Used the new style gripper cylinders Josh ordered. They work great. Like the non-rotating feature they provide.

Had some problem with the robot going too fast into the mold area and stopping. We slowed it down to 80 from 100 and it did not stop anyore.

MP#19- Cores were not outputting a decent Pull signal when I checked it with no load. 24 on the set side, and only 6 volts on the pull side. I set it up to run straight off the controller outputs of Core 2 but ran each coil through a 1/2 amp fuse in case of a short.

I checked operation and verified that core switch signals were reading correctly, labelled everything , and posted a notice to "only use core 2" at the operator panel. It should be O.K. to run now.

I need a controller pendant that works to do anymore testing on the Yushin pickers. Give me a call if there are any questions.

Sean

" C " Shift

  MP- 2    A piece of metal lodged in between the tie bar bushing retainer & the tie bar; it was gauled up.  I stoned off the area & re greased all tie bars before

              they started it up.

 

  MP-24   Tech said they were having heater problems;  the problem was the nozzle heater band was getting pushed back when they ran the sled forward.

              I moved the htr. band clamp back so it wouldn’t  hit in the sprue bushing area, reset heats to s.o.p. sheet, & let um have it.

 

  Cleaned up oil on MP-11-17-& 21

 

  MP- 19   Mark mounted  the core directional  valve. I made up new hoses for the valve & the test cylinder. Core sets but doesn’t pull; still troubleshooting.

 

 

 

   R. Upchurch

   Molding Maint. 

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.