4/30/10

Core 1 wouldn't read the pull switch on MP5. Found a loose connection in the core plug.

When DR18 was started it would index then trip the main breaker to MP25. The process heaters were shorted. I replaced them and started it back up.

The robot on MP25 crashed in the core dummy plug. Straighten the robot arm and set it to rotate above the belt instead of the mold.

Collin Miller

Friday MP05

I finally fixed the problem on MP05 where the screw would drift forward when the pump loaded for Clamp Open/Close and Injection Unit Forward/Retract. Fixing that problem also dramatically made Screw Recover better.
Sent From My Verizon Blackberry

4/29/10

Press 10 ran all night without stopping

Fixed core wiring on MP22

Worked on MP8 robot

Replaced right side push button on fan housing press on MP8

Collin Miller

4-29-10

MP10-  Kept going down all day with the pumps kicking off.  Was getting a 5220 alarm, when indicates “Rear Door”.  On this machine, “Rear Door” does not refer to the Non-Operator side door, but the doors that are to the Rear (away from injection unit) of the machine.  I usually call these doors the “gates”.  Anyway, Mark noticed that the non-operator side rear door limit switch needed to travel a good bit before it was made so he adjusted it.

After this, the machine still kept going down.  We spent a little time troubleshooting it, but it finally got so bad it was doing it every shot they needed to run so I jumped wire #69 to #220.

This should get them running, but it needs to be removed later and the problem fixed.

It only does it when the mold is first closed, so it may be a short in a core wire or something.  The only other inputs grouped with the rear doors all seem to deal with options or the cores.  If something was shorted and dragging the voltage down on the entire group, this is the alarm you would likely see first because it kills the pump.

 

Thanks

 

  Joshua Ledbetter

  Manufacturing Engineer

  Oreck Manufacturing Company

  931-239-3235

 

4.29.10 D shift

Mp#10 stopped a few times, the techs did not say anything about it until I asked. I caught it once but it was because it had ran out of material and did not make shot size.

Mp#8- looked into redoing the other EOAT in the shop. Could not locate any 5/16 -24 threaded rod to make standoff studs for the disks. Need to get some. I sent Mark an email.
I do have some ideas we could try with the classic fan EOAT.

Began greasing and Pm'ing presses. We need to update press assignments or work out a plan of some kind that works.

Mp#18- I have been looking into the interface details to tie in the sprue picker. I think that one of the interface boxes will work. I have started on some notes that I will submit for Josh's review on Monday.
After looking at the interface schematics, I think it might be likely we can make something similar from scratch to do a few more presses that only require pickers.

Call if there are any questions.

Sean

" C " SHIFT

 MP-21   Replaced pump hydraulic Hose.

 

MP-26  Fabricated top safety door – It’ll work for now.

 

MP-24  Cores not working;  The eject. back common  on the machine side plug wasn’t hooked up. OK now.

 

MP-17  Cleaned up oil , replaced pads, & emptied jug.

 

 

 

 

R.UPCHURCH

MOLDING MAINT.

April 27, 2010

Spent several hours on our favorite two presses today, MP8 and 10

 

It all started with MP10 stopping periodically. (The pump dropping out)  We wanted to rule out machine or robot.

A jumper was placed between pins 19 and 27 in the robot interface plug to bypass the robot estop stuff.

The pump would continue to drop out here and there.  It seems to always drop out when the robot is either on its way to drop a part off or down in the conveyor guard, so basically when the machine is clamping up or building tonnage.  Looked at the control cabinet door switches and added screws to keep control power on solid.  Replaced the bottom safety switch on the back door, fixed the latch on the back door, it was rolling back some after you closed it.  The purge cover door switch cable was just bare wires twisted together, wirenutted and taped it up.  This is where we got to when MP8

Reared its ugly head.

 

MP8 would not pick parts and the EOAT was all out of whack.  So a couple of hours later we started picking parts again on a consistent basis.

We should put our heads together with our tooling and look at some improvements.  Gary and I talked and he brought up some good points that could fix some problems we saw today.  Tie the two discs together at the proper center spacing, fab and mount them so they cannot turn.  Use a single plate across the tool to represent the discs and insert the two tabs into the plate.  Separate the gripper mounts from the disc mount so they could be moved independently.  Just some thoughts, we desperately need to do something.

 

We received our new hydraulic oil today.

 

Poppet valves came in today.

 

 

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

 

4.25.10 D shift

Mp#2- repaired a broken core sensor wire.

Mp#3-repaired the vacuum switch on the robot, somehow the wires got ripped out. I tied them up neatly.

Mp#4-There was purge material all around the nozzle heater wires. Carefully cut away material and taped the wires back up out of the way.

Mp#5- had borrowed the vac switch off that robot to get #3 running and then soldered back the broken one and replaced it on #5 robot. I checked and adjusted the sensor so that it was working good. It is O.K. to run now.

The edge fan that is running in the vibratory welder is in need of ejectors to eject it from sticking in the tool fixture. Even when the parts are cold they can be difficult to remove. They may already have an engineering change planned but if not, someone needs to take another look at it.

Cleaned up and 5-s'd in the shop. Have a good week, call if there are any questions.

Sean

" C " SHIFT

  Mezzanine – Dryers 6, 21, & 32 – All  were in alarm; had to adjust index limit switches.

 

MP-22  Robot dropping parts;  Tightened up all suction cup mounts.

 

MP-16   Nozzle kept freezing off.  Replaced nozzle band.

 

Lubed all tie-bars. Wiped down & lubed tie bars on presses not running.

 

MP-21   Need to order new pump hose – back side- marked with red paint. It’s leaking at crimp.

 

  R.UPCHURCH

  MOLDING MAINT.

" C " SHIFT

 I vacuumed out all the oil pans & emptied all the oil catch bottles. Also cleaned up oil on MP-21.

 

Emptied oil vac.

 

MP-12   Eye wasn’t reading on eagle fan tester; also the air bladder was popping out of the fan when it inflated.  I adjusted the eye & cleaned the bladder

            with alcohol. Working OK.

 

Mark is ordering more hydraulic fluid & some more ½”  female quick connects to install on maifolds for the oil vac.

 

 

    R. UPCHURCH

    MOLDING MAINT.

" C " SHIFT

MP-20    Blow back -  Removed & replaced two nozzle heaters.

 

MP-21   Grinder quit.  Wire came loose from E-Stop.

 

MP-17 Oil running on floor again- jug filled up. Cleaned up. Oil tank was empty. I filled it.

 

 

 

 R. Upchurch

Molding Maint.

4.19.10 D shift

Mp#1- made 4 ejector bars per Bill Potters Request at 16- 3/4" each.
Also finished connecting front water manifold hoses on it.

Repaired the wheel press for the baseplates, it had a sensor out of adjustment and another sensor completely loose. Checked operation and moved back onto floor.

Dryer# 17-alarmed and went into shutdown mode. It did it because it was set-up in the diagnosis pages to fatal out in an overtemp condition. Simply reset it after checking it over, filters, motor operation, contactors, etc. No further problems the rest of the shift.

Hot Stamp press on #12- the process technician (Roy Smith) asked me to assist him in setting it up as he was having difficulty. We got it going after much adjustment. I recommended that using set-up sheets would help him in the future.

Ronnie and I looked over the new Press 1 and discussed lubrication, when the machine manual comes in I would like to have a look at it. I hear Nissei went up on the price of manuals now?

Reminder, I will be out on PTO Tonight as well as next week on Thursday.

Call if there are any questions.

Sean

4/17/10

Replaced the conveyor belt relay in number 4 robot

Worked on the loader on MP22. Had to adjust the sensor and the load timers

Work the rest of the night on number 8 robot. The round back stop on the EOAT broke one of the guides off. I modified another one and got it running again finally.

Collin

4.15.10 D shift

Worked on the new machine installation. Turned on the water to #26 and checked for leaks, It is O.K.
Ran air line over to #26 and put several quick connects at rear of the press.
Built and mounted the water manifold bracket for front half water onpress #1. Will continue on Monday.

Sean

4

April 14, 2010

MP10 Robot travelled too far in the Y up direction and lost power, bumped it down and referenced it and it was fine.

 

Replaced nozzle heater band on MP19.

 

Temp Controller on MP15 failed and we did not have the replacement.  Found one similar and tried it, no good.  Installed an old model to get us by until one comes in and it worked, but had to jump out the alarm to the machine.

 

Met with Lakeland Electric on MP1 electrical and made materials list.

 

Wired the two transformers on MP26.

 

That’s all I can remember,  4/14/10

 

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

 

4/12/10

Filled MP26 with hydraulic oil

Put the material hopper on MP1 and connected the airline. After the electric and material lines are installed I'll find a good location to mount the power switch.

Fixed a bad air leak on MP14

Collin Miller

4.12.10 D shift

#5- they put a new tool in and needed some core switch adapter cables, I made them up and put them on.

Worked on water for 26 all night, got to a stopping point and discussed everything with Mark as to where we were at with it.

He is going to order/pickup some additional materials.

Spoke with Gary about the hopper for #1 needing an adapter plate due to the differences in footprint, etc.

I put in for a PTO day on the 20th of this month.

Call if there are any questions.

Sean

4.11.10 D shift

MP#5- Had the same problem that 3 had the other day with that Decompress Hoses valve-A156. The coil had shot in it as well and blew the fuse. Changed coil and fuse, then restarted, then talked to Marty and Bill about a problem with the cushion moving all over the place in cycle.

Worked on inconsistent cushion problem that many of the technicians have complained about. Decided to inspect the screwtip after discussing it with Marty and Bill. Pulled it out and really could not determine that it was bad, but, put a ball check in it while it was down to eliminate that. It worked, aligned the nozzle/sled back up and tightened everything back down, re-zeroed the screw position and started it back. Had no further problems with cushion.
There is a problem with the injection unit when it sucks the screw back after building a shot, it is making a loud hydraulic "Shuttering" sound. It is really difficult to describe, but you know that there is something wrong. It is running good parts now, but we need to get that injection valve tuned better or something. Open for suggestions. Will look into it further tomorrow.

Continued with water on #26 the rest of the night.

Call if there are any questions.

Sean

" 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