5.18.10 D shift

Mp#1-Put together a water manifold sheild to help direct any future leaks.

Mp#23 robot- Made a sprue gripper extension to pick offset runners (work order request). Helped them get it going.

Mp#21 robot- Replaced a section of tubing that had blown out.

Used 10x6.5mm metric tubing.

Put the new molds in the tool room.

Call if there any questions.

Sean

" C " Shift

  MP-23   Control power kept kicking off.  Mark and I checked it out; found the 3 amp control breaker was bad – replaced.

 

 MP-5 Installed  “T”  for gauge @ pressure transducer port.

 

MP-8  Made a fixture to check for bad ends on fan housings.

 

MP-1 Cleaned up water under clamp. Cleaned & checked operation of cabinet fan.

 

 

R. Upchurch

Molding Maint.

Tuesday

MP01 is still down with the servo drive alarm.  Mark is still doing some investigating before we send the thing in for repair.

 

  Joshua Ledbetter

  Molding Maintenance Manager

  Manufacturing Engineer

  Oreck Manufacturing Company

  931-239-3235

 

5.17.10 D shift

Mp#1- Motor power goes off after 1 second, then alarms "5E33" Clamp axis driver error (regeneration abnorm).

Checked it out, found wires burnt open from what appeared to have gotten wet. Repaired regen circuit wiring. Alarm on servo amp cleared but alarm on machine display still comes up as before.

I downloaded the Yaskawa manual for that particular servo amp and motor, it indicated that there were maybe a few solutions to this error.
1. Replace the servo pak
2. Replace the regenerative pak (it could be defective I suspect).
3. Repair wiring to regenerative pak.

After making the repairs and reading further, I found that resistance specs for that servo pak model was 2.4 ohms. We have 3.4 actual now.

This is why I suspect a faulty regen pak.

There is reference to an incorrect pulse count vs. pulse set value, this is supposedly a result of this cause, which may be cleared (with the host controller)if I knew how to do that.

We would likely need that digital operator that we just now ordered to do that?

I turned over everything I had to Mark when he came in and I think he is going to see about making sure that any internal faults get cleared and seeing what else can be done aside from ordering new expensive parts.

Call me if you have any specific questions.

Also worked on the Hot stamp press on #20. It was not reading the down switch and had to be set-up correctly.

Sean

5.13.10 D shift

Mp#4-conveyor quit. Reinstalled chain and readjusted belt tracking.
Working fine now.

Mp#5-overtravelled once and had to be rehomed, problem was a loose cable connection in panel where someone had moved the cabinet.

Mp#6- techs couldn't get the conveyor to work, jumper was not connected.

Mp#19- Nozzle was not working, found loose wiring connection, no further problems.

SB#2- Ran out of material, cap was off of header on catwalk.

Hot stamp press on #21- showing "eater control error". Found bad connection on thermocouple. Replaced the thermocouple (Type J) no further problems.

Call if there are any questions. I did check out the manual on the new star and on behalf of this shift, thanks for the new robot!~

Sean

" C " Shift

 Built & installed three more conveyor trays; only need one more to complete all.

 

MP-22  Checked & set torque on screw gun.

 

MP-1  thru  MP-12   Checked & lubed tie bars—blew out cabinet filters.  (  MP-6 & 8  need new cabinet fans )

 

MP-11  Cleaned up oil under clamp unit – Clamp seal needs to be replaced.

 

MP-17  Discharge line came off of our recirculating pump—blew oil on floor--  cleaned up & replaced hose.

 

 

 

  R.Upchurch

 Molding Maint.

" C " Shift

 MP-24  Oil leaking from tank hatch, where the parts bin track is mounted. Replaced mounting bracket & tightened back down.

 

Surge bin 2 was clogged. Took line apart outside where it 90’s up. Vacuumed out line all the way back to silo. Readjusted flow tube. OK  for now.

 

MP-4  Set up the timer for core 2 & installed a new bolt for one missing from the bottom core 2 cylinder.

 

Trying to locate & tighten some of the fitting leaks.

 

 

 R.Upchurch

 Molding Maint.

The week of May 3rd, 2010

Got Hopper w/ sensor and Jet Loader installed for MP26

 

Added the color port for MP26

 

Installed stainless 90s, new hose, and clamps above the surge bins for plastic load lines

 

Freed up valve under surge bin 1

 

Ordered wands for grinders, short and long.  Will be ready for pick up May 7, 2010

 

Installed the ladder for the feeder bowl on MP10

 

Replaced busted 480VAC plug on grinder on MP2

 

Ordered the mistakeproofing sensors for hole in baseplates (Wheel Press)

 

Ordered 3” Round Black Delrin

 

Picked up 5/8-11 X 4”  SHCS for mold setter

 

 

 

 

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

 

5/1/10

Put the barrel shroud back on MP1 after a bleed off

Core 2 pull quit reading in MP4. the bottom sensor wasn't working. I found another used sensor which would work with a magnet but not on the cylinder. The original senor started working again after I put a magnet to it. It quit one more during the shift so I removed it and stuck the magnet to it again to get it working. I don't know if there are any of these sensors it stock somewhere.

Cleaned the filters in the loader on MP23

Collin

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.