6.4.10 D-shift

Mp#5- stopped for the prefill alarm again. I couldn't find any information about what was done to it the other day to get it going. I tried calibrating the tonnage transducer again, but it did not work. Milacron thought there was problem with the FHD board for it to be continuing to have this problem. It is down now.

Jerome never replied to my request to schedule it down to do the screw-tip, so for now I will leave it.

I was able to extract the broken peices out of the screw for MP#13. I think it will be alright to use. Still need a new tip though.

Right now I plan on leaving at 2am Saturday night.

Will work all night Sunday.
Off on Monday.
Will work Tuesday through Friday nights.

Call if there are any questions.

P.S. Leave me some info this time on #5 so I can gain a better understanding of how to patch this thing for production. Thanks.

Sean.

" C " Shift

MP-13   Pulled the screw & screw tip. The rear seat wasn’t there. They continued to run it after it broke, so the threads in the screw were gone.

          Nissei didn’t have a 32mm screw in stock, so I called Chaseland  to make us one. They will fax the quote for the screw & tip Monday.

 

MP-14   Jason said some metal was showing up when he purged it out. Thought I was going to have to tear into that one when I finished 13.

           He got it running, so hopefully this one won’t jam up the check ring.

 

 

 

 

 

  R. Upchurch

6.3.10 B shift

Mp#13-Redid the heater bands on the nozzle. Checked and found that screw tip was indeed broken. Mitch was running it but they were scrapping too many so they eventually shut it down.

Repaired the cannister gate cutter fixture. Tested it out and it works great.

The drill press in the rework area broke the quill return spring. I was able to heat and rebend it and it is working again for now but we need to order another one. I gave Mark a lead with the drill press info.

Cleaned up oil around #17 and #21. Put some new oil absorbent down.

I am sending Jerome an email to see if he will leave #5 down on Saturday nite to do the screw tip change and barrel measurements.

Call if there are any questions.


Sean

Out of plant

I will be out tomorrow, Friday the 4th.
Josh
Sent From My Verizon Blackberry

Thursday A Shift

Suspect screw tip in 13 is broke. I've ordered a new one that will be there tomorrow. 
Josh
Sent From My Verizon Blackberry

6.1.10 D-shift

Mp#5- stopped for "Prefill did not open in time" alarm.
I was able to open the clamp by changing the offset for clamp tonnage on menu 93 from 1799 to 2250,and menu 92/convec 921, from 2000 to 2350 to get the clamp tonnage to zero, but it will not run yet. It now will alarm again but will open if you clear the alarm.
I spoke with Clarence at Milacron service who thought it sounded like the prefill valve was bad. I looked in MRO for another directional valve like it but couldn't locate one. They are using press #3 or I would have tried some parts from it maybe. I wasn't so convinced it was the valve bad yet, and I want to talk with Josh about it first.

Mp#11- Potter asked me to check the cores when I came in, I checked that the machine was working fine, used our test rig to verify switches and hoses. They had the collar tool out working on it and when it was set back in they never worked, it appears to be jammed up internally.

Worked on DME boxes, replaced cooling fan, and installed #3 jumper in all of them so they will work with the new style cards.

Changed the cord plug on liquid colr pump for 13 also.

May want to look over the gate cutting fixture that is for the cannisters. it is in the tool room because it needs another braket made. It looks like it is time for an overhaul of that fixture, I am welcome to any ideas with it.

Be back in at 6pm.

Sean

This week 5/24/10

Ordered new Saskawa servo amp from Nissei for MP1.  Should be here 6/1/10.  Called Saskawa and requested they send us our unrepaired unit and regenerative pack.

Should be here 6/1/10.  Nissei is now set up to accept P.O.’s, net 30.

 

Set up welder ejectors on MP12 for new Edge fan housing ejector cylinders, used outputs 12 and 13, top two single valves.  Firing sequence is top ejectors step 5, bottom ejectors step 6.  When door open part is laying loose for operator to remove.

 

Changed out safety latches in hoist ring hooks in molding production area.  (both hoists)

 

Installed additional 480 outlet on MP18.  Two outlets share a 30A breaker for Thermalators.

 

Fabbed and installed extrusion frame to hang heater wire junction box on MP2.  Mount junction box to new frame.  Replace and label all heater wiring.

 

Install and adjust spare Robot EOAT for fan housing on MP8

 

Replaced  (4)  2” load system hose sections up in mezzanine area with what hose we had on hand.  More hose is coming.  Replaced 2.5” material hose on top of surge bins.  Installed elbows and partially hard piped some drops.  We are trying to eliminate all vacuum leaks.

 

Install sand paper to the bottom of rework fixture for orbiter disks and realign.

 

Worked on color pump signal for MP1.  Parts are here to steal a signal from the output of the servo drive to the motor.

 

 

 

 

 

 

 

 

 

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

 

This week 5/24/10

Ordered new Saskawa servo amp from Nissei for MP1.  Should be here 6/1/10.  Called Saskawa and requested they send us our unrepaired unit and regenerative pack.

Should be here 6/1/10.  Nissei is now set up to accept P.O.’s, net 30.

 

Set up welder ejectors on MP12 for new Edge fan housing ejector cylinders, used outputs 12 and 13, top two single valves.  Firing sequence is top ejectors step 5, bottom ejectors step 6.  When door open part is laying loose for operator to remove.

 

Changed out safety latches in hoist ring hooks in molding production area.  (both hoists)

 

Installed additional 480 outlet on MP18.  Two outlets share a 30A breaker for Thermalators.

 

Fabbed and installed extrusion frame to hang heater wire junction box on MP2.  Mount junction box to new frame.  Replace and label all heater wiring.

 

Install and adjust spare Robot EOAT for fan housing on MP8

 

Replaced  (4)  2” load system hose sections up in mezzanine area with what hose we had on hand.  More hose is coming.  Replaced 2.5” material hose on top of surge bins.  Installed elbows and partially hard piped some drops.  We are trying to eliminate all vacuum leaks.

 

Install sand paper to the bottom of rework fixture for orbiter disks and realign.

 

 

 

 

 

 

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

 

5.27.10 D shift

Replaced wiring to purge sheilds on presses #6 and #12, tied them up neatly and repaired sheilds with new screws and fasteners, etc.

Checked all of the presses that were down for loose safety circuit switches and door latches, fixed whatever I found. Replaced screws as needed.
Checked the lube lines for broken fittings.

MP#8 -Finshed where Ronnie left off on oil pan clean-up.

I left a paper for Mark to see about ordering those vacuum drainage reservoirs for the 500 Cincinatti's clamp drain line. They might give us one as a sample since you order them 48 to a case.?

Mark and I went over the procedure for HMI programming for the AEC robot displays.

Call if there are any questions...have a great weekend. I will be working Tuesday-Friday or Saturday nights next week or until? I sent Darryl an email.

Sean

" C " SHIFT

MP-19-22-23-25   Filled lube reservoirs.

 

MP-19 & 22   Replaced broken tie bar & skate lube fittings

 

MP-21  Robot crashed into mold. All of the gripper mounts were either bent or broken off. Replaced all mounts, tightened the gripper posts, chased

      threads & replaced bolts on eoat mount.

 

MP-6 Vacuumed out oil pan.

 

 

 

R. Upchurch

Molding Maint.

5.26.10 D shift

Mp#260 Changed out the temperature contoller. It quit reading actual temp. Auto-tuned the new one. Checked operation, O.K. to run.

#11-Robot
Would not reference the Z-axis. Went thru the whole z-circuit, found loose connection on break relay module.

Call if there are any questions.
Thanks.
Sean

Molding Support Tracking Spreadsheet

Hey Guys,

I put together a To-Do spreadsheet today and put it on the server.  Attached is a shortcut. 

The spreadsheet has multiple page tabs at the bottom for Issues, Parts, Projects, and ShutDown Projects.

Some of the cells have drop down boxes for your convenience. 

Collin- Don’t let your feelings get hurt because I left your name out of the “Assigned To” drop down box.

 

Thanks

 

  Joshua Ledbetter

  Molding Maintenance Manager

  Manufacturing Engineer

  Oreck Manufacturing Company

  931-239-3235

 

5.23.10 Weekend D-shift

Worked on conveyors repairing broken parts and generally looking them over to see if they need anything. There is still one that is going to need the Baldor drive repaired or replaced, but it is working for now.

#3 has a busted reservoir basin for the drain line that draws from the clamp seal. It is mounted under the automatic lube greaser. The words respiratory health care are printed on it so maybe it is something we can get cheaply at a hospital supply place?

#10- Had issues with the ultrasonic welder. The thermolator had been off and the positive stop was adjusted too far down. It was giving an error some of the time that would require you to press the reset button. It is working fine now.

Cal if there are any questions.

" C " Shift Weekend

 

MP-22  Broken glass on control panel—Ordered new one for Saturday delivery

 

MP-2  Tech had core problems--  checked & found sequence was set wrong.  Also DME hooked up wrong; heater was plugged in to zone 1 – TC was plugged in to

            Zone 2.  After correcting it, found it had a bad heater. Tooling to change it out.

 

MP-13  Tech said when sled was run in, the nozzle heat would drop out. When I went to check on it, Bill had started it up & it was OK. He said to let it run.

           ( For future reference )

 

I called Nissei about oiler fittings—They said they would send the right ones & for us to just keep the other fittings.

 

MP-22   The control panel glass & sheet came in---  Installed & checked out.  Also made a cover for it.  I need more hinges to make covers for the other ones.

 

MP-24  Installed a plug for the mold cores to the machine.

 

MP-17 Cleaned up oil jug overflow on clamp end.

 

MP-23  Weak vacuum on eoat suction cups--- tightened up all the fittings—OK

 

MP-23 Replaced the nozzle heater band.

 

MP-22  Could not change the screw back position.  I had to reset the injection scale. ( Press & hold the alarm reset while running the screw all the way back, then all the

           way forward, release reset button, then you can change the setting ).        

           

 

MP- 22  Getting a lot of color swirls in natural bag stiffener.  It wouldn’t purge out. I pulled the nozzle tip & the adapter. The adapter wasn’t seating, so I cleaned it out &  

             had tooling reface it. I reinstalled it & they were starting it up on “ D “ shift.

 

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.