8.5.10 D shift

Yushin Picker project- Made some progress. The other relay interface box would not work. The controller pendant would operate the picker manually, but when I would try to put it into "Auto" with the Mold Open limit and safety gate signals jumped out, it gave a 5555 alarm, which was not found in the manual information.

Where I am now is, I put the 110vac transformer on the other relay box (the one from 18) and got it working again. Because that model of relay box indicates using the newer style pendants, and because that box supports features that the newer pendant has, I got the other controller cable to use with it when it comes back from being repaired. I do think we should attempt using the old style pendants unless we have a valid interface diagram for them. I contacted Yushin via E-mail for more specific information and am awaiting a response.

The Barrel for MP#1 did not come in last night.

There has been a molding meeting scheduled for Tuesday 5 and 6 pm.

Call if there are any questions.

Sean

" C " SHIFT

I worked on the Classic fascia hot stamp. I got it set up with the small print pad. Randy is supposed to get us the QVC pad with the large print so we

  can locate & drill the mounting holes .

 

I also worked on the Eagle fascia hot stamp. I got the mounting plate cut to fit & transferred holes in the slots to the base. All that’s left is mounting

  the pad to the hot plate & set up.

 

MP-2  The top core on the top cover mold was bleeding off. I put a gauge on the valve & saw it was dropping out. They had it on core 2, so I changed

   It over to core 1 & it worked fine. Will need to check it out when they finish the run.

 

I touched base with security & receiving all day --- Still no sign of the barrel.  WT #*@*!!!!!!!!!!

 

 

 

R. Upchurch

8.04.10 D shift

Mp#18- Ran into problems using the interface box that was on it. It was first bringing up " 0000 " on the pendant display. When I checked for 24volts on the interface board, I was reading 52 volts. Shortly there after it blew a fuse on the 200 volt power circuit.
I took the interface into the shop along with the picker from 14 so I could work on it while they ran press 18.
I hooked up a 200vac supply circuit to it again and it was blowing those fuses as well, but not the ones on the intrface board, so I am looking at a bad transformer possibly on that interface.

Then I looked at the other interface and found a bad fuse on the board. I replaced it and followed through the relays on the diagram. I tested the picker out on it and it worked fine. I jumped out the option we will likely not use (injection verified) so it would not need a relay there. I labelled all the wires after tracing them back on the terminal strip and will put the SPI plug on it tomorrow and double check the wire connections in press #18 if it is down.

I will let you know how it goes.

MP#1-Ronnie is going to call me today when(if) the barrel comes in today and I will help him install it and get it going. provided we have all the parts.

Call if there are any questions.

Sean

" C " Shift Weekend

MP- Robot kept stopping on “ Y “ axis. We found the over stroke block had moved.

 

MP-5  Robot CPU fault.  Mark pulled & replaced the cpu card & cleared the fault.

 

MP-20  Replaced the nozzle heater band & thermocouple.

 

MP-16  Ejector cylinder bolts broke; Found  1/8”  difference in the knock-out length.  Had tooling turn down knock-outs, replaced eject. bolts,

      & made a new eject. switch bracket.

 

Ordered more brass compression fittings from Nissei. ( for tie bar lube )

 

MP-5   Core 2 Leaking at manifold. Removed the fittings and put new Teflon on.

 

MP-6 thru 12  Vacuumed out oil pans.

 

MP-3  hooked up core switches & hydraulics on funnel mold.

 

MP-26  The chiller return line ball valve is cracked -  the valve that comes out of the 4” line up top.

 

MP-3   The barrel end cap is leaking. I kept an eye on it so they could finish the run. At the end of  C  shift, they needed about 100 more parts.

          They’re doing a mold change tonight. The end cap needs to come off to clean & reseat; That is if it’s not cracked.

 

 

 

       R, Upchurch

7.27.10 D shift

Mp#20- Changed out the motor starter...was bad.

Welded the tank for the handle project. It needs to marked for the chiller fitting locations and I will weld the nipples in place and anything else that needs done.

Mp#18- Installed the 120vac Robot receptacle. Fused for 5 amps and checked that E-stop killed power. Labelled everything.

Mp#2- Got an error E00240. We powered it down and when it came back up it automatically went into reloading from the boot card.

When it came back up it evidently did not have the core 2 programming saved on the boot card because it does not have the page on the menu.

It is operational right now as the mold in it is only using core 1, but likely we need to reinstall that.

Call if there are any questions, be back Friday.

Sean

" C " Shift

MP-18  Installed chain on dummy plug.

 

MP-22  The parts were getting black swirls.  We pulled the nozzle & adapter and got Fred to turn down the threads for a better seat.

 

MP-21   Put new heat shrink tubing on the large fan grippers.

 

We started fabricating the water tank for the Hokey handles .

 

MP-6-7-8 & 9  Vacuumed out oil pans.

 

 

 

R. Upchurch

7.21.10-

Mp#25- replaced bands on nozzle and 1st band.

Mp#20- Replaced 3 nozzle bands and reset sled pressure switch. Reinstalled shims under sled as well as i could . looking at a better solution for this repair but for now it is runnable.

Fabricated a detangler for the springs at baseplate sub-assy area. Will put it into use tonight.

" C " Shift

MP-11  Cores not working.  There was a bad spot in the cable. Replaced the cable & six pin plug. Rewired the bad one.

 

Mixer # 1   Replaced the air cylinder on the dump valve; next to the one that was replaced last week. It was getting weak.

 

I made the Eagle fascia hot stamp pads a stock item. It wasn’t done when Randy ordered them & there was only one spare. When the

  new pads come in for the hokey, I’ll get those put in stock too. Randy only ordered two.

 

 

 

   R. Upchurch   

7/17/10 weekend D shift

We have the Hot Stamp for the fascia cover working. Ronnie mentioned that someone needs to get another flat shaped "Oreck" hot stamp pad made because we used the ones for the HOKY which are curved.

Likely it will cause it to eventually wear out and then there will be none to replace it with.

It is in the shop.

Robot on #9- Rack and gear stripped out on the X- axis. I replaced them both and cleaned and greased the bearings. O.K. to run.

Mp#19- at 7pm on Sunday, we found the grinder completely full of santoprene from the handle overmold. It had not melted down yet but was on its way. The operator on our shift had put no runners in it yet because he was told that it was not working from the previous operator.

Mp#13- had a water leak and water got into the ejector valve cover causing it to short and malfunction. They had reported to Ronnie that it was running and the ejectors just quit working. We cleaned it out and they started working again. It stopped a few more times and I blew everything out with an air hose under there and set-up a fan for the rest of the night.

Robot on #4-Put new Keenserts in the Robot wrist to accept end of arm tooling. Holes were stripped out.

Mp#20- Butterfly bolts broke on ejector platen and eject forward switch was damaged. Replaced screws and switch, checked operation. O.k. to run.

Call if there are any questions.

Sean

" C " Shift

MP-17  PVC rusted the hopper;  It wasn’t sprayed with acid neutralizer.  I took it off & bead blasted it.

 

MP-21   Worked with Mark on the robot vacuum switch.

 

 We rounded up some more of the large metric wrenches & hung them up with the rest of the wrenches.

 

 The aluminum came in. We put the sheets in the rack & the plates for the fixtures are on our work table.

 

 I moved the hot stamp to our shop & will get started on it when Randy gets the nest to me.

 

 

 

 

 R. Upchurch

MP21 Robot

Robot on MP21, vacuum would not work.  Voltage was toggling on board but not out on the connector (V3V) for vacuum solenoid, solid red wire was broken in tray somewhere.  Spliced into another connector.  OK.

 

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

 

Week of July 12, 2010

MP4,  Zone 1 was running away, contactor stuck, replaced with new one.

 

MP15,  Replace small shock absorber on crosswise for sprue picker.  More are on order.

 

We received a spare pressure transducer for the Cincinati’s.  It is on shelves to the left in MRO.

 

Helped Gary change linear scale for the clamp on MP21.  The new scale is different and requires an inline transformer plugged in to the clamp board.

 

Ordered program change to include additional core sequence for MP25 from NIssei to EJECT before CORE pull.

 

Worked on MP21 inject side.  Back Screw position was stopping short of desired location.  Made adjustments to internal codes 32 and 33 to remedy.

I sent out procedure on previous log.

 

Talked with R Russell about Hoky wheel and hub press.  Ordered 2 hand tie down and pilot operated valve for new station.  Also ordered alum tabletop.

 

Working on setting up Vendor for Robot EOAT quick change plates.  I tested the orings on the dovetail slide and they held at 80psi.

 

Filled out PR for Rapid Grinder components destroyed by grinding hot runners.  It was rejected at this time due to lack of funds.

 

Ordered, received, installed new hooks and shackles for robot chain slings.  They are located in the bottom of the gray cabinet in the shop labled Large Hand Tools.

 

Ordered fittings and bolt kit for core valve install on MP23. 

 

Ordered and received Asco valves for Thermolators.  They are located in MRO on the RH shelves above the alum load system fittings.

 

Started replacing the adjustable stop screws with winged handles on MP23 Robot.  Some bolt hole patterns were to close for 2 handles.  I will check with HIro for some different stops.  More handles with longer bolts and metal handle are on order.

 

Any questions just give me a call,

 

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

 

MP21 Toshiba ISE250N Procedure to Make Screw Return to Full Back Position

MP21 (TOSHIBA ISE250N) Screw Back Position Correction

 

1)   With the power on, open the Main Control Cabinet Doors,

 

2)       On the inside of the LH door, locate a blue tuning pot, with the numbers 0-9,

it is extreme upper LH side of injection control board under a terminal strip, dial the

pot to the #1 position.

 

3)       Under the blue tuning pot, locate and depress, a push button labeled “3SW”.

 

4)       Now, over on the Data Cell Display, punch in code 32 and change the value to 1.0 or .5

Record the original value.

 

5)      Now punch in code 33 and change the value to 40.  Record the original value.

Make sure the value you enter are retained.

 

6)      Turn the tuning pot back to the “0” position.

 

7)  Depress the “3SW” push button.  You are finished.

 

Original Values on July 14, 2010 were Code 32 = 4.0 and Code 33 = 16.

 

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

 

7.12.10 D shift

Worked on liquid color pumps that were left on the cart in the shop. Repaired one of them.
One needs a new wheel for the color tube pump.
The other two are probably not worth repairing as they likely have been dropped really hard.
One of them had the tranformer knocked completely from the board.
The other has a short somewhere in the board and also has a bad shaft on the gear housing.
I red tagged them accordingly.

Also worked on water strainers and drained water from some of the water traps that you could see water standing in.

We had some trouble with EOAT on presses #22 and #4 but just parts coming loose.

Left at 4 a.m.

Call if there are any questions or anything I can do to help.

Sean

6.28.10 D shift

Put up the aluminum brackets on all of the presses that Bill Potter requested for the purge checklist sheet he wants to display.

Installed the new core standard on presses #9 and #10.

Replaced the ejector limit switch flag on press#7, it had broken. Made one from stronger materials.

Replaced the handle on the pilot fan tester, it was broken.

I will continue to watch the presses that are down and work from the "tracker"list.

Call if you need to.

Sean

6.24.10 D shift

Finished putting up the EOAT Boards.
Suggest that we put up some guidelines for the techs to see when hanging new tool arms etc., so it will remain organized.

Changed out the bottom core switch on #4 last night.

I think it had come out of adjustment, but the LED was not working.

When I installed the new switch, LED would not work on it either.

The input was reading on menu 41 though.

I checked the switch with my meter and it appears to be good so I will returtn it to MRO.

Installed new core standard plug on MP #3, also installed ejector back limit switch receptacle on junction box (in parallel) so it can be used either way.


Talked to everyone on the D shift and there are 3 guys who want to volunteer for any or all of the 3 work-days of shutdown. They are all mechanically inclined.

1 process tech- Johnny Stamps
1 moldsetter- Cameron Wilson
1 operator- Mike Sells

They understand that it is likely 8 hrs /dayshift ,if they can work. ?

I told them I would let them know by Monday or Tuesday so please get back to me by then.

Thanks

Sean

6.23.10 D shift

GR6- grinder, tore it completely apart and started reassembling it. I still have more plastic to clean out from the screen area (slow going), but it looks like I will only need to do some welding on the pan to complete the repair.

It was welded once before and had new bearings/seals installed last time. They appear to be holding up o.k. for now, so we won't need any new parts for it, unless just want to buy a new pan, etc?

Repalced the nozzle tip and T/C on #13.

Placed a note on the loader for 25. Someone had switch 1 on and 2 off, this was causing the loader to load constantly even though the sensor appeared to be working. I placed a label on it so they would know to use 2 with that sensor cable.

Left at 4:30a.m. puts me at around 40 hrs right now. Plan on working till 6a.m. on Thursday night.

Call if there are any questions.

Sean

6.22.10 B shift

Put up EOAT boards outside of molding office. Will continue the rest of it after I find some wood. I used what Facilities had in their locker area. I made a note on the "Tracker" spreadsheet about what wood I need but I may be able to scratch it up from around the pallet room or something.

Tightened up the filter clamps for the vacuum loader pumps. Looks like they had come out of adjustment.

I plan to tear down the peanut butter grinder Wednesday evening and should have an idea of what parts we will need to get it going again by Thursday morning.

Left at 12:30 a.m.- trying to keep hours down this week. I'll be in the next 2 nights and try to take off Fri-Sat-Sunday.

Call if there are any questions.

Shutdown Attachment

Sorry, I didn’t send attachment.  Here it is..

 

  Joshua Ledbetter

  Molding Maintenance Manager

  Manufacturing Engineer

  Oreck Manufacturing Company

  931-239-3235

 

Shutdown 2010

Attached is a calendar for shutdown this year.  Also, for anyone who does not already know, we are tracking issues, projects, and parts ordering here-  O:\Molding\MOLDINGSUPPORT\Oreck\Departments\Maintenance\Tracker.xls

 

  Joshua Ledbetter

  Molding Maintenance Manager

  Manufacturing Engineer

  Oreck Manufacturing Company

  931-239-3235