Ronnie Upchurch

              10/22/10

 

MP-16   Installed a flow control valve on the eject. retract line.

 

MP-21  They changed the nozzle tip from a button tip to a  2”.  I installed a tip heater band and replaced the adapter band that was burned out.

 

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

 

MP-4  At 5pm the tech told me the robot crashed. I checked & the “Y” axis had extended to the mold & hit the stationary side. It broke the “C” air

          cylinder, two vacuum fittings, & bent two suction cup brackets. I removed the eoat & cylinder & turned it over to Sean Man.

 

              10/23/10

 

MP-9  The “Z” axis set point was drifting. I checked the encoder – everything was tight. I tightened the “Z” axis belt & rebooted the robot. It looks

          consistent now.

 

MP-22  The hotstamp heats kept going off. I checked all the heater connections. I reseated the T.C. plug on the board. It’s running & hasn’t cut off

            in four hours.

 

MP-11  The PS-2 pressure switch on the injection unit quit working. I replaced it.

10.22.10 D-shift Sean

Mp#4 Robot- repaired the C-axis wrist cylinder. The threads had snapped on the cylinder shaft when it crashed on Friday. Drilled out the end of the shaft and tapped it for set screw. Reassembled and tested operations. Replaced 2 broken fittings on the vacuum cups. It will run for now until we can get a replacement cylinder on order within the next few days.

Mp#9 Robot- The Y-axis was not homing in the same place and eventually would not home, although it was still referencing. Found the Y-home switch "flag" had loosened and slipped down. It took several attempts to locate it correectly until it would operate correctly. Also inspected the encoder, bolts, and belts while up there.


Had another water leak on MP#1- broke some of the same water lines on the fan mold (same reason as before on 21).

Luckily there was not any water spray to cause damage to the robot or injection molding machine.!

Call if there are any questions. I will not be in tonight for PTO time. Have a great day!

Sean

Week of October 18, 2010

Made program changes to the PLC and Quickpanel on MP5 Robot for an I/O Monitoring Screen.  The new screen can be accessed from the main menu.  Please try to check it out and use it as much as possible, we need to see if everything works correctly and if we want any more changes.  If you have any questions or suggestions please let me know. 

 

Picked up an inline, directional control valve for the eject retract on MP16 to slow down breakage of butterfly bolts.  Ronnie installed and set it to smooth out the banging on the retract.

 

We received the replacement seals for the Novatec Proportional Valves.  They are in MRO.

 

Small ice cube relays were ordered for the AEC Robot control cabinets, RB, RYS, and RZS.

 

The new butterfly plate, guide rod, and knockout rods for MP20 were finished and Gary installed.

 

Helped Mitch set the welder outputs in MP12.

 

Tightened and realigned clamp cylinder on MP10 connector welder.

 

Ordered the steel for Robot Riser spacers.  Josh got the prints for the machine mounts.  The steel should be here this Saturday.  We can start making them next week.

 

Started working on In Mold Labeling Project

 

Changed out more of the 3 pin color pumps connectors to 2 pin.

 

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    931.646.7615

 

10-18-2010,

Good Morning Gents,

 

Lots of little stuff last night like plug it up turn it on.

Had issue with mp5 the cores not always working reseat I/O boards and they seemed to work for a sort while. Finally found a very loose wire on board in #6 slot in control rack.

 Hasn’t missed a lick since.       

 

Not really anything else major to speak of.

 

Have Great Day

Mike

10.19.10- D shift

Mp#9- Robot kept stopping, It was stopping over the conveyor every time. I noticed the speeds on the axis were all maxed out. I slowed them down to around 9800 each and it did not stop anymore afterwards.

Mp#10- Robot did not stop any at all tonight. Good Job guys!
Vacuumed oil out from under 10 also.

Mp#2- replaced nozzle heater band and fuse from bleedoff. Had to burn out the sprue plastic with oxy/acetylene torch.

Mp#16, Mp#19- PM'd.

Mp#8- Fan Housing press had problems with the nut press die magnet/ locating pin getting stuck inside the recess orifice. Took the one off the spare press and replaced it.

Left the damaged one in the shop for Gary or Mike to make a new one by...maybe?

Call if there are any questions.

Have a great day!

Sean

10.14.10 D shift-Sean

Mp#11- Sled would not go back. removed the V26 solenoid valve assy. and cleaned out the check valve and orifices with solvent and air nozzle. It appeared to be clogged and dirty. Reassembled, checked operation, O.K. to run.
Also refilled with about 20 gallons of Rando 46 hydraulic fluid.

Mp#23- Nozzle was not heating (according to the tech). Found band clamp broken and the other one missing. He still wanted to change the band out anyway, so we did.

The ink pad printer nest assy appears to be loose but all the screws are tight on it. Mostly looks like slop in the xy table, except too much ? I also could not locate the manuals for it. The last time I knew where they were was inside the pad printer. Now no idea? I was going to see what kind of pm inspection it needed?

Call if there are any questions, have a great weekend.

Sean

10.14.10 D shift

Mp#15- Zone 1 overtemp.

Found the problem to be an incorrect thermocouple type. It had a "j" type and it should have been a "k" type.

There were 2 more J type in the MRO location where the K's were supposed to be and I almost made the same mistake that someone else had made, of putting one on. Instead I used a nozzle band K type and put it under the band on the first zone.

It is running good and staying exactly on temperature now.

Fixed the leak on MP#2.

Refilled 17 with oil and cleaned up the oil dry.

Checked out the milacron dryer DR17 and it is fine.

Checked out DR2, looped it out for a few hours and checked the beds, it is fine too.

Sent an email to one metal supplier to see if they can get us some brass peices for the sled shims the right dimensions that I measured tonight.

Be back at 2pm today.

Don't call, I won't answer....lol.

Sean

thermocouple calibrator

This is the lowest priced calibrator I found on the web at $195.00

http://www.omega.com/pptst/CL3512A.html

Omega's are a good brand and this tool will allow us to read the output from a thermocouple or send a signal to a temperature controller for comparison or tuning.

With as much machinery we use with temperature related controls, this tool is a must for any professional maintenance department such as Oreck's.

Check it out!

10.10.10 D shift weekend Sean

Mp#1- was making a squeaking sound when the screw was almost complete with building a shot. I greased the extruder bearing assembly but that did not appear to be the source of the sound. Then I actually put a little grease on the screw itself at the back of where it entered the barrel and it seamed to help. It did not run long enough to know for sure though and likely needs to be inspected further when it starts back up.





Mp#3- Had an E00240 error. Had to reboot from the boot card. Then we had to reload a set-up in it. Ran good the rest of the day.



Mp#5-had leaks from where someone just left a hose dragging beside the clamp.



Mp#2- Has a leak on the core/ejector hose valve block we installed for the steamer molds. When it goes down we can re-do it. Put it on a shared tasks outlook item.



DR#6- Finished what Ronnie was working on and replaced the desiccant in all of the canisters. Checked it out with the Dew point meter @-40. Tagged it and located it in the mezz room.



We have been seeing quite a few dryer issues lately. I followed the email suggestions for testing the touch pad on that Cincinnati dryer/hopper and it appeared that the display board is likely defective as jumpering the touch pad pins gave no response.



Checked out several DME cards, replaced fuses and tested them on a mold. They all worked fine. Tagged them and put them back out on the shelf.



Worked on PM's all weekend. Finding many issues with loose components on the loading system. Also finding robot Y-axis are getting loosened. Tightening them up, and other wrist components are getting loose.



One issue that we need to start getting into is the sled shims on these Nissei machines. Many are working out from under the sleds. I think we can get some brass the full length of the guides and secure it with screws? The problem is that we will have to schedule them down and figure out how to get them elevated enough to install them. Shouldn't be too much of a problem. I will measure all of them that need repaired now and come up with a parts list on Thursday morning.



Since Ronnie is going to be out on the

Ronnie Upchurch

I emptied all the overflow jugs on the presses, cleaned up the oil on MP-17, & vacuumed the pan on MP-6.

 

MP-4   I made an eoat for the rear steemer handle mold & installed it.

           Somebody left the air poppet fittings out of the mold. We found them in tooling & installed them.

       

 

D-6  ran in the maint. shop for nearly 24 hrs. & the beds never did dry. I started pulling the desiccant cans to change them out.

Ronnie Upchurch

 10/8/10

 

MP-16  The touch pad on the Milacron dryer wasn’t working. I called & requested a quote from Uni-Dyn.

 

MP-11  The core pull hydraulic hose came loose at the threads behind the quick-connect. It was never tightened. I cleaned up an oil pond around the press.It ran all night

     & nobody saw it leaking.

 

Dryer- D-7 on the mezzanine had a bad regin. contactor. Replaced

 

 

10/9/10

 

Mezzanine -  I played musical dryers all day to get one that worked.  I pulled D-6 off station 2  & took it to the shop. I replaced it with D-32 from floor. I looped out

      D-7 on station 4, to try & dry the beds. I also loop out D-6 in the shop to see if it would dry out. After several hours, D-7 came down to – 40, so I put it on station 2.

      D-32 wasn’t drying, so I looped it out.  D-32 & D-6 , after  6 to 8 hours, the dewpoint is finally starting to drop somewhat.

 

MP-3 Installed core plug on the steemer handle mold.

 

MP-1 Die height alarm- The position had to be moved manually before the auto die height function would work.It was too close to the end of the threads to lock in.

         After that, it was getting an eject alarm----- I found the knock-outs weren’t tied in. OK  now.

 

MP-3  Robot was alarming out – not seeing eject. forward.  Found the multi-eject. on the special option page was not turned on. OK now.

 

Ronnie Upchurch

MP-23  I worked with Mark M. setting up the new eoat for the 2 cav. fan  mold 74022.

 

MP- 6  The mold wouldn’t close. I checked all the limit switches & found the operator side gate switch wasn’t making. I adjusted the jam-

      bar  flag.

 

MP- 1  It was getting a lube alarm. Josh reset the manual lube count to the maximum setting.

 

Two molds fell off the pallet while being transported.  We got them stood up & checked them out for damage. Mold 76003 cav.1 had a broke strap bolt.

       76003 cav. 2 had a pinched wire & cracked mounting brackets on the heater junction box. All is repaired except the box. We can fix it when they

       Finish the run on MP-6.

 

MP-17 Cleaned up oil .

 

MP- 6  Vacuumed out oil pan. Oil vac. is still behind the press.

10.5.10 Sean D-shift

Mp#5- Put the EOAT w/gate cutter back on and set values into the controller from the set-up sheet. Should be ready to start up.

Re-did some hydraulic core 2 fittings that were leaking and had been red tagged for repair. No further leaking.

Mp#3- Put the new EOAT w/gate cutter on and set it in as close as possible w/out running parts. I dry cycled it several times to check operation and get it timed close. May need to adjust the clamp position and ejectors, or the Y-axis up or down.

CAUTION!- The cutters are very SHARP. I bumped into them and punctured by hand!

Set the dryer temp correctly on the stainless cincinatti dryer on the mezzanine. It went down for wet material mid-shift, and after looking at it, it had been set to 32 F..?
Set it at 180 and it has been running fine.

Call if you have any questions. Be back Friday.

Josh-I submitted the rest of my PTO for the year, on your desk.

Thanks,

Sean

9.30.10 Sean

Mp#2- Smashed core wires twice. They have been tied up as neatly as possible to prevent further problems.

Got called into the assembly area to assist with helping the girl get the programming software working for the stepper drivers in the lab. ?

Mp#1- baseplate press stopped operating. Found sensor loose on the shuttle forward position.

Mp#21- while doing the PM I found the press had no control power. Looking further, it seems that the power from the disconnect on the bus was 100 volts short on the brown leg?
Mark and Gary are investigating that further now.

Have a portable hopper loader receptacle that is broken, may need to either order a replacement receptacle or rewire with something else on both ends.

Worked on PM's the rest of the time in between activities.

Call if there are any questions. have a great weekend.

Sean

9.29.10 Sean

Mp#5- They had a problem with the cores not working at all.
I went through replacing hoses and checking with the test cylinder and still was not working. Put gages on and had pressure at valve, but not at cylinders.
They would work when i probed valve m,anually.
Then I checked voltages at coils and had none on the set side.
At this point neither core 1 or core 2 were working but I was focusing on #1 for now.
Then I noticed that the output menu 41 slot 6 would energize 2 outputs when trying core 1, but the card was only lighting up the led for pressure and not the set output.
I tried swapping the card and then both sets of cores started working.
I suspected that there was a problem with the output card that I had moved to slot 8 so I left it down until we could find another one.
Ronnie mentioned that they had worked on it today but was not real sure what was done to get it going again.
I would like to know what you found?

Also had the problem with the Chilled water supply being dirty, in which I discovered, after speaking with Ronnie colson, that there is no filtration on the Chilled water system.? I temporarily bypassed the pressure switches on the Thermolators pumping chilled water until the problem is resolved and we have taken the corrective actions.

Call if there are any questions. Enjoy your evening!

Sean.

Ronnie Upchurch

MP-15  Oil leak.  I am ordering a new pump seal for this one.

 

We were having problems with thermolators cutting off on MP-2 & 3. ( chiller supply )  The flow & temp looked OK.  In tooling the EDM was over heating.

     they bled the line & got quite a bit of air & rusty water out. After that, the thermolators straightened out. There must have been an air lock.

     Ronnie Coleson was notified.

 

I installed the new overload on MP-5. They will hang the base plate back in.

 

If the hydraulic oil doesn’t come in today, I’ll call them in the morning.   

Mike Daniels-B Shift

Good morning Gents,

 

Typical night in molding no major problems. Mp2 has a issue with the core switches, the i/o page shows they are set when they are and pulled when they are but when put in cycle clamp moves about 6in. then stops and reads core 1 not pulled when it is. We ran it on timers  with no problems.

Repaired 3 more trollies

Replaced prox switch on fixture on mp10

Replaced blown nozzle heat fuse on mp2

 

Have a great day

Gone Fishin

 Mike

Sept 28, 2010

MP5 keeps tripping overload on pump.  A complete contactor and overload should be here Wed. UPS Red.

They moved the baseplate mold to #1.

 

Lexan sheets came in today.  Been trying to replace broken panels in trolleys as I can, if you pick up where I left off, measure each one individually as there are slight differences between them.

 

 

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    931.646.7615

 

9.26.10 D-shift Weekend

Stripped equipment Friday. Reassembled the grinder on Saturday.
Worked on PM's Sunday. Turned in some work orders for some of the issues we had.
There was a problem with #4 that had to do with frayed core wire and a blown fuse.
We cleaned out all the water strainers on all the presses this morning.
I have noticed that the moisture in the air system seems to have been resolved.

I will be coming in on Wednesday at 10a.m. for Forklift refresher training. Afterwards I will see whats going on with our PM program. call if there are any questions.

Have a great day!

Sean

Ronnie Upchurch

One of the bucket tumblers quit working. I just had to tighten the belt. I asked Elaine to order two more motors for the two spare tumblers. I put them

       in the trailer for now.

 

MP-7  The bolts vibrated loose & the deflector fell in the grinder. I cleaned it out & restarted it. It still needs a new deflector.

 

MP-2  I hooked up the cores to the eject circuit for them. Also replaced a broken core switch on the stationary side. One of the mold heater plug pins was pushed in

        & not making contact; repaired.

 

MP-6  The clamp wouldn’t close. I tried probing the valve, no luck. When I opened the cabinet to check the input & restarted the pump, it started working.

 

I worked on stripping & scrapping equipment in shop. I cleaned out the cabinet in the bone yard.

 

I finished up on the grinder that Sean put back together. We put it back in service Sunday.

 

Cleaned up oil on 17 & 21.

 

I put the gaylord of spare parts in the trailer.