Ronnie Upchurch

                         11/01/10

 

MP-13  Blow back – tightened down sled & replaced 2 nozz. bands.

 

MP-15 Solid state relay on nozz. heaters was staying energized – rebooted press & is working fine.

 

MP-9  Need to look at building new eoat for handle mold. The small cups don’t hold good on textured parts.

 

Brought grinder in from trailer. The repair parts came in.

 

                        11/02/10

 

MP-14  The timer relay on the thermolator went out. Replaced & Mark ordered more.

 

MP-11  Mold hanger broke a switch & a fitting on the core cylinder .  Mold # 75033.  Mark repaired.

 

MP-3  The Z axis contactor went out. Mark installed a new contactor & overload.

 

MP-21  A water pipe broke in the stripper plate – fan mold. Tooling  removed the broken threads.

 

MP-5  The wheel press staying down after pressing the wheels in.  Someone had turned the pressure up too high & the over stroke switch was making.

          Readjusted to 100 psi.

11.2.10 D shift Sean

Mp#2- had some problems with the core pull switch not reading. I went through it several times and it will read for awhile then quit again. We put it on timers til it comes out again.

MP#5- the base plate press needs a block to support the spring, and another spring detangler made up so they can run them both. Not urgent at this time.

MP#4- had to modify the gate cutter fixture to accomodate the change to the runner location on the tool. Works fine now.

MP#10- Nut Press. Cleaned out the vibratory bowl, tracks, and rails. Stoned the scratches out as good as I could. Noticed that the upper metal rails are magnetized and caused my screwdriver to become magnetized as well. I think an option to help prevent them from hanging up so bad would be to created new upper rails from a different material such as aluminum or plastic?

Helped the technicians and mold setter, set-up the mold and robot on #1,(at their request). They were not sure how to hook up the core hydraulic unit, etc. and we got the robot programmed in and going good. Also showed them how to save programs in all of the star robots again.

Mp#9- Robot is stopping intermittently above the conveyor, either going up or down. I slowed down the speeds and it seemed to reduce the frequency. I tried to watch it as much as I could but got called away. The vacuum switch is adjusted correctly so it is not that. I watched the brake modules and they were working correctly when it stopped once. I think it is probably a loose connection, but they did not want to shut it down completely for me to look at it.?

Went over the access receivers in the mezzanine. Several had loose screws and were loosing suction, etc. In general I looked around for anything else that might need repaired, etc.

Call if you have any questions.

Sean

Ronnie Upchurch

                 10/27/10

 

MP-12   Blow back -  the mold wasn’t centered in the check ring. I replaced one nozz. adapter  heater band.

 

MP-17 Cleaned up oil.

 

                10/28/10

 

MP-10  Cleaned oil from nut feeder. I gave them some alcohol & a bucket to clean nuts. Mark emailed engineering so they can contact vender.

 

D-32  Alarm  11  -   The turntable switch was out of adjustment.

 

MP-6   They changed to polycarb on the base plate. Mark turned the pressure up on the wheel press.

 

MP- 25 Set up chute for hokey handle water cooling tank.

 

10.28.10 D shift Sean

The robot on #6 has been dropping the parts into the grinder off/on all night. The cause is that the press will often mold baseplates with too much flash on the runner. This causes the gate cutters not to completely cut through the gate. This in turn causes the runner gripper to hold onto everything until it drops all of it into the grinder. FYI- ?

Replaced the regen heaters and the regen blower on DR#5. It is in the shop looped out until the cans have cycled enough to run on the floor.

Mostly had problems related to people not understanding how things operate correctly.

Did PM on 21, press and robot.

Also, the water bath operation for the Hokey handle was requiring them to hand dry each part with an air blow-off tool. I put up a cart with a wire frame basket and a fan blowing down on it so they could spread them out and most of the water could dry off before they got to the drying stage. We may want to look at that operation again for improvements?

I will probably come in sometime this weekend to discuss PM's with Mike. Likely on Sunday night early.

Call if you need something. have a good weekend.

Sean

10.27.10 D shift Sean

The Square nut press on #10 has problems with sticking due to the unusually oily nuts. I cleaned the entire vibrator bowl out and wiped out the slide tracks, but, until the nuts are degreased better, they will continue to get stuck.

I asked Darryl to speak with Wayne McConnel about looking into this oil issue with the vendors possibly? I do not remember having this problem when this began, do you?

Darryl said they had always been that way and there was nothing he could do, it would cost Oreck more forthe supplier to degrease them.?

Anyway, there it is.

Mark and I arrived at a PM program draft proposal which should be implemented soon for our team.

Other than that I continued with PM's.

The Robot riser has been painted and should be dry.

Call if I can help in any way!

Sean

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.