12.29.10 - D shift - Sean

Worked with Mike Daniels on PM's all night.

Nothing Major happening worth mentioning.

Hope next year goes as smoothly as tonight did!

Call if you need bailed out of jail! Happy new year team!

Sean

12.27.10 - D shift Sean

Mp#5- Cores not working...found loose terminal strip on Output card 6

MP#21- Bleedoff at Nozzle. Took out 3 heaterbands and thermocouple. Looked like the sled forward switch had worked loose causing the problem. Had no more trouble after we started it back up.

Mp #2- Zone 3 had a bad band. Replaced it. Replaced the fuses and checked operation...O.K. to run.

Continued with PM's. Worked on #10 press and robot tonight.

Call if you have any questions. Have a successful day!

Sean

12.19.10 D shift Sean

Mp#8- Replaced the ejector hydraulic hoses. They had been red tagged since 2008, so i replaced them and checked operation.

Continued working on PM's.

Need to order some cabinet fans again in 120VAC.

Have a great day!

Sean

12.18.10 D shift - Sean

Continued with PM's...Presses and robots #2 and #4 tonight.

Had an issue with #23 ejector encoder was not reading right after they set a mold in it.

I changed the offset on the VRE encoder offset and it started working correctly. I did check to see if anything was loose on the encoder first but it appeared tight.

Sean

Ronnie Upchurch

                   12/08/10

 

Worked on fascia hot stamp.

 

MP-13  Pulled barrel cover & cleaned off blow back – ¾ down the barrel. I was able to save heater band wiring & the covers , with some minor body work.

 

MP-19 The DME t.c. was reading low , but the mold heater was running away. I found that the t,c, wire had been pinched behind the mold clamp. Replaced.

 

 

                   12/09/10

 

MP-13  Pulled  the Conair heater to get the part #. There were two possible numbers for that model.  I ordered replacements .  There are only two heaters

       Per zone – 240 v.

 

MP-10   We cleaned out the nut feeder , Again , & cleaned a box of nuts. Mark adjusted the tracks.

 

MP-26  The center knock-out mounting stud on the eject. plate fell off.  Reinstalled.

 

I ordered a new adjustment screw & nut for MP-24 spacer adjustment.

 

I sent the top cover drill out for repair.

 

I ordered a new replacement motor for the small Solo grinder.

MP05 Robot

MP05 Robot has been stopping the last week or so randomly with a “Mold is not open- Robot in Unsafe Position error”. 

ANYTIME you get this error it means that the mold is not at it’s Open Limit and also the robot is not on either the Y-Up safety switch or Z-Out Safety Switch.

The Power Supply was low and what was happening was the 20 VDC that made it back to the coil on RYS or RZS would allow it to drop out one or both of them every now and again.

 

Mark adjusted the PS up to around 26VDC and fixed the problem.

 

Thanks

 

Joshua Ledbetter

Molding Maintenance Manager &

Manufacturing Engineer

Oreck Manufacturing Company

(C) 931-239-3235

(F) 931-646-7615

 

12.5.10- Dshift Sean

Mp#24- Made a new "bushing replacement part". Checked operation, O.K. to run.

Worked on PM's.

Replaced damed plugs on #10 connector mold from where it had been damaged before.

Made some adjustments to the nut press so nuts would slide down correctly.

Started making another component for the fan mold in #25, to grip instead of using the vacuum cup. (Requested by Darryl B.)

Call if you have any questions.

If you are reading this it is because I did post a blog...reciprocate the info!

Knowledge is power! Share the wealth!

Thanks,

Sean

Ronnie Upchurch

            12/03/10

 

MP-25   Replaced a broken air quick connect fitting on robot eoat.

 

MP-10   Added hydraulic fluid.

 

I helped Josh & Mark get old press 13 moved out.

 

I replaced the pneumatic drill on the top cover fixture. I will send the broken one out for repair.

 

            12/04/10

 

Moved the home sensor block over some for the single cavity connector mold.

 

Worked on the degate & lable fixture in shop.

 

MP-5   The tech said that core 2 on the top cover mold wasn’t pulling. I found the bottom core not hooked in to the cylinder.

 

            12/05/10

 

MP-22   PMed  the robot.

 

I  mounted  the motor on the polisher  test fixture table.  It’s the one they test the brush pans on.

 

Cleaned up some in shop.

11.29.10- D shift Sean

PM'd- MP#25 machine and robot.

Dryer DR#6 on mezzanine alarm for Regen Overload. reset OL's and had no further problems with it.

Hope everyone had a great Holiday. Call if there are any questions.

Sean

11.11.10 D-shift Sean

Mp#7- Robot PM. Had to use 2 of the spare air lines on the Y-axis arm, they were leaking. Inspected it thoroughly, cleaned and lubed. Ready to go.

Continued training on the robots with the techs on this shift.

I will continue touching up the presses with a little paint as they are down. I just need some roller pads and a roller handle if somebody happens to go to Lowes any this week or next.

Also, it should be noted that yesterday, before I left, Darryl had asked me to help him repair #24. Apparently they had tried to put two full width spacers on the clamp and it had worked loose and possibly damaged the threads? He got it started and reassembled, but thetre may still be some damage and further problems when the spacer needs to be changed out again. FYI.
The mold setter on D shift knows more about it.

Call if there are any questions.

Sean

11.10.10 D-shift Sean

Made a drive roller shaft for the small conveyor. Installed it and reassembled the conveyor and checked operation. O.K. to run, located it in the auxilliary equipment area.

Also moved the Milacron dryer to auxilliary equipment area as well. It ran most of the night without incident.

Mp#23- Darryl said that Bill and his techs were able to run the 2-cavity fan with the conveyor turned out away from the press and unload the parts 4 across the belt.? He asked me to set it up to do that but I was not able to make the crosswise move during Pack 1 or Pack 2. When I changed the modes, it changed on both Packs. Any idea how they did this? I would like to know.

Continued working on Pm's.

Painted the angle iron brackets Yellow with spray paint. It is a light coat but all I could find.
There was some driveway marking paint that was very flat and I didn't think it was a good idea to use that.

What was the story with 17? I heard it went down for maintenance? That we are shopping for a replacement?

Call if there are any questions! Have a great day!

Sean

Ronnie Upchurch

   MP-5  Replaced the nozzle heater band & fuse. The wire broke off & shorted out.

 

  MP-17  Cleaned up – changed out pads- emptied jug.

 

  Sean fabricated a motor-mount belt tension bracket & a safety switch block. I tapped out the 10 mm holes & mounted the bracket & block. I also installed the blades.

          We still need the key for the safety switch & knobs for the block handles. I sent Mark the part numbers.

 

 

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