MP05

The Core Problem on MP05 ended up being in the Output Card Plug itself.  J1 on the plug is the +24VDC for the first four outputs.  If you took the plug off and looked at it, the pins in the socket were broke on one side and bent back on the other.  Gary replaced the plug and so far it is OK.

 

Thanks

 

Joshua Ledbetter

Molding Maintenance Manager &

Manufacturing Engineer

Oreck Manufacturing Company

(C) 931-239-3235

(F) 931-646-7615

 

1.6.11 D-shift...Sean

Mp#5- had problems with cores again off/on all night (4 times).

I swapped out cards, solenoid coils, checked power supplies (except under load when problem occurs), ohmed out each contact on card 6's terminal strip back to common strip.

Checked the 235 contactor contacts and voltages (safety gate relay). The last thing I did to get it running again was to spray out from behind the backplane with dustoff.

Also checked for loose wires in the core switch boxes...although signals were present anyway.

When it malfunctions, it simply does not indicate on the board that it is outputting a signal. It is running now but thats where I was with it.

DR 23- The Milacron dryer was overtemp1 alarming. I went through the normal checklist and the only thing I noticed was that the cabinet fans were not working due to the faulty temp switch that controlled them. I jumpered the switch and it seemed to have fixed it.

Call if you have any questions. Good weekend to all!

Sean

Jan 6, 2011

Thursday, January 06, 2011,

 

Finished conveyor docking on IML automation cell.

 

Worked w/ Randy Russell on new Bag Dock Heat Staker station design.  Gathered materials for job.

 

Worked on materials for new Fan Housing Tester.

 

8 and skate today.

 

 

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

 

1.5.11- Dshift...Sean

Mp#5- Cores quit working again. I went through and rang everything out from the #57 common wire, through to the output card's terminal strip at A233. It ohmed out fine. I looked at the backplane with the card out and some of the prongs that hold the card in position may have been spread out more than the others so I used a pin to push them back and help grip the board better. Put it back together and they started working again.

I pretty much went over everything looking for a loose connection and really didn't find anything...so it made me ask if the output card had something getting hot and cutting out? Then after awhile, it was cooling down and working again? We'll see?

Mp#23- was giving an 32036 alarm involving the ejectors possibly "timing out too soon?"
we put some cycle start time on it and slowed down the ejectors and it seemed to have went away.

I sent a molding support workorder regarding sled skate strips coming out. FYI. Need to find a way to keep that brass under there...open for suggestions.

Worked on PM #9- press and robot.

Have a good day.

Sean

January 5, 2011

Wednesday, Jan 5, 2011

 

Put MP13 back together, broken butterfly bolts, had to extract one screw.  Knockout bars were different lengths.  I noticed that the butterfly plate has been welded on and the bolt heads have to be turned down to enter the counterbore, so I think we should order a new one.

 

Wired the conveyor up for the automation cell for IML, working on the docking locators for it.  Received the locate and shuttle tooling from Star.

 

Made a list of tooling that needs to be made for Josh on the new fan housing tester.  Need to order the rest of the purchased item tomorrow.

 

8 and skate today.

 

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

 

1.2.11 - D-shift Sean

Worked on PM's.

Robot and Press#5 tonight. The Y-axis lower pulley was bent and scraping the arm. I tried straightening it and using longer screws and nuts behind them. It didn't seem to help much so I added a right angle bracket to help brace it better.

It repair works... but... the drawback is that it shortened up the distance the Y-axis goes fully up by about 2cm. I had to adjust the Y-home switch for the repair also. It does clear the tiebars and door when traveling out the beam though.

Now we are getting ready to run it. Also used a hand grinder to clean the drag marks and burrs from the Y-arm.

Other than that, worked on regular start up stuff, nothing major.

Call if there are any questions. Have a nice day!

Sean

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