10.21.14 Night Shift Activities

Wired the Mold in #2 with our regular 6 pin connector configuration.

Installed the service call light on Mp#0. It works good, but the mold setter has some concerns that it may too high to get the crane pendant around when he is moving tools around.? I told him I can come back and shorten it if it looks necessary.

Mp#4- Had some issues with a control fuse fail alarm. Found that the tool that went in had a jumper in the 6 pin core plug connector that was causing a direct short. I removed it and replaced the fuse.

Mp#27/28- checked the gender on the cores, changed fittings on #28, and color coded them. They are O.K. to run.

Mp#0-Grinder blew 2 FRS-R-30 amp fuses. I replaced them, and cleared the blades.
also-The pin broke in that tank mold again and the techs wanted to change the robot program to run Vac 2 only so we edited the program and removed all of the related Part Grip 1 instructions in it.

Have a great day!

List of Molding Items and Projects Ongoing - (sent to our maintenance group only)

Sorry this is long-part of trying to organize to stay on task.

Conveyor Belts

• The gearbox is leaking and needs replaced. They run around $350 for new ones. We can get them from many places online such as PLC Center or Grainger, etc. We may have a spare somewhere, but I looked in MRO and did not locate one.
• The model is a Boston gearbox Cat No.F715-50T-B5-G, INPUT HP:.270, Ratio 50, OUTPUT TORQUE: 351.
• The conveyor belt itself needs replaced on Mp#12, it has a major tear/cut in it. We should be able to make one in-house.

 

 

Mp#9

• The aluminum hopper access safety ladder is located in the bunker and still needs to be installed. We should have some pieces of aluminum rail in the shop to facilitate that install, although the holes may have to be relocated to account for the taller machine size.

Mp#5

• The hydraulic hose on the upper traverse cylinder needs replaced. It is blistered and likely to fail soon. I think Kenny is already checking on a replacement.
• The liquid color signal cable also needs rerouted or replaced and mounted within an electrical box.

Mp#4

• The conduit going to the heater band wire terminal box is damaged and the section needs replaced, or repaired with a conduit body. I recommend replacing it completely.

Leaks

Mp#14- small leak under clamp valve stack, needs O-rings replaced.
Mp#27- small leak under clamp valve stack, needs O-rings replaced.
Mp#21- small leak under clamp valve stack, needs O-rings replaced.

 Door Glass Replacement

Mp#4- Rear door glass needs replaced.
Mp#7- Rear door glass needs replaced.
Mp#10- Front door glass is cracked.
Mp#13-Rear door glass needs replaced.
Mp#21-Rear door glass needs replaced.

E-Stop Pushbutton Padlock attachment project

The following machines remain to be modified: 6,7,9,13,14,18,20,21,27,and 28. (10)
This will require that we order 10 Allen Bradley 800T-FX6D4 E-stop switches with 2 contact blocks each (20 total).
 This will also require 5 more of the 800T-N314 Pushbutton padlocking attachments to complete this job and permit us to lockout the E-stop pushbutton devices at the operator stations.

Service call Lights

Mp#0 and #1 are the only two lights remaining to be installed. They will be remotely installed so that operators can have quick access to them from the injection unit end. The lights, cable, conduit, and boxes are in the shop and these will be installed during times when they are not in production.

Core Standardization within Molding

Getting the Machines standardized against the molds has been a challenge during this transition. With exception to Mp#0 and Mp#1- I think we have all decided to standardize all of the other presses to use the quick disconnect fittings that we stock in the MRO crib.

 

 

The idea follows the gender rule that if something is flowing out of it-then it should be a male fitting.
Likewise- if flow is moving into it- then it should be female.

Standard being:
Male for the SET side = Green Color Code
Female for the Pull side = Red Color Code

This color code applies to both Machines and Molds which, upon completion, will better expedite mold changes and avoid unnecessary delays of adapting hydraulic fittings.

*Additionally, if the connection does not work correctly, this should eliminate concerns of the machine being the problem and assist in locating the real underlying issue on the mold.

At this time, the following presses remain to be changed over, color coded, and checked for correct operation: 6,7,9,18,20,21,27,and 28. It also would not hurt to check the others and re-freshen with spray paint colors.

*Some other considerations that have not been determined yet are for the standardization of the air gate valve lines, the hydraulic gate valve lines, and/or air core/poppets. I would suggest that since many have blue and orange lines already in place, that we come up with something around those colors.? Any thoughts?

CORLOGIX

"What is Corlogix?" ...it is a made up name to call a Core Signal Logic Box. It's also the PLC program name.
The Corlogix boxes were/are being constructed to accommodate the problem with voltage drop across the multi-voltage sensors that were run on 110VAC in El Paso on the Van Dorn machines.
The Corlogix box uses the PLC to signal condition the 110VAC into a 24VDC signal that Milacron and our other machines use as core input signals.

Because of the fact that TTI already has so many of these sensors in use on their molds, it was determined that it was not cost effective, or even practical to convert every mold to a mechanical limit type switch. The Corlogix approach was a workable-cost savings approach that has been proven to work at other injection molding shops.

Additionally, it was decided that we would continue to use the already present 12 pin Trylok connectors currently on the TTI Molds when they arrived. For two reasons- we needed additional pins in the plugs for inputs, and we had many of them.

What is important to understand about the Corlogix project is:

• Molds wired for Corlogix cannot be hung in MP#0 or MP#1 at all. Those tools must stay in their original configuration-as they were from El Paso.
• 110VAC -IS APPLIED- to the sensors in/on the mold, so damaged cables must be handled with care and repaired immediately.
•  24 Volts DC is connected to the IMM at normal connection points.
• If the ejector back switch is used, it must be connected to Cable #1 on the Corlogix box, and turned on.
• The "Code" on each mold should be determined when the tool is wired. this sets up the logic within the PLC as to monitor specific PLC inputs (i.e. 2 switches, 4 switches in series, one switch on each side, etc..)
• Molds that do not employ these AC sensors should simply be converted to our regular 6 pin configuration.
• I will be updating all of the Corlogix notes, files, tables, schematics, and diagrams to the equipment list under the cores section soon for reference.

 I still have more work in finessing the two boxes in use at this time, getting all of the lights working correctly, and constructing two more units. So any suggestions or help on them is welcome.

Have a great day!

Dryer Situation

The dryer I worked on last night turned out to have had a bed heater contactor that had welded closed across the contacts. This caused the heaters to remain in an energized state indefinitely. ..which ultimately led to the meltdown condition.

Welded contacts are a typical problem for contactors that resistive loads with dry contacts.

Additionally, the dryer was designed without fuse protection in the heater circuit.

The manufacturer designed this particular dryer model to rely on only control monitoring parameters to avoid this problem (setting over-temperature limits, etc.) Which we will ensure are set correctly once repairs are complete.

As it stands, the majority of damage was done to the hoses, dessicant,  and some insulation.