1.09.15 Pad Printer PLC Programs

Kent Pad Printers

The Melsec GX Developer software is installed on the Molding Laptop now. The cable drivers are installed and I have uploaded programs and saved them in the C:/ drive from several of the pad printers. Program, Parameter, and Device data are included by Model and pad printer # (i.e.pp3,etc.).

When the GX software comes up, under the Project tab, you will see a list of the available pad printer programs. There is also a software .pdf users manual in the O:/molding/equipment/pad printer file for reference. I will also add the notes I have on reading and writing to and from the PLC's once they are ready to simplify the process.

As far as the memory loss-battery back up issue, I am still researching the dilemma.

 Additionally, there could still be issues where some of the pad printers have already lost some of the settings. For example, I  have already found an issue with one of the KIPP 200's (PP4) as soon as I powered it up. Although it allowed me to upload and monitor the program, I am getting some kind of 30,000 cycle lube fault that will not leave the HMI screen and the plc itself is showing no faults or errors. It may be an issue with the HMI or otherwise, but I could not locate that specific operator manual to investigate it. Everything online that I found was related to the type that did not have the touch screen.

Lastly, we need to get some more male plugs for the pad printers and hot stamps. If we have them already, I could not find them....probably needs to be a stock item?

 

 

 

12.16.14- Night shift

Mp#0-

We worked with the robot program to get the parts without breaking the side tabs. Roy and I adjusted positions and played with speeds and timing until we had them running acceptably.

Mp#21-

The robot would not power up.
We initially thought the problem was related to an axis off switch condition but later found the drives were all showing error 3 - under voltage fault. Traced it back to the contactor which was apparently just stuck a little. I freed it and it began working fine.

Mp #4-

The mold setter requested four new small length hydraulic hoses so that we can get away from excessive wear from hoses rubbing on the machine because they are too long. I made 4 new 24" lines w/ fittings.
Also had trouble with the set signal on the cores for the mold they put in it.

Harpo work station-

I mounted items to the control cabinet. Put the PLC in and powered it up, downloaded the SOLEPLT1 program that I uploaded from the firstbstation. I also knocked out the holes for the E-stop panel and mounted the switches we had.

Have a great day!

12.4.14 - Night Shift Activities

Mp#28- Added the liquid color feeder signal to the machine. Checked operation, O.K. to run. Also drilled and tapped the hopper throat for the color tubing access.

Hopper #4 in Mezzanine- The suction valve cylinder was remaining open causing everything on that pump not to load. Checked the spring return on the cylinder and it was fine. Found the problem to be the exhaust port clogged with dust and oil debris. Cleaned and reinstalled the exhaust fitting and checked operation. No further problems.

Had another issue with the floor in front of molding. Ask me about it and I will tell you!

Call if you have any questions.

Have a great day!

12.3.14- Night Shift Activities

Mp#0-We got the robot set up to pull parts. Ran a few shots and realized the bottom core block was not releasing correctly. Found that the mold was missing the horn pins for the slide. They were broken and nowhere to be found. We pulled the front and tooling made some new ones. Then we started it up running on the robot at approximately 5 a.m.

Mp#24- The material loader suction motor wore out. I broke it down and found the brushes worn out and the commutator was so worn that entire motor replacement will be required. There wasnt one in stock so we need to order one asap unless there may be one at algood whse.?

MP#4- Nozzle band had bleed off.  Had to replace the tip band and thermocouple.

Also looked at the mitsubishi PLCs in the pad printers. They all have the Melsec plcs model FX1n.  We should use the GX-Programmer software or more current. Programming cables are about 25$.

12.1.14 Night Shift Activities

Wired the mold that Kenny and I discussed would need sequence valves installed for the required part eject logic. It will need to be connected to both Core 1 and 2. the cables are labeled respectively.

Mp#0- The tool had to be repaired and was not finished on our shift for us to be able to start it on the robot.

Mp#3-The tube extension tool was hung and I had been asked to wire the mold last week for the corlogix. Unfortunately, it cannot run in the Milacron machines using the switches because of the logic sequence it requires. It must run on timers because the ejectors must move forward before the cores are fully set so that the parts will remove from the cavities correctly. When the mold comes out again, I will need to remove the switch hardware.

Mp#19- The grinder would not start. Found a loose connection in the screen safety circuit.

Mp#1- Nozzle bled off and they lost the end nozzle heater band. Replaced it with a new one from MRO as the old one was not repairable.

Mp#23- Had an issue where the cores would not work because of an ejector back switch fault. The actual problem turned out to be due to a bad core pull switch on the upper cylinder. It was staying made which caused the machine to stop pulling it prematurely, which in turn, caused the ejectors to extend with the upper cylinder improperly located. This caused the pin behind the core to break and stick out slightly, not allowing the ejectors to make the back limit switch. The mold will be removed for repair and a new core switch installed at that time. Ronnie and I found a new Warner magnetic 2-wire prox in MRO.

Have a great day!

11.24.14-Night shift activities

Sepro with vacuum cups: http://youtu.be/VwYqEqSjl3I

11.6.14 Night shift activities

We had a scheduled power outage Thursday night and shut down at midnight.

Continued working on the Corlogix box #3.

Had an old service parts tool in #23 that needed the thermocouples rewired and labelled.

I put away the hydraulic fittings that came in. The hose crimp fittings are near the hose crimp machine.  The others are in the bins.

Roy and I reviewed and edited the robot program on press #0 for two parts but when we began to start it up we found the pins broken. The tool was pulled out for repairs and rehung but was not started up so no parts were run. The program will need to be checked out at start up.