Today my coworker and I worked on the stuff related to RGV (rail guided vehicle). Since the chiller, and the reservoir hadn't arrived yet.
First, we needed to install the cages on the buffer stations, then we had to install the cages outside the RGV. We had to mix and match different sizes of cages in order for them to fit in between the machines. Next, we set the anchors down for the buffer stations, and the only thing they needed was to have the maintenance guys to drill holes to secure them down.
Also, the machine was ready for air, but we wouldn't be able to use it until we got the chiller. It seems like the chiller was the bottleneck of our installation.
Tuesday, November 8, 2011
Monday, November 7, 2011
Teledyne Day 6
Woke up 5:30AM to catch the 8:30AM flight to Mobile, Alabama today. By the time I got to the customer site it was already 3:00PM. This week I got to work with a different person from the company.
The machine finally had power, however, the chiller was not here yet, we decided not to turn the power on because we would have to jump all kinds of stuff (coolant tank, chiller, matrix magazine, and etc). It seemed like the stuff we needed to install hasn't arrived yet, and we tried our best to do whatever we can. We secured the toe clamps and the anchors down of the machine.
Friday, November 4, 2011
Teledyne Day 5
We arrived at the customer site 7AM just like any other day, yet the buffer stations hadn't arrived yet, and we were informed by the customer that the buffer stations would arrive around noon. In the mean while, we thought we had nothing to do again this morning. My co-worker was looking through all the installation parts, but he could not find the chiller and the reservoir for the coolant. We even asked the customer to double check the storage room of all the cargoes, but there weren't any chiller nor reservoir.
Later on, after we made a couple of phone calls back to the office. We found out that Japan had made a mistaken when they shipped the chiller and the reservoir. Apparently, those stuffs were with the magazine (Not the matrix magazine), and it was located in a storage in California.
Now we feared that even if we got the power for the machine on Monday, we wouldn't dare to operate it without either the chiller or the reservoir installed.
Finally it's Friday and I am glad that I get to fly back to Chicago today.
Later on, after we made a couple of phone calls back to the office. We found out that Japan had made a mistaken when they shipped the chiller and the reservoir. Apparently, those stuffs were with the magazine (Not the matrix magazine), and it was located in a storage in California.
Now we feared that even if we got the power for the machine on Monday, we wouldn't dare to operate it without either the chiller or the reservoir installed.
Finally it's Friday and I am glad that I get to fly back to Chicago today.
Thursday, November 3, 2011
Teledyne Day 4
Arrived at the customer site 7AM like usual, we asked the electricians about the power through the machine, and he told us that we would not get power until next Monday. Therefore, the things we could do was minimal. I installed the lamp inside the machine, and also the light outside the machine. Then I installed the cover that's below the table, I aslo put some silicone glue around just to double checked that coolant would not leak through the cover.
We pretty much did what we could do with all the stuff we had got, if only if the buffer stations were here, then we could have installed them. It seemed like today was another easy day, nothing much to do yet we had to look like we were doing something.
Wednesday, November 2, 2011
Teledyne Day 3
Got the the factory 7:00 AM in the morning, and the workers there had already moved the machine to where the center line was. We then asked them to move the machine to the center point, but before machine got to the center point we could see that the machine was already interfering the RGV system.
We double checked our measurements, however, everything was correct according to the machine layout blueprint. If our measurements were correct, then it must be something wrong with the blueprint. Shortly, we made a phone call back to the office, after some time we were told that the blueprints we had were for pre-minor changed machines, not for the minor changed machines. No wonder it did not look right when we tried to set the machine down.
Both of my coworker and I felt frustrated although it was not our fault to begin with. Nonetheless, we felt that customers must think we are dumb couldn't even read the blueprint correctly. As the results, we had to move the machine out of the way for the workers to re-drill the holes that were based on the REAL center lines.
Finally, we moved the machine to the real center point this time, and we began to house cleaning of the machine to get rid of the grease. We also took off the brackets off the machines. The rest of the stuff would require power to do, and that would be for tomorrow.
We double checked our measurements, however, everything was correct according to the machine layout blueprint. If our measurements were correct, then it must be something wrong with the blueprint. Shortly, we made a phone call back to the office, after some time we were told that the blueprints we had were for pre-minor changed machines, not for the minor changed machines. No wonder it did not look right when we tried to set the machine down.
Both of my coworker and I felt frustrated although it was not our fault to begin with. Nonetheless, we felt that customers must think we are dumb couldn't even read the blueprint correctly. As the results, we had to move the machine out of the way for the workers to re-drill the holes that were based on the REAL center lines.
Finally, we moved the machine to the real center point this time, and we began to house cleaning of the machine to get rid of the grease. We also took off the brackets off the machines. The rest of the stuff would require power to do, and that would be for tomorrow.
Tuesday, November 1, 2011
Teledyne Day 2
We got into the factory 7 in the morning, and the workers there started working at 5.
We continued looking at the layout sheet of the machines, and identified the center point of the CNC machines. There are 4 red triangles on the left, right, front, and rear of the machine. The center point will be the reference point for everything( RGV system, toe clamp, and etc...)
There was already a machine already running with the RGV system at the factory. In order to measure the distances from one machine to another machine, we had to use other points instead of the center point because the chip conveyor was in the way, there would be no way we can locate the center point of the running machine unless we had the chip conveyor removed. Therefore, we had to look at the layout sheet and do some simple addition and subtraction to figure out what to measure to obtain our distance between two machines.
Once we had that established, we began to mark the points on the foundation for the maintenance people to drill holes. While they were drilling the holes, we were called by customer to fix the servo alarm on another machine FA800.
The servo alarm only happened intermittently, and it was almost like the problem I encountered when I was in Acme Industries. We checked the phase current of Y-axis servo amplifier which was the one having problems, and we found out that the current varied drastically when the spindle went up and down. Up until this point, the machines showed no alarms so we could only make hypothesis that it was an electrical problem whereas mechanical problem would alarm out constantly.
This FA800 uses 16i Fanuc control with Toyoda servo amplifiers, therefore we would have to wait until the alarm shows up to read the exact alarm number.
We continued looking at the layout sheet of the machines, and identified the center point of the CNC machines. There are 4 red triangles on the left, right, front, and rear of the machine. The center point will be the reference point for everything( RGV system, toe clamp, and etc...)
There was already a machine already running with the RGV system at the factory. In order to measure the distances from one machine to another machine, we had to use other points instead of the center point because the chip conveyor was in the way, there would be no way we can locate the center point of the running machine unless we had the chip conveyor removed. Therefore, we had to look at the layout sheet and do some simple addition and subtraction to figure out what to measure to obtain our distance between two machines.
Once we had that established, we began to mark the points on the foundation for the maintenance people to drill holes. While they were drilling the holes, we were called by customer to fix the servo alarm on another machine FA800.
The servo alarm only happened intermittently, and it was almost like the problem I encountered when I was in Acme Industries. We checked the phase current of Y-axis servo amplifier which was the one having problems, and we found out that the current varied drastically when the spindle went up and down. Up until this point, the machines showed no alarms so we could only make hypothesis that it was an electrical problem whereas mechanical problem would alarm out constantly.
This FA800 uses 16i Fanuc control with Toyoda servo amplifiers, therefore we would have to wait until the alarm shows up to read the exact alarm number.
Monday, October 31, 2011
Teledyne Day 1
I got sent back to Mobile, Al again, and this time is for real.
The customer is called Teledyne Continental Motors Inc, and it is bought by a Chinese company from what I've heard.
I arrived at the customer site, and got my escort badge and everything. I had to watch a safety video as well. Since this is an union company so they are very strict on everything especially safety. I had to wear goggles, and ear plugs at all time.
This would be my first time installing RGV, and the CNC machine also came with a matrix magazine, a magazine that can hold tons of tools. My associate and I looked up the layout of the machines and located the holes that goes into the foundation because the position of the CNC machine sits on will be very crucial for the RGV.
The customer is called Teledyne Continental Motors Inc, and it is bought by a Chinese company from what I've heard.
I arrived at the customer site, and got my escort badge and everything. I had to watch a safety video as well. Since this is an union company so they are very strict on everything especially safety. I had to wear goggles, and ear plugs at all time.
This would be my first time installing RGV, and the CNC machine also came with a matrix magazine, a magazine that can hold tons of tools. My associate and I looked up the layout of the machines and located the holes that goes into the foundation because the position of the CNC machine sits on will be very crucial for the RGV.
Friday, October 28, 2011
Car overheating
On the way back home from work on Thursday my car almost overheated. Thus I had to take a day off on Friday to have my car fixed.
Needless to say, my car is old so it's prone to have many problems. I spent about $1000 to fix the car. The radiator was leaking so I had to have it replaced, and the rear calipers were worn out.
Apparently, I have to wait another 4 months until I can get my company car. Until then, I hope there won't be any problem with this car.
Needless to say, my car is old so it's prone to have many problems. I spent about $1000 to fix the car. The radiator was leaking so I had to have it replaced, and the rear calipers were worn out.
Apparently, I have to wait another 4 months until I can get my company car. Until then, I hope there won't be any problem with this car.
Thursday, October 27, 2011
Acme Industries Day 1
Today I drove to a company that just south of the office, in Elk Grove Village, IL. The problem that the customer had was the servo alarm, and it's an old machine that used the Toyoda-made servo amplifier. Thus, I had to use the PUK control unit to read the alarm from the servo amplifier.
At first, we thought it was the encoder cable being bad, but after a general inspections we found no worn on the encoder cable. In addition, we did not have any encoder cable in stock so if even it was the cause of the encoder cable we couldn't do anything about it. However, we did have a a new servo motor in stock that we could replace the old one.
The nature of this problem happened intermittently hence it was hard for us to diagnose what exactly was the problem causing the servo alarm. Nonetheless, we replaced the servo motor, and had the customer run overnight then next morning we would come back and check if there is any alarms at all.
At first, we thought it was the encoder cable being bad, but after a general inspections we found no worn on the encoder cable. In addition, we did not have any encoder cable in stock so if even it was the cause of the encoder cable we couldn't do anything about it. However, we did have a a new servo motor in stock that we could replace the old one.
The nature of this problem happened intermittently hence it was hard for us to diagnose what exactly was the problem causing the servo alarm. Nonetheless, we replaced the servo motor, and had the customer run overnight then next morning we would come back and check if there is any alarms at all.
Wednesday, October 26, 2011
Toyoda Machinery Day 1
I flew in Chicago this morning from Mobile, Alabama. I landed around 12:30 PM central time. I took the cab back to my apartment to unload luggage before heading back to Toyoda HQ.
I entered the office around 1:45 PM, and I felt great to be back in the office to see people that I always talked to on the phone, but never get the chance to see their faces. Now I could associate the voices with faces.
Apparently, my toolbox was shipped to Mobile, AL in behave of my request. I had never thought that the work order down in Mobile would get cancelled all the sudden. In conclusion, I had to ask the hotel which had my toolbox to ship my toolbox back to Toyoda HQ.
Next time I would make sure that I would carry my toolbox wherever I go unless I was told directly by my boss.
I entered the office around 1:45 PM, and I felt great to be back in the office to see people that I always talked to on the phone, but never get the chance to see their faces. Now I could associate the voices with faces.
Apparently, my toolbox was shipped to Mobile, AL in behave of my request. I had never thought that the work order down in Mobile would get cancelled all the sudden. In conclusion, I had to ask the hotel which had my toolbox to ship my toolbox back to Toyoda HQ.
Next time I would make sure that I would carry my toolbox wherever I go unless I was told directly by my boss.
Tuesday, October 25, 2011
Mobile Alabama Day 1
Just landed in Mobile, Alabama this evening. It was a long flight from Idaho Falls, ID. It took almost 9 hours to travel.
Upon arriving at the Mobile Regional Airport I was informed by another coworker who is already at the customer's site saying that the RGV load station's paint was incorrect. Thus, the customer would like to have it repaint otherwise the work cannot continue. However, due to the nature of the load station, it won't happen anytime soon so I ended up staying in Mobile for a night.
I am flying back to the office tomorrow, and finally I can go back home.
Upon arriving at the Mobile Regional Airport I was informed by another coworker who is already at the customer's site saying that the RGV load station's paint was incorrect. Thus, the customer would like to have it repaint otherwise the work cannot continue. However, due to the nature of the load station, it won't happen anytime soon so I ended up staying in Mobile for a night.
I am flying back to the office tomorrow, and finally I can go back home.
Monday, October 24, 2011
Anderson Manufacturing Day 3
Ah today is Monday wake up 6:30AM and get ready for work.
Today's task is to test the spindle working properly or not. First of all, we do M19 (spindle orientation) and run the dial gauge to make sure the key it's oriented. The tolerance is 0.10 to 0.15mm. Secondly, we test the coolant through the spindle by doing M12 (Spindle through coolant), and M8 (External spindle coolant on). However, the coolant is not coming out as much as expected, and we troubleshoot the problem by checking the hose from the pump, and the hose to the spindle.
As the result, it turns out that the coolant pumps' filters are dirty. We ask the customers to clean the pump filters, and as soon as it is cleaned the coolant comes out as it should like a water gun.
Finally, we get our service reports signed by the customer and say farewell to Idaho Falls.
Today's task is to test the spindle working properly or not. First of all, we do M19 (spindle orientation) and run the dial gauge to make sure the key it's oriented. The tolerance is 0.10 to 0.15mm. Secondly, we test the coolant through the spindle by doing M12 (Spindle through coolant), and M8 (External spindle coolant on). However, the coolant is not coming out as much as expected, and we troubleshoot the problem by checking the hose from the pump, and the hose to the spindle.
As the result, it turns out that the coolant pumps' filters are dirty. We ask the customers to clean the pump filters, and as soon as it is cleaned the coolant comes out as it should like a water gun.
Finally, we get our service reports signed by the customer and say farewell to Idaho Falls.
Saturday, October 22, 2011
Anderson Manufacturing Day 2
Today was Saturday, and I woke up at 6:30AM, and it was still dark outside. The weather is definitely much colder than what it was in San Antonio, TX.
My coworker and I arrived at the customer's site around 7:30AM, and we started taking apart the stuff that prevent us from taking out the spindle. The machine was FA450-III with aluminum chips all over the places. Apparently, spindle installation was not a "hard" job, when I said hard job I meant a job that required a lot of thinking. Instead, spindle installation was a dirty job. You would get all your clothes dirty with oils, coolants, metal chips, and whatever you could think of.
First of all, we had to remove all the hydraulics hoses that connected to the spindle, and then took off the air hoses that running through the spindle as well. The process of doing that required labeling everything that we remved or disconnected. After we had done that we proceeded to remove control box off the spindle. However, before we could remove the control box we had to disconnect the wires from or to spindle. The customer did not have any crane so the only option we had was the fork lift, we proceeded using fork lift to pick the control box, and set it aside so we could get into the spindle unit without any hinderance.
We used the threaded rod to push out the spindle slowly, and once it was out about 75%, we again used the fork lift to pull out the spindle. We had to remove the spindle cap so we could run the wire for the new spindle.
After hours of working, we finally had the new spindle put into the machine, and on Monday we will test if it works or not.
My coworker and I arrived at the customer's site around 7:30AM, and we started taking apart the stuff that prevent us from taking out the spindle. The machine was FA450-III with aluminum chips all over the places. Apparently, spindle installation was not a "hard" job, when I said hard job I meant a job that required a lot of thinking. Instead, spindle installation was a dirty job. You would get all your clothes dirty with oils, coolants, metal chips, and whatever you could think of.
First of all, we had to remove all the hydraulics hoses that connected to the spindle, and then took off the air hoses that running through the spindle as well. The process of doing that required labeling everything that we remved or disconnected. After we had done that we proceeded to remove control box off the spindle. However, before we could remove the control box we had to disconnect the wires from or to spindle. The customer did not have any crane so the only option we had was the fork lift, we proceeded using fork lift to pick the control box, and set it aside so we could get into the spindle unit without any hinderance.
We used the threaded rod to push out the spindle slowly, and once it was out about 75%, we again used the fork lift to pull out the spindle. We had to remove the spindle cap so we could run the wire for the new spindle.
After hours of working, we finally had the new spindle put into the machine, and on Monday we will test if it works or not.
Friday, October 21, 2011
Anderson Manufacturing Day 1
I flew in Idaho Falls, ID this morning. The weather here is colder than San Antonio, TX. The task is spindle installation, and the customer has already taken the coolant tank out so all we need to do now it's to take the spindle out.
However, before we do that we have to go into the PMC ladder and jump the alarms, and once you have done that you will have to also use wire jump the emergency stop in order to control on (hydraulic on).
Due to the fact that I left my toolbox, and m co-worker's luggages didn't arrive on time, we had to stop what we are doing after jumping the coolant tank.
However, before we do that we have to go into the PMC ladder and jump the alarms, and once you have done that you will have to also use wire jump the emergency stop in order to control on (hydraulic on).
Due to the fact that I left my toolbox, and m co-worker's luggages didn't arrive on time, we had to stop what we are doing after jumping the coolant tank.
Thursday, October 20, 2011
TME X + Day 3
Today I get to test the tool change making sure it works. First of all, I have to determine what to align first. Align magazine with s-arm or spindle with s-arm. In order to determine which is which, you'll have to see how s-arm is bolted on to. If it is bolted onto the spindle side, then you align with magazine first, and if it's bolted on the magazine side then you align with the spindle first.
Once you have aligned the s-arm with the correct one, then you put down the test ring and use a scale to feel if the spindle is aligned correctly with the s-arm, and you also measure the distance from the face of the test ring to the face of the spindle by using caliper. Typing M991 All axis interlock off to align the spindle to the s-arm.
Next, you will put a real tool inside the tool pocket and run a M907 s-arm jogging mode to see how the tool fits into the spindle, once it's in you use the caliper to measure the distance again, it should be only couple decimal micron-meter off.
Also, I get to do the coolant modification today. Basically TME uses external coolant tank instead of the stock coolant tank that comes with the machine. Hence, I have to remove the solenoid valve and make it so it's independent from the machine. The concept is fairly simple, however, the hardest part of this task is that it takes a lot of energy to take off the hoses, nuts, that connected to the solenoid.
Once you have aligned the s-arm with the correct one, then you put down the test ring and use a scale to feel if the spindle is aligned correctly with the s-arm, and you also measure the distance from the face of the test ring to the face of the spindle by using caliper. Typing M991 All axis interlock off to align the spindle to the s-arm.
Next, you will put a real tool inside the tool pocket and run a M907 s-arm jogging mode to see how the tool fits into the spindle, once it's in you use the caliper to measure the distance again, it should be only couple decimal micron-meter off.
Also, I get to do the coolant modification today. Basically TME uses external coolant tank instead of the stock coolant tank that comes with the machine. Hence, I have to remove the solenoid valve and make it so it's independent from the machine. The concept is fairly simple, however, the hardest part of this task is that it takes a lot of energy to take off the hoses, nuts, that connected to the solenoid.
Wednesday, October 19, 2011
TME X + Day 2
Today, I got to set home positions for x,y,z, and also do the geometry check. I can still count how many times I have done this... probably twice only... I've got all my formula for calculating the home position for y, and z axises.
Also, I learned how to push/pull the magazine of 630SX. If you ain't got a cheater bar then it would be a hard task to loosen those bolts that lock down the magazine.
Parameter 1320 it's the setting for overtravel, it is useful if the home position is set way off from the real home position.
Also, I learned how to push/pull the magazine of 630SX. If you ain't got a cheater bar then it would be a hard task to loosen those bolts that lock down the magazine.
Parameter 1320 it's the setting for overtravel, it is useful if the home position is set way off from the real home position.
Tuesday, October 18, 2011
TME X + Day 1
Just got back from CFAN yesterday, now I am back in TME (Texas Machine Enterprise). I think I have been in TME for a month now. Today I continued working on the FH630SX, my task today was to install the air socket blow modification for the tool change. I think this is the second time I am installing the air socket blow. It wasn't an hard task, but since it's only my second time it still took me a while to finish it.
Of course, I helped my coworker to put up some metal sheets. Often times the metal sheets won't fit, and we will have to drill holes and what not. I think metals sheets are the most worthless things in this job...
Of course, I helped my coworker to put up some metal sheets. Often times the metal sheets won't fit, and we will have to drill holes and what not. I think metals sheets are the most worthless things in this job...
Monday, October 17, 2011
CFAN
This morning my co-work and I drove to San Macros from San Antonio to do my first repair assignment. So far all I have been doing is installation hence this repair assignment makes me kind of exciting!!!
The machine we had to fix was FH1050, an old CNC machine. Apparently the pallet door has crashed into the fixture when it tried to do the pallet change which caused the bolt shearing off. As result, the pallet door just dropped down. At first, I thought it's going to be a tricky repair job, but it turned out it's just some simple door fix...
However, I still learned a lot from today. I got to have a real time experience with the FH1050 a little bit. FH1050 uses old FANUC control the 16i control, some commands are different but overall they are more or less the same.
The machine we had to fix was FH1050, an old CNC machine. Apparently the pallet door has crashed into the fixture when it tried to do the pallet change which caused the bolt shearing off. As result, the pallet door just dropped down. At first, I thought it's going to be a tricky repair job, but it turned out it's just some simple door fix...
However, I still learned a lot from today. I got to have a real time experience with the FH1050 a little bit. FH1050 uses old FANUC control the 16i control, some commands are different but overall they are more or less the same.
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