Autowel Doc.docx

Equipment

Date 12/17/2018

1. H-Beam Drilling

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12/18/2018

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12/19/2018

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12/20/2018

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Activities Remove rust on the LM guide, ball screw and drill holders. Started replacing hose of mist oil. Tested machine movement of each part. Replaced sensor of top spindle ATC unit to new one (Autonics PR12-4DN) Replaced signal light to new one. Old hose mist oil supply was completely replaced to new hose for all 3 axis. Tested auto tool change system and adjust tolerance of auto tool change position for top spindle and completed orientation of the drill holder positions. Filled mist oil into the tank of 3 axis. Operator training and operator tested the machine. Replaced tube mist oil supply. Provided training for operating program set up again. Operator set up program and tried drilling and cutting marking.

12/21/2018 

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Explained IT engineer how to make DXF file by AUTOCAD and we explained operators how to load DXF file and how to check if there is any error on the data. We provided some sample DXF files for your reference. Provided a training for scribing marking function. Operators tried setting work data for drilling, cutting marking, welding marking and scribing marking.

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Remarks Need to provide OT sensor and compressor with complete air filtering system. (Will be provided soon) Need to replace mist oil pump to a new one.

Items needed for PR; 1. Mist oil pump 2. OT Sensor (Model : PR124DN2)

12/22/2018

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Marking tool replacement. Tested scribing and marking and provide operators training. Provided maintenance training. Found two OT sensors not working on the top and on the right hand side spindle part so we install jump cable so we can operate the machines. Found cable shortage of scribing marking motor because compressed air contain water and filtering unit cant filter the water from the air supply.

Problem Cable shortage of scribing marking motor.

Cause Compressed air contains water and filtering unit can’t filter.

Probable Solution Need to provide air compressor with complete air filtering system. Will be provided soon.

Mist oil pump defective.

Not working due to long period of time that has not been used.

Need to replace for new mist oil pump.

Defective 2 unit of OT sensors (Jumper wire has been tap for the meantime in order for the machine be operated)

Damage due to not been used in long period of time.

Need to replace of new OT sensor ( Model: PR12-4DN2)

Equipment

Date 12/17/2018

2. Band Sawing Machine 1

12/18/2018

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12/19/2018

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12/20/2018 12/21/2018

12/22/2018

Problems

Activities Replaced blade rotation speed to new one. Slide in angle turning stocked due to rust has been solved. Replaced lamp and ballast stabilizer to new one for cutting position. Replaced chip brush motor and reducer to new one due to old motor rotation speed was slow. Repaired coolant pump and adjusted main hydraulic pressure and band saw blade tension pressure. Testing cutting H-beam Installing cable protection for wires. Tested cutting H-beam after change bad cables to new one for inverter. We did operator training and explained about some problem such as chip brush motor position, vibration and no display blade rotation speed.

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Items Needed for PR; 1. Blade for band sawing machine.

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Operator tried cutting H-beam by Band saw after drilling and cutting marking.

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Maintenance team aligned the band saw blade angle for straight cutting.

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Provided maintenance training.

Cause

Remarks Need to replace blades to a new one. (Care of Operation)

Solution

Blade teeth’s has few pitting’s. (Still can be used for operation)

Equipment 3. Band Sawing Machine 2

Date 12/17/2018

12/18/2018

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Damage due to long period of time that has not been used.

Replace for new blade.

Activities Replaced blade rotation speed to new one. Vertical clamp slide stocked due to rust has been solved.

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Replaced lamp and ballast stabilizer to new one for cutting position. Replaced chip brush motor and reducer to new one due to old motor rotation speed was slow. Repaired coolant pump and adjusted main hydraulic pressure and band saw blade tension pressure. Testing cutting H-beam.

12/19/2018

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Installing cable protection for wires.

12/20/2018

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Operator tried cutting H-beam by Band saw after drilling and cutting marking.

12/21/2018

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Maintenance team aligned the band saw blade angle for straight cutting.

12/22/2018

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Provided maintenance training.

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Problems Blade teeth’s has few pitting’s. (Still can be used for operation)

Cause Damage due to long period of time that has not been used.

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Remarks Need to replace blades to a new one. (Care of Operation)

Items Needed for PR; 1. Blade for band sawing machine.

Solution Replace for new blade.

Equipment

Date 12/17/2018

4. H-Beam Beveling Machine

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Activities Changed correct direction of hydraulic pump by switching two main power cables. Installed the repaired touch monitor and tested touch monitor.

Items Needed for PR;

12/18/2018

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Finding solution for PLC program of Autowel.

12/19/2018

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12/20/2018

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Improved PLC program and tested automatic mode. Modified PLC program for basic function can be working and we tested operation. Found many broken insert tips on the scallop cutters. Provided training for operators.

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Remarks Purchase insert to replace the broken one.

1. Insert tips for HBeam Beveling Machine.

12/21/2018

12/22/2018

Problems Damage insert tip of Scallop cutters

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KOTEC engineer reviewed PLC program and tested operation movement at automatic mode.

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Provided maintenance training.

Cause Occur upon testing due to wrong direction of scallop cutters.

Solution Purchase insert to replace the broken one.

Equipment

Date 12/17/2018

5. Gas and Plasma Cutting Machine

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Activities Replace kaliburn remote control for plasma torch height control to new one. Replaced 4 limit switches to new one. Installed 2 braking resistors on servo drive for V&Y axis. Installed oxygen and gas hose for plasma power source and gas line.

12/18/2018

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LPG gas and oxygen are connected temporary to try testing machine.

12/19/2018

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Tested cutting by both plasma and gas.

12/20/2018

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Provided operator training and operator tested gas cutting.

12/21/2018

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Provided nesting software but failed to run the program due to error that VBA is not installed on the computer.

12/22/2018

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Provided maintenance training.

Problems Connection of LPG gas, Oxygen and Compressed Air.

Cause No connection suitable for real operation.

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Remarks Need to provide bigger oxygen tank and manifold that has 3 output supply. Need to run nesting software but as of 1/4/2018 email of Kotec that the nesting software do not support our operating system here in the Philippines so they are suggesting to use our existing nesting the Pronest and Turbonest and upgrade this nesting for the Autowel Machines.

Solution Need to provide bigger oxygen tank and manifold that has 3 output supply.