A.T.U.  Inc.

Automation Controls 

John Washinsky, pres. 

Phone(336) 712-0569
EMAIL: ATUdesigns@gmail.com
Web Site :http://ATU1/ATU

Po. Box 1725
Clemmons, NC 27012

revised 9/7/2014

Project History

2014

Data Colection Work Cell Controller

Designed  and programmed an Ethernet based Data Collection system for a stamping press work cell. Using a Redlion Graphite HMI, programmed Crimson to communicate with the press control and auxillary equipment. It gathers real time data and calculates equipemnt efficiency. The data will be uploaded to a factory wide information system.

Electricians Training Simulator Programming

Programmed an Autoamtion Direct DL106 and a Redlion G3 display to train and test plant technicians for proper troubleshooting  of high voltage electrical panels. The HMI simulated a Fluke mulitmeter at low voltage. The system incorporated a card reader to identify the test subject and record all actions in a text file to be later uploaded to a USB drive.

Servo Actuator Refurbish

Implemented JVL Ethenet IP based servo actuators and a Compact Logix PLC  to replace compound pneumatic cylinders on an existing connector assembly machine. The new system interfaced with the existing SLC500 PLC and PanelView Plus HMI to provide micro adjustments  and multiple part number recipies.



2013

Universal Stamping/Injection Molding  inspection Reeler

Designed  and programmed a control system for a flexible combination inspection platform and reeler. Using an Automation Direct CLICK PLC and Cmore Micro HMI, the operator can configure the reeler system for payout or take-up oepration for either stamping or injection molded product on a strip. Two Cognex vision systems are interfaced to inspect incoming or outgoing product. 

Connector Inspection Machine

Designed and programmed a control system for a conector assembly inspection machine. The system utilized an Omron CJ2 processor and Redlion G3 HMI. The system incorporated several servo actuators, a Cognex Barcode Reader, continuity tester and a Keyence  laser marking system. 

Connector Packaging Control Refurbish

Designed and programmed a control system for a conector assembly packaging machine. The system utilized an Omron CJ2 processor and Redlion G3 HMI. The system incorporated  a servo actuator and pneumatic system.

Laser Ablation Calibration Tool

Using an encoder simulator and a dedicated rate meter, designed and built a calibration tool. 


2012

Molded Connector Inspection machines
Designed  and programed a control system  to inspect connectors as they are produced on an injection molding machine.  System included a Control Logix PLC with a  PC based HMI touch screen.   Interfaced with 2 Cognex vision systems and provided a Part Number database for machine configuration data.  Designed extensive diagnostic tools for maintenance personel.  Created an algorithm using a sliding average to detect trends in rejected parts to detect process problems.
 
Terminal Sleeve Insertion Machine
Designed  and programed an automated control system  to orient and insert a barrel shaped sleeve onto terminals in strip form. Machine incorporated  a Control Logix PLC, Panel View PLUS and 4 Kinetix Servo Drives controlled over Ethernet IP.  Wrote automated homing  routines for easy loading of new material.  Machine ran in excess of 350 insertions/minute. Designed extensive diagnostic and manual screens for maintenance personel.

Insert Molding Vision Inspection System
Modified an exsiting insert molding automation system to control 2 Cognex Vision inspection cameras that check incoming material prior to molding.  Modified the AutomationDirect PLC to communicate via Modbus TCP/IP to receive inspection results.  Failed parts are tracked to automatically advance damaged strip out of the mold, preventing delicate and expensive tooling from being damaged.

Control System Upgrade for Automated Lathe
Replaced  a Horner Electric HMI/PLC on an automated grinder/lathe with an AutomationDirect  DoMore PLC and Redlion Display.
Machine was down for less than 2 days during the upgrade.

2011

Automotive Control Module Assembly Conveyor
Designed  and programed an automated control system  to manually assemble and inspect automotive control module.  System included a pallet conveyor controlled by a Control Logix PLC with 2 PC based HMI touch screens.  Provided pallet tracking using Balluf RFID tags to direct defective parts for rework. Interfaced with a Cognex vision system and provided a Part Number database for machine configuration data. Designed extensive diagnostic screens for maintenance personel.

Production Monitoring Upgrade
Using a Redlion HMI, wrote a collection of Crimson scripts to  record machine utilization statistical data by shift. Provided real time feedback for the operator, if production rates are being satisfied. Upgraded displays on SLC500 and Omron PLC's.


2010

Mold Protection Upgrade
Modified automation control package to automatically detect different types of mold crash protection and change the control sequence for the appropriate hardware.
Allowed customers to migrate newer proection design and continue to run older molds without any input from the operators.

Safety Door Control for Milling Machines
Designed a control system to interlock end mill machine motor and feed table motor with safety doors.  Control system prevents mill from starting if either motor is left in the "ON" postion when systerm is reset.  System did not require any major modifications to the machine.

Part Number Database
Modified an OMRON CJ series PLC and Omron HMI to add a Part Number recipe database to an existing machine. Stored various machine setup data, including serveal Cognex vision systems.

3-Phase Power Monitor
Implemented a 3 phase power monitor to record kW hours used.

2009

Servo Feed Automation for Insert Molding Operation
Redesigned control system for bidirectional insert molding automated feed system. Utilized 2 Automation Direct Sure Servos communciating via Modbus to an Automation Direct PLC. Programed Cmore HMI to provide a Part Number database to automatically select feed and machine parameters. Later adapted system to work with a hot sprue system.

Air Cylinder/Servo Actuator  Retrofit
Replaced air cylinder arrangement with a IAI Servo Actuator system for a connector assembly bend module. Previous system used a series of air cylinders to bend connector lead wires. Adjustment was non repeatable and difficult. New system utilized an IAI Actuator controled via Device Net module.  Modified SLC500 program to provide fine adjustments via the HMI and stored adjustments according to Part Number.

Assembly Machine Reprograming
Reprogrammed a retooled assembly machine to run a different product line. Modified an Omron CJ series PLC and Omron HMI, writing a new sequence and adding a Cognex Inspection camera.

Refurbished Napkin Folding Machine
Designed a new control package for a 50 year old napkin folding machine. Design incorporated mulitple AC drives, web handling and Automation Direct DL260 PLC and a Proface HMI.


Heat Exchanger Tube Assembly System
Designed a control system using an Allen-Bradley Compact Logix processor to control a manufacturing cell that assembled heat exchangers made from copper tubing. The system incorporated setting up PID loops to control hydraulic cylinders for part movement, insertion and forming. An AB Panel View Plus HMI was used to setup all control parameters to a part number storage/retrieval system and provide manual mode and diagnostic capabilities.  Machine runs beyond designed production rate.

 

Enhanced Data Acquisition System
Added a Redlion G3 display to the standard data collection package from 2007. The HMI adds easy access to changing parameters, improved real time data displays, trend graphs and a part number storage/retrieval system. Communication to downstream equipment via the G3 protocol conversion is also going to be added at a future date.

 

Enhanced Auxiliary Press Control
Improved upon the original 2007 design adding additional control options. Also provided a single connector system for press interface and 2 programmable high speed counters for part feed verification.

 

Servo System Upgrade
Designed a drop in module to replace an Adept servo axis that is no longer produced. The system was replaced with a standard leadscrew axis and an Allen-Bradley Servo drive. The system was integrated into an existing AB Control Logix  PLC.

 

Servo Walking Beam Upgrade
Refurbished a machine previously using a Stelron type walking beam with a servo actuator and Yaskawa drive/control.  The previous machine, controlled by an AB PLC5 processor was reduced in size. When this done, much of the wiring to the removed parts of the machine was left exposed. Schematics had to be revised and the excess wiring removed. The PLC program was changed to reflect the removal of stations.  The servo drive had to be integrated into the PLC program the servo program written to provide the motion required to control the walking beam. A Redlion G3 HMI was added to provide access to parameters in the Servo indexing module and for diagnostic capabilities.

 

Servo Walking Beam Upgrade
Refurbished a machine previously using a Stelron type walking beam with a servo actuator and Yaskawa drive/control.  The previous machine, controlled by an AB PLC5 processor was reduced in size. When this done, much of the wiring to the removed parts of the machine was left exposed. Schematics had to be revised and the excess wiring removed. The PLC program was changed to reflect the removal of stations.  The servo drive had to be integrated into the PLC program the servo program written to provide the motion required

 

Japanese Machine Troubleshooting

 Contracted to troubleshoot and debug an assembly machine that was controlled by an OMRON PLC. Used CX1 to first document and then make the required changes to the PLC program. Improved uptime of the machine and reduced scrap with the program changes.

2007

Data Acquisition System
Designed a system using a small Automation Direct PLC and networked  PC to collect analog data from a continuous process. One thousand data points are collected every 10 seconds and transferred to a PC using a an OPC server.  The data is then time stamped and stored in an Excel file for DVD archival. VBA macros were written to provide a real time display graph and an easy way to analyze different sets of data points. An algorithm in the PLC was created using standard deviation to detect abnormal process problems.

Vision System Downloader
Wrote a VisualBasic.net program to communicate with 7 Cognex Vision Systems and an Allen-Bradley SLC500 PLC over Ethernet. It  provided recipe data downloading with read back verification and part number storage in an Access Data Base.

Vision System PLC communications
Wrote a detailed step by step illustrated procedure for plant maintenance personal to setup Modbus communications between a Cognex Vision system and an Automation Direct Ethernet module.
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Auxiliary Press Control
Designed a flexible control package to make it easy to connect and coordinate the operation of auxiliary feeders, reeling and inspection equipment to work with a stamping press. Included a small Automation Direct  PLC and touch screen for plant personal to completely setup and configure the device without the use of a laptop.

Keyence Laser Integration
Wrote an extensive Allen-Bradely control logix  5000 PLC program to  communicate directly with a Keyence CO2 marking laser. The program module allowed the machine operator to completely customize the mark and save the settings with the part  number data base in the machine. Diagnostic screens provided detailed error information for maintenance personal to test  Laser functions. The final installation involved removing the previous laser marking system and installing the Keyence system in less than 8 hours.

Assembly Machine PLC  Programming
Upgraded the firmware in several Allen-Bradley Control Logix processors. Modified PLC programs in several machines using Allen-Bradley Control Logix ,Compact Logix and  SLC500 and Automation Direct PLC's.

2006

Control System for Leak Testing of  Metal Castings
        Designed and built a control system for pressure testing  metal castings for the automotive industry.  Machine used an Automation Direct PLC, Proface HMI ,Cincinnati  Pressure Tester and a Microscan Bar Code Scanner.

Assembly Machine PLC  Programming
Modified PLC programs in several machines using Allen-Bradley Control Logix ,Compact Logix and  SLC500, Omron and Automation Direct PLC's.

2005

Assembly Machine PLC  Programming
     Designed a 2nd generation injection molding automation system with updated controls , a Proface operator interface and an encoder based feed verification system.

Assembly Machine PLC  Programming
Upgraded the firmware in several Allen-Bradley Control Logix processors. Modified PLC programs in several machines using Allen-Bradley Control Logix ,Compact Logix and  SLC500 and Automation Direct PLC's.
Refurbished several existing PLC based machines and installed Automation Direct PLC's. . Modified PLC programs in several machines using Allen-Bradley Control Logix , Allen-Bradley SLC500 and Automation Direct PLC's.

2004

Refurbished Connector Insertion Machine
        Reprogrammed  a connector assembly insertion module using an Omron C200HX  plc  with Servo  Feed unit.  Installed and programmed a new Proface operator display. Added complete part number recipe management and diagnostic maintenance screens.

Injection Molding  Vision System interface
        Designed control interface for high speed triggering of  a PPT  Impact Vision system using Automation Direct DL06 in an insert molding operation

Assembly Machine PLC  Programming
        Changed an Allen Bradley SLC 5/04   program on a Swiss built connector assembly machine to add a high speed counter module and make program bug fixes and improvements.  Sections of the program had to be translated from Dutch before changes could be made.
        Changed an Allen Bradley SLC 5/04   program on a German built connector assembly machine to add a high speed counter module and add diagnostic tools for logging and displaying  reject information using the Panel View Display.

2003

Assembly Machine PLC  Programming

           Documented PLC programs for multiple Japanese built connector assembly machines. PLC's used were NAIS  FP3.  Programs were poorly translated and were difficult to make changes. Used NAIS  FPWIN GR  programming software to comment, document and make added changes to lower scrap, improve quality and improve counting accuracy.  Modified the Matushita IOP  operator displays.  Developed a low cost method for gauging parts in the assembly process.

2002

Assembly System Programming

    Programmed multiple Pacific Scientific Servo axis assembly equipment , establishing a PLC/Servo interface and a programmable CNC type Control system.

Pallet Assembly System Upgrade

Allen Bradley Control Logics 5000 with multi-Axis Servo Pick and Place Units. Made on-line changes while process was running with minimal interruption in production. Improved through-put of machine from less than 4000  pieces/shift  to consistently  over 8000 pieces /shift with improved diagnostic capability.

1999-2001

Insert Molding Control System

    Designed a PLC control system for a customer to control an insert molding strip handling system.  System included a Stepper Motor drive and multiple part number recipe storage with easy to use operator interface.  Project involved multiple systems on a tight schedule. All systems were delivered on time and within cost.

Vision System Transport System Control

    Designed  PLC controls to interface with a PPT vision system and provide repeatable stopping for movement of strip through the material handling system.

Assembly System Programming

    Programmed multiple Pacific Scientific Servo axis assembly equipment , establishing a PLC/Servo interface and a programmable coordinate system.
    Added Diagnostic Screens for an Allen Bradley Control Logics based assembly line which included I/O status and Force test.
. Developed  teach screens for defining move points of a multi-axis servo pick and place system. Had to work with a system that  was without  comments or electrical prints.

Amp Incorporated Machine Development  1982-1999

Department Group Leader for machine controls when Tyco International dissolved the Machine Development organization during their acquisition of Amp Incorporated in 1999.
17 years of experience designing  PLC based and computer based embedded control systems for high speed assembly, inspection and packaging machines for the electronic connector industry.
 
 
 
 
 
 
 

1999

Stacked Multiport Modjack Test Fixture
     Automated test fixture which incorporated a PlcDirect 205 PLC with a Cirrus contiuity/short/hipot tester to test a 32 port ethernet jack connector.  Using an Analog module, the PLC measured the current in each of  the 32 LED's with a resolution of 100ua. The PLC remotely controlled the Cirrus unit and the system displayed to the operator the faulted circuit or LED.

Hydraulic Punch Press modifications
     Modified the control program of a Micrologix 1000 PLC to run an air feed and reeler added to a hydraulic punch press.

110 Block Connector to Board Insertion Machine
    Fully automatic assembly machine to insert a vibratory bowl fed connector into a small PC board. Machine incorporated a 3 axis PacSci 950 servo system with PACLAN  communications. The servo system was controlled by a  PLC Direct 450 PLC via a Modbus link. A DirectTouch Color LCD display provided the operator display and programming of setup parameters.
 

1998

Grease Dispensing System
     Developed a multiple PLC control scheme using a PLC Direct 105 and 250 to control air piloted metering valves dispensing a heavy sealant being injected into a telephone cable connector. The system varied the valve timing dependent on material temperature and pressure operating at 60 feet/minute.

Modular Jack Inspection System
    Developed a 2 camera in-line video inspection application operating at 145 assemblies/minute. Using the Acuity Power Vision System, the tasks involved front lighting and  required the development of custom morphology to enhance the connectors features under  constantly changing product surface conditions.
 

1997

Modular Plug Assembly Machine  - 3rd Generation
    High speed (425 assemblies /minute). Controlled by a PLC Direct 440, with interrupts. Allen Bradley Machine Vision  CVIM2 inspection of 100% of the parts. The machine used a small stepper motor to automatically reposition the cameras for each part size. Utilized  the smart slice remote I/O system to control the vibratory feeder, automatic packaging system and reeling system.  Automatic part changeover configuration of the vision system using an Ascii Basic Module. Developed a Visual Basic HMI that also collected machine production data. This information was then used by VBA macros to create HTML pages for the company intranet, updated automatically on the hour.

1996

Infoport PCMCIA Cable Connector Assembly Machine
    Extremely small and difficult tolerances for the assembly of cable connectors used on PCMCIA cards. Motion control consisted of an 8 axis Pacsci SERCOS based PC control servo system. Multiple assembly heads and an 8ft servo controlled walking beam system capable of 85+ strokes /minute. Visual Basic HMI. 100% inspection utilizing a 3 camera Allen Bradley CVIM2 machine vision inspection system. To meet resolution requirements, each camera had to be strobed 3 times per part.. PLC Direct 440  master control networked with a secondary 440 to perform on line continuity and short electrical testing.  Developed a protocol using the Ascii Basic Module  to communicate with the PC based Servo system. The ABM also reconfigured the vision system using the AB RS232 protocol.

1995

CAT 5 Multiport Array Insert Molding Reeling Systems

   Developed a servo positioning and reeling system for an insert molding operation on a vertical injection molding machine. Two Pacsci 750 systems positioned 4 strips into the mold/die while the overall process was controlled by a PlcDirect440 and smart slice remote I/O system. The PLC also controlled the custom sprue picker robot and interfaced with the Engle molding press to provide mold safety.

Modular Plug Assembly Machine   - 2nd Generation Controls modified for use in SPAIN
    Same as 1992 machine but redesigned to accept different voltage and frequency. Many components were changed to meet the needs of  AMP Spain.

1994

Selectable Punch and Forming Die
    Developed a   system using a PLC direct 240 PLC to control 5 air cylinders in a forming die which made a metal shield for a variable length part. The system replaced 8 different sets of change tooling and provided an electronic change over via the DV1000 operator interface.

CAT4 Multiport Array Insert Molding Reeling Systems
    Used an air feed  and reeling system for an insert molding operation on a vertical injection molding machine. Two strips were controlled by  PlcDirect340 system. The PLC also controlled the custom sprue picker robot and interfaced with the Engle molding press to provide mold safety.
 

1993

Multiport Inline HIPOT Inspection System
    Developed a 600 VDC Hipot Test for use on a multiport assembly machine.. The unit consists of a High Voltage Power supply, high speed reed relays and a Keyance KV40 PLC which also performed a high speed continuity and short test. It ran all 3 tests at 150 ports/minute..

CHAMP 4th Generation Assembly/Inspection/Packaging Retrofit
    Upgraded STD BUS embedded control system on assembly machine to use a PLC Direct 440 with interrupt control. Replaced touch screen display with TCP Smart Touch Display. Added PLC network communications to the Inspection Module for transmission of setup data. An Ascii Basic Module was added to the module to send configuration data to the PC based Inspection System. The packaging system STD BUS system was replaced with a 440 CPU and pulse modules to control the stepper motors.

1992

Modular Plug Assembly Machine   - 2nd Generation Controls
    High speed (350-400 assemblies /minute). Controlled by a PLC Direct 440, Allen Bradley Machine Vision  CVIM  inspection of 100% of the parts. Utilized  the smart slice remote I/O system to control the vibratory feeder, automatic packaging system and reeling system.  Used a TCP Smart Touch Display  for the HMI to setup the machine parameters.

CHAMP 4th Generation Inspection System

    Worked closely with an outside vendor to develop a PC based inspection machine. The unit consisted of a constant velocity belt with an encoder tracking system that took multiple pictures of each part as it passed through the system. Custom light sources were developed to inspect terminal coplanarity. The system inspected 100% at 140 assemblies/minute.
 

1989-1991

Mylar/Polyester Film Laminator
    The machine joined 2 films together which involved control of a corona treatment roller ,  IR oven,  induction heated rollers, web tension controls, positioning and speed control.  A TI305 was used to automatically control the entire process. A Computer Dynamics 186 STD BUS computer was added to collect data from Newport meters monitoring 9 different process parameters, a Burr Brown ASCII terminal, a Redlion Rate/Footage meter and from the PLC. The monitoring system was written in C and involved writing  protocols for all the meters, the operator terminal and the PLC communications. A windows DDE driver was written for Windows 3.11 using MS Windows SDK  to communicate over a BITBUS network to the STD BUS computer and poll data from the machine. The DDE link transferred production and trace information to an Excel spreadsheet which was running Excel 4.0 macros on a remote PC. A data collection  spread sheet was automatically generated for each roll of material produced.
 

Modular Plug Assembly Machine  1st generation Controls
      High speed (325 assemblies /minute). Controlled by a GE Series 1 PLC.  High Speed counter module was used to count the inserted terminals.
 

Robotic Insertion Machine

    Worked with an outside vendor to develop a 110 connector to PC board insertion machine using an Adept Robot for the control system.

1985 - 1989

Modular Plug Strip  Assembly Machine
    Controls consisted of an 8085 STD BUS embedded computer and an ASCII Text touch screen. The operator used the display to program selective insertion of the part. Counter timer card was used as a high speed pin counter.

CHAMP Packaging Machine
     Developed an embedded control system  using STD BUS 8085 computers and a IEE488 communications network. to control a machine that packaged the connectors into an egg crate style box. The parts were singulated, rotated and dumped row by row into a foam tray. STD BUS pulse indexer cards were used to control 4 Compumotor stepper drives. Absolute resolvers verified positions of each axis. The machine received setup and command information via the 488 link.

CHAMP 4th Generation Assembly Machine

    Developed an embedded control system  using STD BUS 8085 computers and a IEE488 communications network. The system used Ascii text touch screen displays and allowed control of the entire line from any terminal on the machine. The assembly machine used a centrifugal bowl feed system, ultrasonic loop controls and a pulse train DC motor speed control.

1982 -1984

    Designed several reeling systems using AB PLC2 and OMRON S6   PLC's for injection overmold processes.  Worked with line scan camera's in development of a proprietary vision inspection system using STD BUS 8085 embedded computer systems
 
 

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