A.T.U.  Inc.

Automation Controls Consulting

John Washinsky, pres. 

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

109 Duxbury CT
Clemmons NC  27012
revised 8/14/2008

1999-Present  ATU  Automation - Automation Consultant
  • Control System for Metal Tube Assembly Operation                                              Designed and built a Compact Logix controlled hydraulically operated assembly cell for the manufacture of copper heat exchanger tubes. Included mulitple of PID control loops and a detailed operator interface.
  • Online Data Analysis system                                                                                       Designed , built and installed a PLC based data collection and analysis control system to determine defective parts in a 2 part sealant dispensing process. Using an OPC server, upto 1000 data points were collected and recorded for archival and later analyis. Algorithms were developed to determine and reject defective parts using the PLC. 
  • Feed control System for Insert Molding operation                                                              Designed , built and installed a PLC controlled, stepper motor feed and reeling control systems for an automated plastic injection molding production line. User friendly and versatile system with recipemanagement. Completed 20 units on time and within budget. 
  • Pallet Assembly System Upgrade

  • Documented, debugged  and upgraded an existing production line with  diagnostic capabilities. 
    Control system consisted of an Allen-Bradley  Control-Logix 5000  control system with multi-Axis Servo pick and place units. Improved output of machine from 4000 pieces/shift to 8500 pieces/shift. 
  • Assembly Equipment Programing

  • Programed several pieces of assembly equipment which included PLC's, Servo Drives and Touch Screen Displays. 

1982-1999 AMP Inc. Winston-Salem, NC

Senior Machine Development Engineer

Designed control systems for assembly, stamping and injection molding of small, high tolerance electrical connectors for the communications industry. Department dissolved by Tyco after a takeover.

  • Department Group leader for 9 years
In addition to having multiple projects, my responsibilities included organizing work flow for 4 other engineers and up to 6 technicians in the panel construction and wiring area. Provided assistance to technicians in the manufacturing plant. Provided training for electrical engineers on the company rotational engineering program. Driving force behind the company's Electronic Technician Apprenticeship program. 
  • PLC based Control 
Responsibilities include concept, quotation, component selection, electrical design, CAD drawings of schematics, programming, debugging and plant installation. Ranging from small test fixtures to multiple CPU, high speed assembly equipment (450+ Parts/min). Typical machines were walking beam, pneumatic, rotary and servo based. Control packages were approximately $5K to $100K.
  • Motion Control
AC/DC drive systems with analog/pulse control. Sizing of stepper/servo motor systems. PLC pulse modules, stand-alone intelligent drives and multi-axis coordinated motion. Designed an 8 axis assembly machine with servo controlled walking beam and tooling using Sercos based PC controller. 
  • Machine Vision Systems
Applications include multiple image inspections per cycle of small high tolerance parts. Developed lighting and presentation techniques to inspect parts at high rates (450+ parts/min). Developed automatic setup for AB systems
  • Operator Interfaces
Worked with a variety of message displays. Developed an operator interface using a touch screen monitor, Visual Basic and Microsoft Office for part configurations and data acquisition. HTML pages were automatically generated to show production data on company intranet.
  • Embedded Computer Systems
5 years exp. with an 8085 STD Bus development, written in PLM and ASM assembler. Developed multiple CPU applications. Designed a data acquisition system with 80186 STD Bus platform, programmed in Microsoft C. Wrote a DDE driver for BITBUS with Microsoft's SDK development software for Windows 3.11
  • Project Team for Machine Acquisition from Outside Integrators
Worked with several integrators to design controls for assembly equipment, typically in the $250k to $1M + range.
Education 1978-1982 BSEE 1982 Penn State University University Park, Pennsylvania 

3.4 of 4.0 in the Electrical Engineering Curriculum, concentration in computer control


Interests Ukrainian folk art and culture. Wood working Bicycling