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
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
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,
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.
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
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.
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.
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
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
Department Group leader for 9 years
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
Embedded Computer Systems
Worked with several integrators to
design controls for assembly equipment, typically in the $250k to $1M +
Project Team for Machine Acquisition
from Outside Integrators