Project Resume

 Below is a partial & brief listing of projects we have done in recent years.


Alarm manager & light curtain tracking & control system.  PLC based system monitored all safety light curtains and alarm scenarios that prevented a "machine run" condition.  Software coupled with light curtain breakage prompted the machine operator to enter a reason for light curtain breakage.  Software & hardware covered up to 8 zones of protection, encompassing the entire battery assembly machine.  Completed software was implemented to all battery assembly machines. Hardware on this project included 2 GE 90/30 PLCs communicating over a Genius network to a GE90/70 as the main data concentrator. 4 17" remote displays running a Visual Basic application were incorporated for alarm display & operator interface. This application meet the customerís expectations.


6 station 800HP DC wire draw machine. Upgraded the motor drive system and converted the control system to a recipe oriented PLC based control system with dual remote operator interface units, auto field weakening, extensive alarm manager & system diagnostics.  This project exceeded the customer's original control specifications and his personal expectations. He was especially happy with the 1 button start & stop controls that were incorporated into the system. The recipe set-up for the field weakening of the DC motors was also a big hit with the customer. A very very successful project.


A.S.R.S. product storage & retrieval system. Upgraded traffic control software and implemented R.F. ID tagging system to track and transfer product to and from production to storage and from storage to shipping. Transfer of and storage of battery products were fully automated. All batteries are sent to storage for a period of time before final testing & shipping. All batteries from the production area are loaded into multiple slot storage magazines. Each magazine holds approx 24,000 batteries. Batteries coming into the staging area were stacked and sent to one of three holding vaults. Each vault incorporated a crane that would pick up the magazines and take the product to a storage location to be held. The TíCar would take the magazines from a central location to one of the three cranes, or from one of the three cranes to either a shrink wrap area or to a queue for further evaluation. The motion control of the TíCar was control by a GE PLC. Via a optical modem, the PLC would receive information about a storage magazine that was ready for pickup or transfer. The TíCar would then go to that location, pick-up a storage magazine and transfer it to one of 15 drop-off points. In addition, the TíCar had to verify which product was aboard and that it was positioned properly on itís flat bed. A series of conveyor rollers were used in picking-up and depositing storage magazines. Motion control coordination with other pick-up and drop-off conveyors were critical when picking up and dropping off the magazines. A series of optical sensors along with RF ID tags were employed to locate the TíCarís position, and sense conveyor alignment. All motion, conveyor control, sensors and product I.D. was under PLC control. The TíCar employed two sets of conveyors so that it could pick-up two storage magazines and make multiple pick-ups or drop-offs. Each storage magazine weighed about 2,000lbs and the TíCar itself weighed about 2 tons. Motion control of the TíCar, especially during braking and acceleration was critical due to the heavy loads. While transporting product between drop-off and pick-up points, the TíCar was expected to achieve max. speed to minimize transfer times. Special braking and accelerating algorithms were written into the PLC code to accomplish this and not overrun or under-run the target. Hardware on this project included a GE 90/30 PLC with a Ethernet radio communication link. RFID tags were by OMRON. Customer was very satisfied with final results.


Brake pad pre-press operation. Conceptualized, designed, installed and implemented software development for 10 pre-press control systems for the automotive industry. Features included extensive graphics for operator interface, high compliance PID loops for heat control, and extensive safety interlocking to prevent operator injuries. Hardware was 10 GE 90/30 351 PLC systems with 10 Exor (Uniop) BKDR touch screen displays. SCR heat controller packs were custom configured by ADC for this project.


380 Ton chiller plant. Unique software & PLC based control system controlled 6 - 60 ton chiller units. Software featured auto-rotation and automatic swap-out of faulted chiller(s), staggered & stand-alone chiller operation. Central operator interface allowed complete control of entire system, chiller selection, extensive alarm & diagnostic data display. Custom written communications software & daughter board were designed and built to interface with chiller controls. Hardware for this project was a single GE 90/30 331 process or and communications card over a serial communications link to the 6 chiller units. A Cincinnati Electro system displayed was specified for this project.


Automated high speed automotive brake booster tester system. Software and hardware to control traffic flow of brake boosters coming off of the assembly line to final adjustment and testing. Each booster throw out rod was aligned to within .005Ē and sent to a queue. When 1 of 4 testers became available, the brake booster was automatically transferred to a test machine where a series of high speed real world test were performed. Test results were sent to a main data collection system for storage to meet ISO manufacturing requirements and to identify bad boosters. Bad boosters were automatically removed from the assembly line and sent to a re-assembly area. This system featured high speed motion drive systems for real world testing. All machine control, traffic management and motion control was handled by the PLC and external motion control servos and drives. Custom PLC software development interfaced high response Delta-Tau motion control hardware. Booster test rate was 225 units hourly. Hardware for this system were 5 Allen Bradley SLC 5/04 processors linked together via data highway. The operator interface was Cimplicity HMI.


Turbine re-manufacturing powder blending system. PLC controlled, O.I.U. recipe based system that blended various types of additives for the re-manufacturing of aircraft jet engine turbine blades Hardware for this system consisted of a General Electric 90/70 PLC system, running Cimplicity HMI. Recipe control of the blending operation was very extensive. This was an extremely successful project that exceeded the customerís specifications and his expectations.

R.R. Donnelley Financial

Designed various custom ďhardĒ and ďsoftĒ guards and mounting brackets for various machines that included high speed envelope inserters, shrink wrap machines, paper cutter and paper folding machines. Hardware consisted of STI light curtains, custom designed brackets and safety guards. Over 150 mechanical drawings were generated to produce support brackets, guards etc. Over 90 custom pieces were manufactured for this project Hardware on this project were various sizes STI light curtains, custom Plexiglas guards and support brackets. The customer was very, very please with the outcome of this project. His expectations were not only exceeded, but the set-up, alignment & operation of the STI light curtains exceeded our expectations for performance.



Design two custom control systems to accumulate wastewater for PH measurement & control. Each system was designed to monitor the main chemical process for waster water levels. When sufficient levels were available, the waste water was automatically transferred to a series of holding tanks. After approx. 15,000 gallons were collected, the PH of the system was automatically measured and adjusted. After adjustment of the PH, the waste water was tested for other factors and dumped to the city sewer. Several modes were incorporated into the system to allow transfer of material from tank to tank, and to trucks. Switching to emergency holding tanks were also provided. A clean mode for each tank was incorporated to periodically clean the tanks. A mass flow meter was utilized to measure lbs of water needed for cleaning. The operator was able to select and de-select pumps as required or as the process demanded. Extensive graphics displays showed pump operation, process flow selection, valve operation, PH and quantity levels in both % & gallons and extensive diagnostics and alarm functions were incorporated. Hardware on this project was two SLC Allen Bradley 5/05 processors connected via Ethernet link controlled the entire operation. Dual 15Ē OIU's running Wonderware InTouch allowed operation of both systems from two locations within the plant. All valves, instrumentation, control system components were specified by ADC. All radar & point level transmitters were Ohmart Vega, Mass flow meters and PH Analyzers were Micro Motion & Rosemount respectfully. All Valves were Crane, ITT/Richter and DezuriK with special coatings for acid or base chemical transfer. The graphics display was a huge hit with the customer. Simple displays along with bright red process lines indicating flow path selection were easy to read, follow and understand, especially when the process went through multiple valves between multiple buildings. Pump status identification was also made simple by placing bright red ďxĒ over the pumps that were either out of service or off line. Allen Bradley drives were used for tank agitation and Wika instrumentation for pressure indication. The customer was very pleased with the final outcome of this project.