Donald — Controls Engineer

Controls Design – Create controls system that makes the most effective use of the available hardware and software to achieve the Project Goals as defined by the Project Scope. Ensured adherence to BMW v8.1 naming and addressing conventions in ePlan, SAS, and TIA.

Support Production and Improve Communications between four PLCs (S7-300, S7-400, GuardLogix, and MicroLogix). Troubleshooting Production slowdowns via RSLogix 5000. Allen-Bradley PLC Programming for LBLA Project and LTSL Project – Track Shoes for Heavy Equipment Set Network Communication Parameters on PLCs, HMIs, & switches. Wrote routine for Dual Laser Part Measurement, I/O Mapping, Safety I/O Mapping, Indicator Lights, Network Switch Interface, VFD Conveyor Logic. Performed I/O Checks on all Field Modules Primary responsible for Longbar (LBLA) Project LBLA: PLC Programming for Electromagnetic (EM) Cartesian Robotic System, Hydraulic Index Table with EM Turnover, LMI Gocator Vision System, Lowerator, & Conveyor System LBLA: Allen-Bradley HMI User Interface & LMI Gocator Vision System Part Recognition Configuration.

-Added logic for 8 new part types, a tooling and fixture nest with sensing for 25 pieces, and Robot End of Arm Tooling -Robot tooling into existing system

-Created Data Types that were Integral to System Communication & Part Data Collection

-Troubleshooting Production slowdowns via RSLogix 5000, Step7, Red Lion Crimson, Connected Components Workbench, and WinCC Explorer -Working with technicians to troubleshoot any inconsistencies.

-Debug & Optimization of commissioned systems while supporting production -Provide support during downtime to get maintenance back on schedule -Support Production and Improve Communications between four PLCs (S7-300, S7-400, GuardLogix, and MicroLogix), and one Red Lion Data Station Plus Data Logger -Developed an adapted system design with customer feedback and support to complete project goal using existing resources

-Configure all hardware and software to perform as designed and prioritize optimization of system parameters and performance with guidance of Senior Controls and Management. -Commissioning of complete automation systems -Completed system commissioning in harsh weather conditions

-Create controls system that makes the most effective use of the available hardware and software to achieve the Project Goals as defined by the Project Scope.

-Created Data Types that were Integral to System Communication & Part Data Collection

-Design of complete automation systems -Designed Hardware Overview documentation for station fixtures and material-handling end-of-arm tooling, and delegated related tasks to juniors -Design & Commission 6 systems for assembling G05 / G07 Doors -Developed an adapted system design with customer feedback and support to complete project goal using existing resources -Ensured that all system design changes taken into account in PLC logic and HMI files.

-Hydraulic Index Table with EM Turnover,

-Verify that system installation matches the design by performing Input/Output and Communications check, and working with technicians to troubleshoot any inconsistencies.

-RSLinx, RSNetworx, TIA Portal, RSLinx, DeviceNet, Ethernet/IP, ProfiNet, ProfiBUS, EtherCAT

-Configure OPC server to work with additional system devices and components

-Siemens PLC hardware configuration and code modification to integrate new hardware fixtures -Allen-Bradley PLC Programming for LBLA Project and LTSL Project -Communications between four PLCs (S7-300, S7-400, GuardLogix, and MicroLogix), and one Red Lion Data Station Plus Data Logger -Wrote Sequences for 20% of the 4-Zone PLC System -LBLA: PLC Programming for Electromagnetic (EM) Cartesian Robotic System

-KUKA Kore Certification, ABB Robotics -Added logic for 8 new part types, a tooling and fixture nest with sensing for 25 pieces, and Robot End of Arm Tooling

-Create controls system that makes the most effective use of the available hardware and software to achieve the Project Goals as defined by the Project Scope -Design & Commission 6 systems for assembling G05 / G07 Doors

-Troubleshooting Production slowdowns via RSLogix 5000, Step7, Red Lion Crimson, Connected Components Workbench, and WinCC Explorer -Working with technicians to troubleshoot any inconsistencies.

-VFD Conveyor Logic

-EKS InTec Suite (HMI, RobSim, SGView, etc.), WinMOD, SimulationUnit

-Design, Installation, and Commissioning of complete automation systems

-PLC programs to interface with Cognex Cameras and barcode readers

-Configure all hardware and software to perform as designed and prioritize optimization of system parameters and performance with guidance of Senior Controls and Management. -Commissioning of complete automation systems -Completed system commissioning in harsh weather conditions

-STL, LAD (Siemens & Allen-Bradley/Rockwell), FBD, GRAPH 7, BASIC, C++, Java, MS Excel, Beckhoff TwinCAT, ePlan Electric P8 v2.4

-Ensured that all system design changes taken into account in PLC logic and HMI files.

-Allen-Bradley PLC Programming for LBLA Project and LTSL Project – Track Shoes for Heavy Equipment

-Create and modify HMI screens, tags, and faults in ProTools to allow for control of device and parameter display -Set Network Communication Parameters on PLCs, HMIs, & switches -LBLA: Allen-Bradley HMI User Interface -Installed Interface Software on the Siemens HMIs

-Configure OPC server to work with additional system devices and components

-PLC programs to interface with Cognex Cameras and barcode readers, Keyence G2 sensors, Kistler Servo Presses, DeSoutter Smart Arms, Bosch Nutrunners, Siemens RFID sensors, and Pneumatic Manifolds

-PLC, HMI, Bosch Nutrunners, & Kistler Press Programming for PTU Transmission Assembly Line

-Troubleshooting Production slowdowns via RSLogix 5000, Step7, Red Lion Crimson, Connected Components Workbench, and WinCC Explorer -Working with technicians to troubleshoot any inconsistencies.

-EKS InTec Suite (HMI, RobSim, SGView, etc.), WinMOD, SimulationUnit

-LMI Gocator Vision System Part Recognition Configuration

-Controls Engineer: Design, Installation, and Commissioning of complete automation systems -Controls Design – Create controls system that makes the most effective use of the available hardware and software to achieve the Project Goals as defined by the Project Scope -System Installation – Verify that system installation matches the design by performing Input/Output and Communications check, and working with technicians to troubleshoot any inconsistencies. -Project Commissioning – Configure all hardware and software to perform as designed and prioritize optimization of system parameters and performance with guidance of Senior Controls and Management. Gestamp, Union, SC – Design / Commission BMW G05 / G07 Front/Rear Door Lines Controls Designer: Design & Commission 6 systems for assembling G05 / G07 Doors  Designed Hardware Overview documentation for station fixtures and material-handling end-ofarm tooling, and delegated related tasks to juniors.  Assigned I/O & ProfiNet addresses for all devices, and updated through system re-designs.  Ensured adherence to BMW v8.1 naming and addressing conventions in ePlan, SAS, and TIA.  Manage import/export of system hardware data between ePlan and BMW SAS.  Configure all systems in BMW SAS and write sequences for each process.  Configure Hardware for each system in Siemens TIA Portal  Generate/Export base programs from BMW SAS / Import into TIA Portal  Virtually Commission systems at multiple international locations  On-site Commissioning of real components at Installation Site  Debug & Optimization of commissioned systems while supporting production DTNA, Cleveland, NC Cab Clamp & Options Up-fit Up-fit running system to accommodate additional part types / options  Determine / configure interface with in-place system to obtain running files, and create project to perform the up-fit procedures.  Test/Debug system with On-site Controls Engineers & Maintenance Technicians Gestamp, WV – Support  Provide support during downtime to get maintenance back on schedule. Gestamp, Union, SC – BMW F25 Hood Support/Upgrade Support Production and Improve Communications between four PLCs (S7-300, S7-400, GuardLogix, and MicroLogix), and one Red Lion Data Station Plus Data Logger  Improved coordination between PLC zones via improved communications through Red Lion  Added logic and manual controls for new hardware Using Connected Components Workbench and WinCC  Troubleshooting Production slowdowns via RSLogix 5000, Step7, Red Lion Crimson, Connected Components Workbench, and WinCC Explorer Gestamp, Union, SC – Press Line 1 / Press Line 2 Create logic and tags to allow for control of Wandres System and display of system parameter status, and facilitate communication between the S7-400 on the Wandres and the Beckhoff PLCs on Destacker and Line Master in Beckhoff TwinCAT Wandres Blank Cleaner Install & Retrofit Create and modify HMI screens, tags, and faults in ProTools to allow for control of device and parameter display  Configure OPC server to work with additional system devices and components GKN Driveline – Peco Laser Welder Retrofit  Siemens PLC hardware configuration and code modification to integrate new hardware fixtures, I/O, and robot tooling into existing system  Added logic for 8 new part types, a tooling and fixture nest with sensing for 25 pieces, and Robot End of Arm Tooling  Developed an adapted system design with customer feedback and support to complete project goal using existing resources Caterpillar, Skinningrove, UK – Longbar Load Area / Large Track Shoe Load Area Allen-Bradley PLC Programming for LBLA Project and LTSL Project – Track Shoes for Heavy Equipment  Set Network Communication Parameters on PLCs, HMIs, & switches  Wrote routine for Dual Laser Part Measurement, I/O Mapping, Safety I/O Mapping, Indicator Lights, Network Switch Interface, VFD Conveyor Logic  Performed I/O Checks on all Field Modules  Primary responsible for Longbar (LBLA) Project  LBLA: PLC Programming for Electromagnetic (EM) Cartesian Robotic System, Hydraulic Index Table with EM Turnover, LMI Gocator Vision System, Lowerator, & Conveyor System  LBLA: Allen-Bradley HMI User Interface & LMI Gocator Vision System Part Recognition Configuration  Completed system commissioning in harsh weather conditions Faurecia – Seat Track Project PLC Programming for Seat Track Line  Ensured that all system design changes taken into account in PLC logic and HMI files. GKN Drivelines – PTU Project PLC, HMI, Bosch Nutrunners, & Kistler Press Programming for PTU Transmission Assembly Line  Created Data Types that were Integral to System Communication & Part Data Collection  Wrote Sequences for 20% of the 4-Zone PLC System  Created detailed tightening programs for use with Bosch Nutrunners  Configured Pressing Profiles for Kistler Presses using keypad & configuration utility  Created Interfaces, Performed Firmware/Communications Setup, and Installed Interface Software on the Siemens HMIs  PLC programs to interface with Cognex Cameras and barcode readers, Keyence G2 sensors, Kistler Servo Presses, DeSoutter Smart Arms, Bosch Nutrunners, Siemens RFID sensors, and Pneumatic Manifolds

I maintained all of the computers and technological equipment at all of the Mr. Knickerbocker locations. I assisted with all technology-related issues that arose, and maintained the website.

Longbar Load Area / Large Track Shoe Load Area: -Allen-Bradley PLC Programming for LBLA Project and LTSL Project – Track Shoes for Heavy Equipment -Set Network Communication Parameters on PLCs, HMIs, & switches -Wrote routine for Dual Laser Part Measurement, I/O Mapping, Safety I/O Mapping, Indicator Lights, Network Switch Interface, VFD Conveyor Logic -Performed I/O Checks on all Field Modules -Primary responsible for Longbar (LBLA) Project -LBLA: PLC Programming for Electromagnetic (EM) Cartesian Robotic System, Hydraulic Index Table with EM Turnover, LMI Gocator Vision System, Lowerator, & Conveyor System -LBLA: Allen-Bradley HMI User Interface & LMI Gocator Vision System Part Recognition Configuration -Completed system commissioning in harsh weather conditions

Seat Track Project -PLC Programming for Seat Track Line -Ensured that all system design changes taken into account in PLC logic and HMI files.

Cab Clamp & Options Up-fit -Up-fit running system to accommodate additional part types / options -Determine / configure interface with in-place system to obtain running files, and create project to perform the up-fit procedures. -Test/Debug system with On-site Controls Engineers & Maintenance Technicians

Projects: BMW G05 / G07 Front/Rear Door Lines, BMW F25 Hood Support/Upgrade, Press Line 1 / Press Line 2 -Controls Designer: Design & Commission 6 systems for assembling G05 / G07 Doors -Designed Hardware Overview documentation for station fixtures and material-handling end-of-arm tooling, and delegated related tasks to juniors. -Assigned I/O & ProfiNet addresses for all devices, and updated through system re-designs. -Ensured adherence to BMW v8.1 naming and addressing conventions in ePlan, SAS, and TIA. -Manage import/export of system hardware data between ePlan and BMW SAS. -Configure all systems in BMW SAS and write sequences for each process. -Configure Hardware for each system in Siemens TIA Portal -Generate/Export base programs from BMW SAS / Import into TIA Portal -Virtually Commission systems at multiple international locations -On-site Commissioning of real components at Installation Site -Debug & Optimization of commissioned systems while supporting production -Support Production and Improve Communications between four PLCs (S7-300, S7-400, GuardLogix, and MicroLogix), and one Red Lion Data Station Plus Data Logger -Improved coordination between PLC zones via improved communications through Red Lion -Added logic and manual controls for new hardware Using Connected Components Workbench and WinCC -Troubleshooting Production slowdowns via RSLogix 5000, Step7, Red Lion Crimson, Connected Components Workbench, and WinCC Explorer

PTU Project and Peco Laser Welder Retrofit -PLC, HMI, Bosch Nutrunners, & Kistler Press Programming for PTU Transmission Assembly Line -Created Data Types that were Integral to System Communication & Part Data Collection -Wrote Sequences for 20% of the 4-Zone PLC System -Created detailed tightening programs for use with Bosch Nutrunners -Configured Pressing Profiles for Kistler Presses using keypad & configuration utility -Created Interfaces, Performed Firmware/Communications Setup, and Installed Interface Software on the Siemens HMIs -PLC programs to interface with Cognex Cameras and barcode readers, Keyence G2 sensors, Kistler Servo Presses, DeSoutter Smart Arms, Bosch Nutrunners, Siemens RFID sensors, and Pneumatic Manifolds -Siemens PLC hardware configuration and code modification to integrate new hardware fixtures, I/O, and robot tooling into existing system -Added logic for 8 new part types, a tooling and fixture nest with sensing for 25 pieces, and Robot End of Arm Tooling -Developed an adapted system design with customer feedback and support to complete project goal using existing resources

As a General Engineering Technology Major, I took courses that prepared me to work in a variety of Engineering disciplines.