STEVEN — Lead Automation Engineer

Engineering, LLC - Columbus, OH Lead Engineer Intermittently since 1987 - Present I created this sole proprietor private consulting/product development company and have enjoyed performing innovative engineering consulting work for many companies. Projects included automated food processing equipment, interactive and automated public exhibits, embedded firmware, analog and digital hardware design, building prototypes, schematic circuit design, simulation and PCB layout, general research and prototyping/feasibility studies, testing, documentation, motor controls using PLCs and BLDC motors, and legal expert work. See my website at www.RiccaEngineering.Com for more. I do not take on clients when full-time employed. Through these projects, great people and companies I have assisted, I have been able to keep sharp design skills and work on many different applications. Example projects and contract roles: - Lead Automation Engineer for a commercial cooking equipment manufacturer (Henny Penny). - Chief Technical Officer for a mid-stage start-up company (SpecGradeLED, Cols OH)) selling high volume high-power LED lighting for highways, parking lots, stadiums, tunnels and airport apron lighting applications. Led development of custom cast enclosures, control panels, and custom sheet metal brackets for occupancy sensors. Developed custom circuitry for power supply management and provided technical oversight on certification efforts. Assisted Sales department in strategy, power-point presentations and customer facing meetings. Authored many technical papers and blog materials used on the company website. - Developed system architecture and early feasibility concepts for a start-up stadium beverage dispensing company that used CAN communications and magnetic field sensors to control valves and fluid control remotely with reporting to the cloud (Sestra Systems, Sterling VA). - Lead electrical engineer for a start-up alternate energy company (GreenField Solar, West Cleveland) developing a solar concentrating photovoltaic and thermal energy system. Produced a functioning system of proprietary sun tracking hardware/software controls including next generation control system including supervisory CAN. Selection and qualification of solar inverters as well as power distribution components. Technical oversight of field installations in Ohio to power generation companies. - Designed a measurement and data collection unit for a US Air Force program to optically measure hydraulic fluids using IR Pyroelectric detectors. Designed the circuit schematics, PCB layouts, and the embedded firmware architecture while also assisting with the software for this multi-PCB, multimicroprocessor system used by ground maintenance crews servicing combat airplanes. (METSS Inc) - Served as Director of Engineering for over two years with a start-up medical electronics diagnostics company (DiraMed, Cols Oh). A large contributor and named inventor to a US patent which was also granted foreign patent status in over 20 countries - Zero Corrected Optical Blood Glucose Analyte Detector" (US #7039448). Managed the proof of principal research performed at several spectroscopy laboratories. - Designed RF remote control sport hunting aid prototype that led to a patent application. - Developed a boost power supply for a medical imaging product driving high intensity NIR LEDs. - Electrical Engineer consultant for local company (Therapeutic Medical Devices) developing a high volume touch screen tablet based device and software application used by medical patients recently discharged from hospitals. Device interfaces to internal camera and other medical data collection instruments (blood pressure, glucose meter, EKG, etc) via Bluetooth. Device allows patient monitoring and interaction with medical staff without readmitting to hospital. - Redesigned the PCB layout for several large LED price displays for a national gas station chain OEM (Able Advanced Technology, Cols OH) to solve heat distribution issues that were warping boards. - Designed a high intensity LED driver and battery charging circuit for a portable traffic sign application. - Designed a very compact PCB layout solution to interface force sensors inside a US ARMY helmet for a company that tested helmet designs using a DAQ system. - Designed an optical sensing system prototype for use in a golf putting video simulator. The prototype used laser diodes and high speed microprocessor detection. This effort involved circuit design, PCB layout and firmware which communicated to a PC. - Consultant to a start-up company developing a urine collection bag with very accurate level sensing and remote RF data transmission to a centralized monitoring station. Led to patent application. - Development of a consumer item to detect motion and illuminate with solar power recharging. - Development of an automated plant watering system designed for low cost and customer assembly. - Reverse engineered a product and provided a detailed report for a client which allowed them to justify a larger redesign project to stay competitive. - Provided engineering support and architectural system development work for a product line of heater controls and touchscreen connected via ModBus RTU for temperature control in semiconductor and critical pharma manufacturing (BriskHeat, Cols OH). - Designed, programmed, wired and installed controls for several moving, interactive museum exhibits installed in several cities. These were typically PLC based, ModBus connected BLDC motor drivers with position, optical and proximity sensors; as well as, acoustic and custom designed sensors for unusual applications (Boss Display, Cols OH). - Performed expert technical testing and report generation for several legal firms and cases involving medical, industrial and consumer product liabilities. - Provided expert witness deposition testimony involving automotive controls and wiring for an aftermarket patent infringement case. - Developed automated PLC controls to press a spring on bushing assembly using an indexing rotary table, light curtain sensor and hydraulic actuator. - Developed automated PLC controls with HMI for a manufacturing line pressure fryer test cell

IRD Mechanalysis (Now Rockwell Automation) - Worthington, OH Sept 1990 - Dec 1995 Senior Project Engineer - Project Manager - Responsible for system design, integration and project management involving large vibration monitoring process control projects. Used company and COTS products when available, designed custom products to bridge gaps and improve project success. - Rotating machinery vibration and temperature monitoring applications and industries served included power generation (make-up air fans, boiler and oil feed pumps, turbines), transportation systems (railcar wheels and tunnel fans), machining centers to gauge tool wear, paper mills (pumps and web break detection), petrochemical processing plants (crackers, compressors, drill wear detection) - Developed control cabinets and equipment to measure vibration and temperatures of bearings in large fans that were critical to a project that decommissioned stockpiles of military chemical weapons at eight US sites. - Designed semi-automated end-of-line test stations for General Motors transmission, alternator, starter and electric motor divisions. - Coordinated all project cycle engineering functions: design, costing, scheduling, project management, selecting and supervising sub-vendors, testing, and managing field service staff. - Development of redundant power supply for use in Nuclear power plant monitoring application. - Worked with outside sales and customers to develop the best solution and secure orders

Henny Penny Corporation - Eaton, Ohio Oct 2016 - June 2018 Lead Automation Engineer - Contractor - Key technical contributor within a team developing automated equipment involving freezers, fryers and packaging solutions for fast food chains. - Lead team through brainstorming, specifications, prototyping, experimentation, customer acceptance tests, refinements and presentations to stakeholders. - Developed architecture, selected all electrical components including contactors, pumps, VFDs, PLC, sensors and HMI. - Performed all programming which involved five high performance servo motors with embedded assembly programming, large programming effort with three PLC CPUs with many I/O, and an HMI touch screen connected to the cloud for remote access. - Interfaced with external design team to accelerate dispensing equipment development by 3 rd party. - Interfaced PLCs and programmed for a vision recognition sensor and conveyor for packaging option. - This work resulted in several functional prototypes capable of automatically cooking over 200 pounds of product per hour and several patents are pending

Hughey and Phillips - Urbana, Ohio Jan 2014 - Feb 2016 Director of Engineering - Engineering manager for a leading company of FAA regulated obstruction lighting products: Flashing beacons for tall buildings and towers using LED technology and microprocessor controls with remote monitoring via Ethernet, SNMP traps and cellular wireless. - Refined marketing PRS to Engineering specifications and design requirements for engineering team as well as overseeing hardware and software design reviews. - Architecture development for new systems and product roadmap planning. - Design and simulation of circuits, research for new LED lighting approaches including optics and thermal management considerations. - Provided insight and information on competitor products including teardowns, and testing for compliance to FAA certification standards. - Assisted sales and marketing to identify emerging markets and opportunities for new products and interface with key customers. - Developed new control panel system with remote monitoring for use by utilities needing obstruction lighting on very tall high-voltage power distribution towers (345KV). Extensive installation and commissioning oversight and participation for first systems installed. Instructed software engineers and developed methods to overcome high electrical noise present due to corona effects. - Named inventor of US patent # 20160304215, "Obstruction Lighting System Configured to Emit Visible and Infrared Light" - Continued to assist as consultant to company after leaving position

ADB Airfield Solutions - Gahanna, Ohio Feb 2010 - May 2013 Electrical Engineering Group Leader / Program Manager - Engineering manager for the worldwide leading company of airfield lighting products, and signs utilizing high-power LEDs and custom switching power supplies. - Introduced gated design methods, FMEAs and other engineering process improvements. - Supervised and participated with electrical engineering team on research and development, cost reduction and manufacturing support efforts. - Coordinated efforts between engineering and other departments: logistics, quality, sales, tech services, marketing, and production. - Managed large design effort developing next-generation airfield serial communication devices using OFDM and proprietary high reliability communication methods. - Led efforts on a $1million/yr cost reduction for power source product line (4KW - 30KW switcher). - Participated and managed the HW/FW design of a switching power supply to replace large incandescent light panels and signs with LEDs - resulting in over $600K/year manufacturing cost reduction. - Key contributor to redesign a family of 4KW to 30KW power supplies using microprocessor controls and resonant magnetics methods for excellent stability in airfield power distribution applications. - Instructed and worked with service personnel to troubleshoot and overcome field issues and then used these experiences to improve products. - Interfaced and presented highly technical matters to outside customers and the FAA. - Appointed member on the FAA's "Electrical Infrastructure Requirements for Tomorrow" technical test team comprised of engineering leaders in the airfield lighting industry and reporting to the FAA

Battelle Memorial Institute - Columbus, OH March 2006 - Nov 2008 Principal Electrical Engineer - Medical Development Solutions Group - Lead Electrical Engineer on a large clinical diagnostic product development involving over 50 engineers of various disciplines. This automated equipment can process over 250,000 samples a year and contains 17 BLDC servo motors, a centrifuge, and over 50 sensors of many types. Responsible for selecting and designing virtually all elements of the electrical hardware design including system architecture, motor controls, sensors, design of custom PCBs, isolation strategies, and wiring harness design. - Led electrical and software engineering efforts to prototype a docking station for a portable medical product used to administer diabetic medicine. - Team member on development project for electrical and mechanical product FDA verification protocols for a major eye-care client's new surgical product. This product included CAN, Bluetooth and RS-232 serial communications. - Assisted on standards review of a new breathing apparatus medical product. Independent reviewer for IEC 60601 certification reports from Intertek on this project. - Performed high-voltage research and development input for an electrostatic pesticide sprayer product. drive/feedback systems for a screw drive piston cartridge delivery system. Designed, built and tested many configurations of high-voltage multipliers and - Principal electrical engineer on an investigative project to improve reliability of a major hospital bed manufacturer's motorized bed product line. Participation in a multi-disciplined team evaluation led to several improvements of the client's electromechanical mattress inflation control system

June 2004 - March 2006 Invensys Controls (Ranco/Robertshaw) - Plain City, OH Senior Design Engineer - HVAC Equipment Controls / Lead EE Automotive Climate Controls - Engineering leader for high-volume gas fired heating control products used in OEM furnace, fireplace and food cooking products - fryers and ovens. Electrical ownership and oversight of projects to design test and ramp-up manufacturing of a high volume residential furnace controls. Assisted and directed validation procedures, agency approvals, and worked closely with automated functional and in-circuit tester vendors. Assisted manufacturing engineers to tune a new highly automated line at the company's newest high volume facility in Mexico. - Performed engineering oversight and technical maintenance on a diverse line of spark and hot surface igniter gas control and flame control products with over 5000 SKU's typically used in cooking, process control heating, building automation systems and residential climate controls. - Worked with marketing to assess competitor's products and current market needs for ignition control modules. Key architect for a new family platform to address these market needs and open up new opportunities. - Participated in design reviews and contributed engineering solutions to other product divisions at this Engineering center - namely Refrigeration Controls, Smoke Detectors, HVAC Zoning Controls, Automotive Controls and Thermostats. - Also served as the Lead Electrical Engineer for the automotive climate control group. This position interfaced with OEMs to develop cabin zoning controls involving motorized blending doors, multi-port water valves and sensors. Coordinated technical activities of manufacturing plants in Mexico and Michigan to ramp up productions and increase production yields. - Evaluated hundreds of internal products for safety compliance at the hardware and software level when several acquired company's products became part of my product line responsibility. - Developed a new automotive product family to replace an older AC freeze protection control with a microprocessor based design incorporating an innovative production line calibration method

Dynalab Test Systems - Reynoldsburg, OH June 1997 - July 2002 Senior Electronic Engineer / Research & Development - Developed several products and improved an existing line of cable and harness testing analyzers. 1* Investigated alternate architectures for new product family networking and wireless methods. 2* Developed microprocessor relay controls to expand product line for use with harness test fixtures. 3* using our assembly station and end-of-line test products Worked with automotive and appliance OEMs to develop best test methods and approaches for

Danninger Medical Technology, Inc Dublin, OH (now Ortho-Logic) Nov 1995 - June 1997 Senior Electronic Engineer / Research & Development - Product improvements, research, development of electronics and embedded firmware for medical rehabilitation products involving motors for very slow and smooth human joint motion. 4* Redesigned a brushless DC motor drive PCB and embedded firmware to improve reliability. 5* and increasing the average profit margin. Consolidated product lines and implemented design changes reducing the overall cost of goods 6* Improved compressor-less thermal therapy products which pumped chilled and heated water to bandaged areas. 7* Presented new engineering concepts and product roadmap to shareholders and investors. 8* Assisted in transfer of Engineering Intellectual Property to acquiring company

July 1988 - Sept 1990 Toledo Scale (Now Mettler-Toledo) - Worthington, OH Project Engineer - System design and programming involving innovative electronic weighing equipment. - Programmed multi-tasking interfacing software which connected third party or customer's existing PC's, mainframes, card readers, barcode scanners, and PLC's to Toledo Scale proprietary equipment (load cells, conveyer weighers, sorters, drum weighers, classifiers, and rail scales). - Generated software and led teams that developed several firsts in the electronic weighing industry including - self-service money tending truck scales(now CAT scales), food packaging classifiers and wrappers, drum-fillers, barcode weighing stations, railway filling, and liquid batch controls including high speed keg-weighers. - Developed software and controls as part of team implementing one of the first automated packaging routing systems that read bar-codes and logged weight on high speed conveyor lines. The control system actuated gates to route packages to the destination truck loading station. Multiple weigh points and timestamps were performed to verify the package integrity along the route. This system was a precursor to most automated packaging systems used today by UPS, FED-Ex, Amazon and others. - Lead software engineer on retail scale project for first networked scale with an integrated printer. System would update central computer in real-time as produce, bakery, butcher and seafood items were weighed and purchased so that logistic activities would restock these perishable items. Product was developed ahead of schedule, and was tremendously successful - generating over $100 Million in sales per year