David — Electrical Controls Engineer

AB KENETIX 6000 Servo Drives, AB PowerFlex40 series VFD's, AB PanelView 1200 Plus, AB Micro830 PLC

SIMATIC PC/HMI IPC577C, 6SE70 AC Drive and 6RA24 DC Drive

Mitsubishi MELSEC-Q PLC programming

OMRON G9SP Safety Controller code changes

Controls Engineer / Project electrical controls engineer supporting production and maintenance in the assembly and testing of heavy duty, commercial, military vehicle and crane, axles and drive shafts. The companies production lines assemble wheel ends, transfer cases, straight and front wheel drive axles, single and dual rear axles and press, weld and balance drive shafts. The company is updating the PLCs and HMIs and applying the Manufacturing Execution System to its lines to improve safety, quality and productivity.  Designed the control circuit and PLC programming for the RAVEN Balancers #5 - #8 to change the RobertShaw Vibraswitch Model 366 from a Normal Shutdown to an Emergency Stop Shutdown. The project included Mitsubishi MELSEC-Q PLC programming and OMRON G9SP Safety Controller code changes.  Controls design and programming of Rockwell Automation RSLogix 5000 PLC changes to automatically measure drive shaft length with a linear transducer. Code changes will fail and lockout an incorrect length drive shaft length until a department lead clears it. Investigating the application of encoders on the presses to correctly orient the yokes.  Providing engineering design, PLC and HMI code and installation management for the AWD-Axle Line Controls Upgrade project. The controls upgrade includes a new A-B ControlLogix PLC and remote I/O Expansion modules and a Red Lion Controls CR3000 HMI. The MES principles will be applied to this line. The AWD-Axle Line Over-Under Conveyor has a safety required upgrade to add two Pull Cord switches, in the Under Conveyor area a Confined Space, to replace a single E-Stop pushbutton.  Designed and installed new A-B Disconnect operator and Circuit Breakers to make three Balancers Arc Flash compliant.  Redesign of the Wheel End Line -Thrust Bearing Gauge included mechanical design, CAD mechanical and electrical diagrams and an upgrade of a Keyence GT Amplifier and Sensor to measure the Thrust Bearing and the presence of washers. The engineering work provided a cost saving of 64% over buying a new custom device.  Provided engineering design an A-B MicroLogix programming changes to implement the AWD-EVO Oil Fill system that provided oil fill error proofing of the axle wheel ends that required oil to be added. Managed the testing of the GRACO ProDispense lubricate installation system for implementation on the AWD-Axle Line.  The RAL-OP70 Axle Torque Station required A-B ControlLogix troubleshooting to reduce the torque miscounts. The ongoing project added PLC code changes to regulate the timing of the torque counts. This is part of the MES code.  Provided engineering design for the controls and VFD upgrade of the AWD-Transfer Case Tester. This project is an A-B ControlLogix PLC and 753 VFD application.

Plant electrical controls engineer supporting production and maintenance in the production of cement. Position included PLC and HMI programming and troubleshooting. PLCs used were A-B ControlLogix, CompactLogix and MicroLogix. Software was from FL Smith, a leader in cement production systems, on A-B PLC platforms and FL Smith and FactoryTalk Studio HMIs. Projects included the startup of a Truck Cement Loading system, hurricane shutdown and startup and a computer and PLC UPS

NC District Project electrical and maintenance engineering supporting the company's twenty NC East District quarries, with AutoCAD schematics. The quarries extract rock, transport by haulage truck, crush, convey, size, wash, and distribute for use in roads, asphalt, concrete, waterways and construction. Position includes project electrical design and maintenance, and provides troubleshooting and analyzes PLC and HMI Code to improve the plants production.  Provided engineering design, soft start parameters, schematics, and construction management for the 150HP Turbine Pit Pump Soft Start Project. The project included an ABB PST-300 Soft Start.  Project management for the Fuel Management Project that was installed to automatically meter and record diesel dispensing, of the quarries heavy equipment.  Managed a quarries Secondary Tower rewiring project that included the installation and startup of a Thor Stacker conveyor system. The Thor Stacker required GE Proficy programming changes.  Produced a PLC Upgrade Project 2018 budget for a quarries obsolete and unsupported PLC system that will utilize the GE RX3i PLC, GE Proficy software, Wonderware, and CISCO IE3000 for networking with fiber optics, for three network locations.  Designed and managing a plants Recycle Crusher Project that relocates two conveyors and installs a feeder, crusher, crusher support systems and two additional conveyors. Design includes a MOTOTRONICS Soft Starter for the crusher, local and Control Tower controls, and a new power transformer.  Installation and startup of a Thor Stacker extendable conveyor system with an AB ControlLogix PLC.

Contract Project electrical engineering providing management and engineering support of the companies continuous foam manufacturing line process upgrade. The existing line utilizes an AB SLC 5/05 PLC and a vendor industrial computer. Design and documentation, including AutoCAD schematics, for the project includes the installation and programming of pressure, temperature and flow transmitters, and replacement of the AB SLC with an AB CompactLogix PLC and I/O. P&ID drawings of the chemical process have been produced. Electrical design and AutoCAD drawings have been provided for the 480VAC Power Panel, Pouring Line Exhaust Fan Control Panel, and control the UPS power.

–Greenville, SC, Contract (Reason left: Customer Canceled Contract) Project electrical engineering utilizing Rockwell RSLogix 5000 software to identify and program First Out Faults for Kimberly-Clark. The First Out Faults are used to collect downtime data for analysis. Provided off-line PLC code and project spreadsheet for on-line changes at the plant. Specified Hoffman plant floor PC enclosures for K-C's Tm2 Felt View Scanned project.

– Wilson, NC May 2015 – July 2015, Contract (Reason left: Contract complete) Provided electrical engineering project management in research, design, programming, and startup for the MTS Splice Monitor upgrade project, the MTS Steel Ply Measurement Photo-Eye replacement and the MTS Belt Centering panel demolition.  The MTS Splice Monitor upgrade project replaced the existing laser pneumatic mechanical system with a fixed position laser to measure the splice width of the Inner Liner and Body Ply splices of the Green Tire. The system included an upgrade to a Siemens SIMATIC PC/HMI IPC577C and a National Instruments USB-6210 signal conditioner. Design included panel layout, AutoCAD drawings, and the review of the AB ControlLogix PLC code of the existing AB PanelView 1200 Plus.  The MTS Steel Ply Measurement Photo-Eye replacement attempted to replace an existing Omron Infered photo-eye with an ifm Diffuse photo-eye. The steel ply belt splice triggered the photo-eye resulting in a false start to the steel ply length measurement process. The PLC code is being investigated to possibly provide a minimum delay to disallow the false photo-eye activation. Project is ongoing.  Managed the MTS Belt Centering panel demolition that used contracted electricians to successfully remove wiring to the abandoned system.

– Fayetteville, Electrical Engineer, Contract (Reason left: Contract complete) Project engineering included management, design, programming, and startup for the Final Finishing and Component Prep departments in tire manufacturing. Documentation included AutoCAD Electrical schematics. Projects included review of tire press PLC code looking for collision errors, identifying critical press alarms and upgrading the control system on Force Variance Machines.  The review of tire press AB RSLogix 5000 code looking for collision errors between the Loader and the press. Critical press alarms were identified and verified, some were excessive and others did not exist.  The FVM upgrades and replacement designs utilized an AB ControlLogix PLC, AB KENETIX 6000 Servo Drive, utilizing a Sercos fiber optic communication module and AB PowerFlex40 series VFD's.  The FVM startup and commissioning included PLC I/O checkout, PLC programming, servo and VFD drive startups, and interfacing with an upper Level 1 PC network.

– Santiago, Chile, Contract (Reason left: Contract complete) Provided project management of the Final Finish White Sidewall Grinder / Paint Machine and associated conveyor equipment. The project startup is scheduled for January as the grinder and paint machine delivery has been delayed. Startup will include Zone 8 AB ControlLogix PLC and FactoryTalk View ME program changes.  The project altered (7) conveyor drive enclosures from previous projects, to the current design removing and adding components and wiring changes. The drive enclosures include AB PowerFlex 40 VFD's, AB 1734-AENT Point I/O Ethernet Switch, etc.  Provided pre-work lists and marked up drawings for the Zone 8 Control Panel, Zone 8 MCC, and the (7) conveyor drive enclosures as required by the project.

– Brewerton, NY, Contract (Reason Left: Contract Complete) The company designs, manufacturers, commissions and installs case packers, case sealers, robotic palletizers, cartoners, etc. for the consumable manufacturing industries. Documentation included AutoCAD Electrical schematics.  The INTERTAPE Case Conveyor and Schneider Tape Head joint venture project seals the bottom of a case, with water activated tape. The INTERTAPE conveyor and Schneider Tape Head controls were merged utilizing the Rockwell Connected Components Workbench software and AB Micro830 PLC with 24VDC Inputs/Outputs, high speed output for the stepper drive, and an RTD module to control the water temperature for the tape. The Tape Head PLC program was modified to accommodate the conveyor controls and the Tape Head was driven with an Automation Direct Stepper drive and motor.  Wrote the Sequence of Operations and worked on cost reduction for the SR5000WAT Case Sealer. The case sealer has top and bottom water based tape heads and is PLC/HMI controlled with servo drives.

– Durham, NC, Contract (Reason left: Contract complete) Provided automation support for the FDA Validation for the company's two production lines that produce bacteria diagnostic system bottles for the medical industry.  The automation support required uploading, reviewing, and merging PLC and HMI code to analyze the alarms, interlocks, and outdated code to provide written descriptions for the final validation documents to explain how the manufacturing process functions and monitors, the bacteria bottle production.  The PLC and HMI code used AB ControlLogix, RSLogix 5000 and 500, PanelBuilder 32, and Factory Talk View Machine Edition software. The PLC's include ControlLogix, CompactLogix, MicroLogix 1100 and 1200, and SLC 5/04.  The bacteria diagnostic system bottle cap seals were optically inspected with Cognex Vision systems for position and seal.

– Fayetteville, NC, Contract (Reason left: Contract complete) Project engineering included management, design, programming, and startup for the Final Finishing and Component Prep departments in tire manufacturing. Projects included upgrading the control system on three Force Variance Machines, replacement of three additional FVM's, quality control conveyor design, AutoCAD Electrical drawings and documentation.  The FVM upgrades and replacement designs utilized an AB ControlLogix PLC, AB Ultra3000 Servo Drives, that utilized a Sercos fiber optic communication module and AB PowerFlex40, 40P and 70 series VFD's.  The FVM startup and commissioning included PLC programming, PLC I/O checkout, servo and VFD drive startups, and interfacing with an upper level PC network.  The laser thickness measurement system utilized Keyence LK-G5001 Series lasers and the liner width measurement project utilized the Keyence XG-8000L Machine Vision system.

– Bristol, VA. Project management involved in controls, instrumentation and power design, Bill of Materials, AutoCAD schematics, assembly and start-up of Power Centers, Belt Power Centers, VCB's, switchgear, and Metal Enclosed equipment.  The equipment serves the underground and surface mining industries, data processing, solar, and other industries. The equipment utilizes vacuum circuit breakers, load break switches and vacuum load break switches, VFD's, ground monitors, ground fault relays, and some with PLC control. Communications include Ethernet, MODBUS and ControlNet.  Participated in a Kaizen to review, analyze, and present new ideas for the Mining Equipment Process.

– Hendersonville, NC. Project electrical engineering in controls, instrumentation, DC drives, PLC's, MCC's, panel layouts and power applications, for a non-woven manufacturer working with a team concept.  Provided electrical engineering design, installation, start-up and maintenance support, for in-house projects up to $50k. Participated in semi-annual downs, that includes major projects and maintenance of MCC's, and Medium and High Voltage switchgear. Preformed a Medium Voltage PCB Transformer replacement.  Conducted electrical engineering design and provided installation management and start-up assistance, for the Cameron Re-winder project. Demolition included 20, 72" re-winders. Installation included the Cameron Re-winder, installation of Reliance Automax DC Drives, extension of the overhead crane, revisions to the conveyor and wrapper a Modicon 984-80 application, and system start-up. The project transformed the slitting operations from off-line to in-line, reducing the slitting operators by 80% per shift, a company first.  Electrical project management, design, equipment specification, construction management, and programming for the SBII Base-machine Rebuild, an $8.75 million project with a $1.75 million electrical and instrumentation budget. A true Team Concept from design through construction and start-up. Provided project management including design of controls, PLC's, DCS, instrumentation, DC drives and power. The PLC and DCS applications were Reliance Automax and Rosemount RMV9000. Provided base-machine start-up assistance, trouble shooting and training. The scheduled 35-day project was completed in 28 days, which includes the production of first quality spunbond material, on the first day of production start-up, and the project set several new company records for a Spun-bond Rebuild.

– Morgantown, WV. Performed project management for electrical engineering projects, for coal research utilizing controls, instrumentation, PLC's, softstarts, DC drives, panel layouts, power applications, and electronics.  Electrical engineering lead for the design, construction, PLC programming and commissioning of the Tramveyor Continuous Haulage System. The R&D project's budget of $1.25 million, with $250,000 for E&I. The system was controlled with an AB PLC 2/16, two hand held intrinsically safe controllers, and four hydraulic power packs. Administered the MSHA and the State of Pennsylvania equipment approvals. The project set a development section 8- hour shift production record, of 386 feet of advancement breaking the existing record of 302 feet, where each foot of advancement represents 8.8 raw tons of coal.  Provided electronic design, programming and MSHA approvals, for the Down Hole Drill Monitor readout unit that supported the horizontal drilling system for reduction of methane gas, to expedite long-wall panel development. The readout unit was battery powered and displayed the alphanumeric and graphical data, on a LCD screen.  Assisted in the commissioning of the Course Coal Slurry Transport System, a hydraulic form of transporting coal. Tasks included installation, trouble shooting, and operations of the underground and surface pumping stations and the dewatering plant. Electrical equipment included TI-5 PLC, instrumentation, with low and medium voltage pump motor applications.