Clive — Senior Controls Engineer

2002 – Henneke - BMW E53 small parts foaming stations. Complete mechanical, electrical and software design to improve the operation for the loading and unloading of 4 x small part stations for small part foaming on a robot foaming line. This required a new design concept from original design due to unreliability problems. 2003 - Mecanizados - BMW E53 and Saturn LS Vac forming Line Design and build a system that would monitor and control the preheat temperature of vinyl sheeting prior to vac…

2005 – Frimo - Door Panel Edgefold / Punch Presses (6 in total). Complete rebuild of existing BMW E53 door panel edgefold / punch presses. This required a redesign of the electrical controls, replacement of the outdated PLC to the Siemens S7 PLC system as well as design and build of the interface for the BMW E70 / E71 door panel edgefold tools. An HMI panel was installed to assist in machine operation and tool diagnostics. These presses were further modified to accommodate BMW F15 / F16 door…

Design and rebuild high speed inspection machine for medical parts manufacture, utilizing Keyence PLC, Keyence Servo Drives and Keyence vision systems for high speed inspection. (2 cameras, 2 parts/sec). The first vision test consisted of checking 4 areas of the part simultaeously. This was done utilising a mirror system set at 90deg apart and displaying each 90deg segment of the part for visual analysis. The part was passed through the mirror system from a glass rotating disc.

Supporting of manufacturing processes by way of developing online Poke Yoke Systems to confirm integrity of manufacturing / assembly processes.

Improvement of present processes by implementing new technologies which improved quality, flexibilty and reliability of manufacturing systems. This required updates to the electrical design as well as upgrades to PLC controllers and HMI's. Utilization of vision sytems (primarily Keyence) for part(s) inspection.

Henneke - BMW E70 /E71 & VW411 IP Foaming Line Process. Redesign of an existing BMW E70 / E71 IP foaming line process to integrate it with a VW411 foaming line process. This involved the design of the VW411 foaming line process as a stand alone system and then integrating the E70 / E71 IP foaming process into it. This integration involved 2 robots, 2 wet systems and 6 foaming stations. Each foaming station was controlled from a Siemens S7 300 series PLC, as was the VW411 wet system. The BMW E70 / E71 wet system was run from an AB SLC 505 system. Of the 2 robots, one had a single mixhead that was used for the BMW foaming process and the second robot had dual mixhead capability which allowed for the BMW or VW foaming process. It was also necessary to allow, where possible, the ability to run either BMW E70 tooling or VW411 tooling at specific stations. All systems were run on a common Profibus network. A SCADA system was developed to capture all necessary process data from each station for traceability purposes. All process data was displayed on a PC based HMI system running RSView32, allowing BMW & VW data to be available in real time. End Of Line ultrasonic welding and Inspection Station for VW411 IP Design and develop the above station with SMG (outside contractor), to ultrasonically weld the air ducts and inspect IP assy prior to shipment. This involved the programming and controlling the power, depth and time of each welding process, as well as a vision test for speed clip insertion. The station was controlled from a Siemens S7 300 series PLC and HMI panel. The system was integrated into the plants production ware (Matrix), for traceability purposes. Poke Yoke System development using vision system technology, as follows: BMW F15 IP airbag net placement and integrity on completion of injection process. Failure of test will destroy part. VW411 IR camera system (FLIR) to detect voids between skin and substrate after foaming process. Each IP tested will have image stored for traceability purposes. System to confirm correct speakers options on BMW E70/E71 IP assembly line. BMW E70/E71 IP USB connectivity on Glovebox. BMW E70/E71 glovebox assy. Confirmation of assembly of springs and release mechanism. VW411 IP speed clips installation. Ford C520 IP inline inspection (Louisville plant).Utilised 8 Sensopart vision sensors. The system was integrated into the Insequence production software for the printing of the shipping label. BMW F15 instrument panel and door panel end of line inspection stations, utilising Keyence vision systems to sample integrated light bar quality during the IP & DP assembly process, as well as options build. Measurements of the lightbar included overall brightness, color, height, length, homogeneity, hot spots and dark areas. This was developed in conjunction with BMW's development team in Spartanburg and Munich. Mecanizados - BMW E53 and Saturn LS Vac forming Line Design and build a system that would monitor and control the preheat temperature of vinyl sheeting prior to vac forming (laminating) door panels. The new system used a matrix of temperature sensors on the upper and lower heater banks with the temperature control from Siemens HS724 controllers. The system was controlled from an AB SLC504 PLC and the data was captured to a PC based system running RSView32. Microsoft Excel was used as a way to display the vinyl temperature in reatime mode.

Installation and commisioning of multistation assembly & testing lines for Tier 1 manufacturer to BMW and VW.This included foaming systems for IP manufacture. Door panel and top shoulder edgefolding and punching. Development of Poke Yoke systems using vision systems as required, depending on the type of Poke required. Conveyor systems. X,Y,Z co ordinate servo systems for the dispensing of PU products as well as grease products. Skin weakening system of IP skins relating to the airbag deployment on IP's. Test station development to test integrity of new glovebox design, as well as rear door sunshades on BMW X5. This invloved testing closing force of glovebox, opening time of glovebox and testing of glovebox lamp durabilty. Durability of integrated rear door sunshades. Typical test cycles bumbered 20,000, with recording made and rtransfered into Exel spreadsheet.

Improve present processes by implementing new technologies which would improve quality and reliability of manufacturing systems. Identify ways of replacing or updating old, redundant and outdated equipment with more reliable and improved systems. Support quality and production with developing inline Poke Yoke systems. Support product launch teams on new production lines, primarily BMW, VW, GM and Ford. This involves the integration of new tooling and equipment into existing production lines as well as the installation of new lines and technologies.

Electrical hardware and software design on industrial production machinery (primarily for the automotive industry). Design of safety control circuits as well as electrical requirements within NFPA, UL508A & OSHA guidelines. Develop machine control software that includes PLC & HMI programming, motion control, vision, RFID and barcode system installation and commissioning. Support electrical and mechanical installation as well as integration and commissioning. Perform PAT & FAT. Support and develop customer relations. Create controls system documentation as well as machine operating manuals as required. Development of technical requirements as needed by the customer.

September 2004 - May 2015 (10 years 9 months) Page 1 of 1