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 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 distribution in reatime mode. 2003 – Frimo - BMW Z4 Foaming Station. Modification to the Z4 foaming station to accommodate BMW E53 foaming tools. This would allow a backup for the E53 foaming process should there be a failure on the E53 foaming line. This required electrical redesign, as well as the writing of extensive software routines, including AB SLC505 PLC and HMI programming. 2004 - 400T Ona Vertical Press (X2) – BMW X5 / X6 door panel lower carrier manufacture. Redesign of safety circuits, including safety gates, safety posts and estop circuits. Redesign of electrical controls, machine interface and PLC software program to improve press cycle and machine reliability. 2008 – BMW E70 /E71 New Glovebox Design. Design and build test station for testing operational integrity of the new glovebox design. The tests included opening time, closing force and interior lamp operation. The installation was built into an X5 body in white, with a permanently mount IP. The glovebox on test was installed in the IP to reproduce the correct environment for testing. The control and operation of the Glovebox was through an AB SLC 504 PLC and data captured was transferred to a PC system and stored. The PC would display in realtime data from each cycle and display it in an Excel spreadsheet as a graph. Tolerances were set to monitor repeatability performance as well deviations. Total cycle count was also monitored. To confirm operation over extended operating cycles. Due to the success of the Glovebox testing the system was upgraded to include opening forces for the sunshade option as well as centre console lid operation. 2010 – Henneke - BMW E70 /E71 & VW411 IP Foaming Line Process. Redesign of the existing BMW E70 / E71 IP foaming line process to integrate it with 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.

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 panel edgefold tooling, with the emphasis on utilising the Profibus network system for communicating between the press and the tool. 2009 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. 2012 - Injection Line Conveyor Synchronisation System. Design & build of a control system that would monitor part positioning on 6 conveyors feeding injected parts to the main conveyor. This control was to prevent parts falling on each other, with the possibility of damaging them, as they were transferred to the main conveyor for sorting and packing. The system was further developed to do a parts count from each injection machine. The system was controlled by a Siemens S7 PLC & HMI system. 2015 – Branson Vibration Welder Rebuild / upgrade of Branson vibration welding machine to support BMW F15 IP manufacture. This Required the rewiring of machine panel and safety device upgrades, as well as the installation of Siemens S7 PLC and HMI from the existing redundant S5 PLC system. Programming machine to run all four OP1 & OP2 welding tools for F15 IP manufacture. 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.

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