A.T.U. Inc.Automation ControlsJohn Washinsky, pres. |
Phone(336) 712-0569
|
Data Colection Work Cell Controller
Designed and programmed an Ethernet based Data Collection
system for a stamping press work cell. Using a Redlion Graphite HMI,
programmed Crimson to communicate with the press control and auxillary
equipment. It gathers real time data and calculates equipemnt
efficiency. The data will be uploaded to a factory wide information
system.
Electricians Training Simulator Programming
Programmed an Autoamtion Direct DL106 and a Redlion G3 display to
train and test plant technicians for proper troubleshooting of
high voltage electrical panels. The HMI simulated a Fluke mulitmeter at
low voltage. The system incorporated a card reader to identify the test
subject and record all actions in a text file to be later uploaded to a
USB drive.
Servo Actuator Refurbish
Implemented JVL Ethenet IP based servo actuators and a Compact Logix
PLC to replace compound pneumatic cylinders on an existing
connector assembly machine. The new system interfaced with the existing
SLC500 PLC and PanelView Plus HMI to provide micro adjustments and
multiple part number recipies.
Universal Stamping/Injection Molding inspection Reeler
Designed and programmed a control system for a flexible combination inspection platform and reeler. Using an Automation Direct CLICK PLC and Cmore Micro HMI, the operator can configure the reeler system for payout or take-up oepration for either stamping or injection molded product on a strip. Two Cognex vision systems are interfaced to inspect incoming or outgoing product.
Connector Inspection Machine
Designed and programmed a control system for a conector assembly inspection machine. The system utilized an Omron CJ2 processor and Redlion G3 HMI. The system incorporated several servo actuators, a Cognex Barcode Reader, continuity tester and a Keyence laser marking system.
Connector Packaging Control Refurbish
Designed and programmed a control system for a conector assembly
packaging machine. The system utilized an Omron CJ2 processor and
Redlion G3 HMI. The system incorporated a servo actuator and
pneumatic system.
Laser Ablation Calibration Tool
Using an encoder simulator and a dedicated rate meter, designed and built a calibration tool.
Heat Exchanger Tube Assembly System
Designed a control system using an Allen-Bradley Compact Logix processor to
control a manufacturing cell that assembled heat exchangers made from copper
tubing. The system incorporated setting up PID loops to control hydraulic
cylinders for part movement, insertion and forming. An AB Panel View Plus HMI
was used to setup all control parameters to a part number storage/retrieval
system and provide manual mode and diagnostic capabilities. Machine runs beyond designed production rate.
Enhanced Data Acquisition System
Added a Redlion G3 display to the standard data collection package from 2007.
The HMI adds easy access to changing parameters, improved real time data
displays, trend graphs and a part number storage/retrieval system.
Communication to downstream equipment via the G3 protocol conversion is also
going to be added at a future date.
Enhanced Auxiliary Press Control
Improved upon the original 2007 design adding additional control options. Also
provided a single connector system for press interface and 2 programmable high
speed counters for part feed verification.
Servo System Upgrade
Designed a drop in module to replace an Adept servo axis that is no longer
produced. The system was replaced with a standard leadscrew axis and an
Allen-Bradley Servo drive. The system was integrated into an existing AB
Control Logix PLC.
Servo Walking Beam Upgrade
Refurbished a machine previously using a Stelron type walking beam with a servo
actuator and Yaskawa drive/control. The
previous machine, controlled by an AB PLC5 processor was reduced in size. When
this done, much of the wiring to the removed parts of the machine was left
exposed. Schematics had to be revised and the excess wiring removed. The PLC
program was changed to reflect the removal of stations. The servo drive had to be integrated into the
PLC program the servo program written to provide the motion required to control
the walking beam. A Redlion G3 HMI was added to provide access to parameters in
the Servo indexing module and for diagnostic capabilities.
Servo Walking Beam Upgrade
Refurbished a machine previously using a Stelron type walking beam with a servo
actuator and Yaskawa drive/control. The
previous machine, controlled by an AB PLC5 processor was reduced in size. When
this done, much of the wiring to the removed parts of the machine was left
exposed. Schematics had to be revised and the excess wiring removed. The PLC
program was changed to reflect the removal of stations. The servo drive had to be integrated into the
PLC program the servo program written to provide the motion required
Japanese Machine
Troubleshooting
Contracted to troubleshoot and debug an assembly machine that was controlled by an OMRON PLC. Used CX1 to first document and then make the required changes to the PLC program. Improved uptime of the machine and reduced scrap with the program changes.
Data Acquisition System
Designed a system using a small Automation Direct PLC and
networked PC to
collect analog data from a continuous process. One thousand data points
are
collected every 10 seconds and transferred to a PC using a an OPC
server.
The data is then time stamped and stored in an Excel file for DVD
archival. VBA
macros were written to provide a real time display graph and an easy way
to
analyze different sets of data points. An algorithm in the PLC was
created using standard deviation to detect abnormal process problems.
Vision System Downloader
Wrote a VisualBasic.net program to communicate with 7 Cognex Vision Systems and
an Allen-Bradley SLC500 PLC over Ethernet. It provided recipe data
downloading with read back verification and part number storage in an Access
Data Base.
Vision System PLC communications
Wrote a detailed step by step illustrated procedure for plant maintenance
personal to setup Modbus communications between a Cognex Vision system and an
Automation Direct Ethernet module.
.
Auxiliary Press Control
Designed a flexible control package to make it easy to connect and coordinate
the operation of auxiliary feeders, reeling and inspection equipment to work
with a stamping press. Included a small Automation Direct PLC and touch
screen for plant personal to completely setup and configure the device without
the use of a laptop.
Keyence Laser Integration
Wrote an extensive Allen-Bradely control logix 5000 PLC program to
communicate directly with a Keyence CO2 marking laser. The program module
allowed the machine operator to completely customize the mark and save the
settings with the part number data base in the machine. Diagnostic
screens provided detailed error information for maintenance personal to
test Laser functions. The final installation involved removing the
previous laser marking system and installing the Keyence system in less than 8
hours.
Assembly Machine PLC Programming
Upgraded the firmware in several Allen-Bradley Control Logix processors.
Modified PLC programs in several machines using Allen-Bradley Control Logix
,Compact Logix and SLC500 and Automation Direct PLC's.
Control System for Leak Testing of Metal Castings
Designed and built a control
system for pressure testing metal castings for the automotive
industry. Machine used an Automation Direct PLC, Proface HMI ,
Assembly Machine PLC Programming
Modified PLC programs in several machines using Allen-Bradley Control Logix
,Compact Logix and SLC500, Omron and Automation Direct PLC's.
Assembly Machine PLC Programming
Designed a 2nd generation injection molding automation
system with updated controls , a Proface operator interface and an encoder
based feed verification system.
Assembly Machine PLC Programming
Upgraded the firmware in several Allen-Bradley Control Logix processors.
Modified PLC programs in several machines using Allen-Bradley Control Logix
,Compact Logix and SLC500 and Automation Direct PLC's.
Refurbished several existing PLC based machines and installed Automation Direct
PLC's. . Modified PLC programs in several machines using Allen-Bradley Control
Logix , Allen-Bradley SLC500 and Automation Direct PLC's.
Refurbished Connector Insertion Machine
Reprogrammed a connector
assembly insertion module using an Omron C200HX plc with
Servo Feed unit. Installed and programmed a new Proface operator
display. Added complete part number recipe management and diagnostic
maintenance screens.
Injection Molding Vision System interface
Designed control interface for high
speed triggering of a PPT Impact Vision system using Automation
Direct DL06 in an insert molding operation
Assembly Machine PLC Programming
Changed an Allen Bradley SLC
5/04 program on a Swiss built connector assembly machine to add a
high speed counter module and make program bug fixes and improvements.
Sections of the program had to be translated from Dutch before changes could be
made.
Changed an Allen Bradley SLC
5/04 program on a German built connector assembly machine to add a
high speed counter module and add diagnostic tools for logging and
displaying reject information using the Panel View Display.
Assembly Machine PLC Programming
Documented PLC programs for multiple Japanese built connector assembly machines. PLC's used were NAIS FP3. Programs were poorly translated and were difficult to make changes. Used NAIS FPWIN GR programming software to comment, document and make added changes to lower scrap, improve quality and improve counting accuracy. Modified the Matushita IOP operator displays. Developed a low cost method for gauging parts in the assembly process.
Programmed multiple Pacific Scientific Servo axis assembly equipment , establishing a PLC/Servo interface and a programmable CNC type Control system.
Allen Bradley Control Logics 5000 with multi-Axis Servo Pick and Place Units. Made on-line changes while process was running with minimal interruption in production. Improved through-put of machine from less than 4000 pieces/shift to consistently over 8000 pieces /shift with improved diagnostic capability.
Designed a PLC control system for a customer to control an insert molding strip handling system. System included a Stepper Motor drive and multiple part number recipe storage with easy to use operator interface. Project involved multiple systems on a tight schedule. All systems were delivered on time and within cost.
Designed PLC controls to interface with a PPT vision system and provide repeatable stopping for movement of strip through the material handling system.
Programmed multiple Pacific Scientific
Servo axis assembly equipment , establishing a PLC/Servo interface and a
programmable coordinate system.
Added Diagnostic Screens for an Allen Bradley Control Logics
based assembly line which included I/O status and Force test.
. Developed teach screens for defining move points of a multi-axis servo
pick and place system. Had to work with a system that was without
comments or electrical prints.
Department Group Leader for machine controls when Tyco
International dissolved the Machine Development organization during their
acquisition of Amp Incorporated in 1999.
17 years of experience designing PLC based and computer based embedded
control systems for high speed assembly, inspection and packaging machines for
the electronic connector industry.
Stacked Multiport Modjack Test Fixture
Automated test fixture which incorporated a PlcDirect
205 PLC with a Cirrus contiuity/short/hipot tester to test a 32 port ethernet
jack connector. Using an Analog module, the PLC measured the current in
each of the 32 LED's with a resolution of 100ua. The PLC remotely
controlled the Cirrus unit and the system displayed to the operator the faulted
circuit or LED.
Hydraulic Punch Press modifications
Modified the control program of a Micrologix
1000 PLC to run an air feed and reeler added to a hydraulic punch press.
110 Block Connector to Board Insertion Machine
Fully automatic assembly machine to insert a
vibratory bowl fed connector into a small PC board. Machine incorporated
a 3 axis PacSci 950 servo system with PACLAN communications. The servo
system was controlled by a PLC Direct 450 PLC via a Modbus link. A
DirectTouch Color LCD display provided the operator display and programming of
setup parameters.
Grease Dispensing System
Developed a multiple PLC control scheme using a PLC
Direct 105 and 250 to control air piloted metering valves dispensing a heavy
sealant being injected into a telephone cable connector. The system varied the
valve timing dependent on material temperature and pressure operating at 60
feet/minute.
Modular Jack Inspection System
Developed a 2 camera in-line video inspection
application operating at 145 assemblies/minute. Using the Acuity Power Vision
System, the tasks involved front lighting and required the development of
custom morphology to enhance the connectors features under constantly
changing product surface conditions.
Modular Plug Assembly Machine - 3rd Generation
High speed (425 assemblies /minute). Controlled by a PLC
Direct 440, with interrupts. Allen Bradley Machine Vision CVIM2
inspection of 100% of the parts. The machine used a small stepper motor to
automatically reposition the cameras for each part size. Utilized the
smart slice remote I/O system to control the vibratory feeder, automatic
packaging system and reeling system. Automatic part changeover
configuration of the vision system using an Ascii Basic Module. Developed a Visual
Basic HMI that also collected machine production data. This information was
then used by VBA macros to create HTML pages for the company intranet, updated
automatically on the hour.
Infoport PCMCIA Cable Connector Assembly Machine
Extremely small and difficult tolerances for the assembly of
cable connectors used on PCMCIA cards. Motion control consisted of an 8 axis
Pacsci SERCOS based PC control servo system. Multiple assembly heads and an 8ft
servo controlled walking beam system capable of 85+ strokes /minute. Visual
Basic HMI. 100% inspection utilizing a 3 camera Allen Bradley CVIM2 machine
vision inspection system. To meet resolution requirements, each camera had to
be strobed 3 times per part.. PLC Direct 440 master control networked
with a secondary 440 to perform on line continuity and short electrical
testing. Developed a protocol using the Ascii Basic Module to
communicate with the PC based Servo system. The ABM also reconfigured the
vision system using the AB RS232 protocol.
Developed a servo positioning and reeling system for an insert molding operation on a vertical injection molding machine. Two Pacsci 750 systems positioned 4 strips into the mold/die while the overall process was controlled by a PlcDirect440 and smart slice remote I/O system. The PLC also controlled the custom sprue picker robot and interfaced with the Engle molding press to provide mold safety.
Modular Plug Assembly Machine - 2nd Generation Controls
modified for use in
Same as 1992 machine but redesigned to accept different
voltage and frequency. Many components were changed to meet the needs of
AMP Spain.
Selectable Punch and Forming Die
Developed a system using a PLC direct 240
PLC to control 5 air cylinders in a forming die which made a metal shield for a
variable length part. The system replaced 8 different sets of change tooling
and provided an electronic change over via the DV1000 operator interface.
CAT4 Multiport Array Insert Molding Reeling Systems
Used an air feed and reeling system for
an insert molding operation on a vertical injection molding machine. Two strips
were controlled by PlcDirect340 system. The PLC also controlled the
custom sprue picker robot and interfaced with the Engle molding press to
provide mold safety.
Multiport Inline HIPOT Inspection System
Developed a 600 VDC Hipot Test for use on a multiport
assembly machine.. The unit consists of a High Voltage Power supply, high speed
reed relays and a Keyance KV40 PLC which also performed a high speed continuity
and short test. It ran all 3 tests at 150 ports/minute..
CHAMP 4th Generation Assembly/Inspection/Packaging Retrofit
Upgraded STD BUS embedded control system on assembly
machine to use a PLC Direct 440 with interrupt control. Replaced touch screen
display with TCP Smart Touch Display. Added PLC network communications to the
Inspection Module for transmission of setup data. An Ascii Basic Module was
added to the module to send configuration data to the PC based Inspection
System. The packaging system STD BUS system was replaced with a 440 CPU and
pulse modules to control the stepper motors.
Modular Plug Assembly Machine - 2nd
Generation Controls
High speed (350-400 assemblies /minute). Controlled by a PLC
Direct 440, Allen Bradley Machine Vision CVIM inspection of 100% of
the parts. Utilized the smart slice remote I/O system to control the
vibratory feeder, automatic packaging system and reeling system. Used a
TCP Smart Touch Display for the HMI to setup the machine parameters.
CHAMP 4th Generation Inspection System
Worked closely with an outside vendor to develop a PC
based inspection machine. The unit consisted of a constant velocity belt with
an encoder tracking system that took multiple pictures of each part as it
passed through the system. Custom light sources were developed to inspect
terminal coplanarity. The system inspected 100% at 140 assemblies/minute.
Mylar/Polyester Film Laminator
The machine joined 2 films together which involved
control of a corona treatment roller , IR oven, induction heated
rollers, web tension controls, positioning and speed control. A TI305 was
used to automatically control the entire process. A Computer Dynamics 186 STD
BUS computer was added to collect data from
Modular Plug Assembly Machine 1st generation Controls
High speed (325 assemblies /minute).
Controlled by a GE Series 1 PLC. High Speed counter module was used to
count the inserted terminals.
Worked with an outside vendor to develop a 110 connector to PC board insertion machine using an Adept Robot for the control system.
Modular Plug Strip Assembly Machine
Controls consisted of an 8085 STD BUS embedded computer and
an ASCII Text touch screen. The operator used the display to program selective
insertion of the part. Counter timer card was used as a high speed pin counter.
CHAMP Packaging Machine
Developed an embedded control system using STD
BUS 8085 computers and a IEE488 communications network. to control a machine
that packaged the connectors into an egg crate style box. The parts were
singulated, rotated and dumped row by row into a foam tray. STD BUS pulse
indexer cards were used to control 4 Compumotor stepper drives. Absolute
resolvers verified positions of each axis. The machine received setup and
command information via the 488 link.
CHAMP 4th Generation Assembly Machine
Developed an embedded control system using STD BUS 8085 computers and a IEE488 communications network. The system used Ascii text touch screen displays and allowed control of the entire line from any terminal on the machine. The assembly machine used a centrifugal bowl feed system, ultrasonic loop controls and a pulse train DC motor speed control.
Designed several reeling systems using AB
PLC2 and OMRON S6 PLC's for injection overmold processes.
Worked with line scan camera's in development of a proprietary vision
inspection system using STD BUS 8085 embedded computer systems