Senior Controls Programming Engineer / BAUSCH ADVANCED TECHNOLOGY GROUP, Clinton, CT

2023 - Present

BAUSCH designs and manufactures controlled and aseptic fill-finish packaging equipment for the pharmaceutical industry.

• I program 20+ Allen-Bradley CIP servo axis controls for high speed multi-station discrete manufacturing equipment used to fill and dose IV bags, syringes, and vials. This includes coordinated motion articulated robot axes
• Stations include infeed conveyor, main transport, gassing, filling, dosing, stoppering, extraction, and weighing
• Development environment is Allen-Bradley Studio 5000 Logix Designer and FactoryTalk View Site Edition featuring user access control, recipe management, batch reporting, and station configuration, fault annunciating, and tally

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Senior Controls Engineer / MEDLINE, Meriden, CT

2022 - 2023

Medline is the largest privately-held manufacturer and distributor of medical supplies.

• I provide electrical and controls support to 15 production lines centered around packaging of fluid based products.
• I use Allen-Bradley Logix Designer and FactoryTalk View ME to incorporate changes around product changeover.
• I designed, built, and programmed a day-tank system which allows settling and gas diffusion of oral gel prior to injection into packaging. The system uses a diaphragm pump, stainless steel tank, proportional airflow controller, Allen-Bradley 5380 CompactLogix and PanelView Plus 7.
• I designed and tested a prototype vibratory bowl swab delivery system using a Cognex vision system to detect potential jams and alert the operator before they stop the system. This solution allowed a single operator to inspect and monitor the progression of swabs into the injector where two had been necessary prior.
• I integrated Overall Equipment Efficiency productivity appliance into production line equipment to assist in improving productivity. This equipment accepted electrical inputs to monitor cycle time, scrap, and accepted product. I also integrated the appliance into our plant network and performed all of the necessary web-server programming.

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Contingent Controls Engineer / MEDTRONIC, North Haven, CT

2021 - 2022

Medtronic is a medical device manufacturer whose foremost priority is to contribute to human welfare.

• I updated the design and equipment for three discrete manufacturing production cells including platform evaluation, equipment specification, design reviews, quote solicitation, purchasing, and creating the electrical drawings around the new design, and coordinated participation of OEMs where needed. The value of equipment purchased for each cell was typically between $100K and $120K
• I redesigned the motion systems on these cells moving from Allen-Bradley Ultra 3000 and PowerFlex SERCOS and DeviceNet based designs to Allen-Bradley Kinetix 5K series featuring Ethernet/IP integrated motion over CIP protocol
• I updated cell robotic systems to platforms such as Yamaha’s YK250SG SCARA, RCX340 controller with Ethernet/IP and tracking card, and SR1-X slide controllers. as well as IAI RCON-GWG controllers with RCP6(S)CR slides
• I integrated a new vision system into one platform using Cognex 7802 cameras and Vision View 900 HMI
• I designed safety systems integrating Schmersal locking door latches with safety features of the robotic controllers, and Allen-Bradley 440R safety relays
• I troubleshoot Allen-Bradley centric automation cells typically executing a PackML control architecture

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Senior Instrumentation & Controls Engineer / FUELCELL ENERGY INCORPORATED, Danbury, CT

2020

FuelCell Energy designs and installs efficient fuel cell solutions configured for the supply, recovery and storage of energy.

• Two contracts, representing 38% of projects in process, were not executed by the Long Island Power Authority. New hires, recently brought on to restaff engineering, were laid off (link1, link2)
• Using GE Proficy I was able to troubleshoot a persistent issue where the GE View HMI parameters would all go to zero. The issue turned out to be an obsolete drivers on the Series 90-30 IC695ETM001 Ethernet interface board. I remotely gathered the firmware revision levels from the fleet, 50+ units, and implemented a program to update every module
• I used Rockwell's IEC 61499 compliant ISaGRAF distributed control environment to troubleshoot Moore Industries IO modules. This issue involved data transfer hang-ups to the RX3i processor.
• Designed and initiated implementation of an updated historical data logging system; local storage, remote retrieval

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Senior Controls Engineer / GKN AEROSPACE, Cromwell, CT

2020

GKN Aerospace is a major design and build partner of composite aircraft structures through advanced production techniques.

• Although this position was cut short due to the coronavirus crisis, I was able to design the control system for one of the company’s manufacturing processes. This is a multi-axis control using Allen-Bradley Kinetix 5500 drives. The control application involves product transfer on a conveyor and metered application of chemical additives
• Participated in transfer of control hardware platforms, National Instruments to 5380 series Allen-Bradley PLCs
• Completed training activities including: Rockwell Automation CCN144-A: Kinetix 5700 (CIP) Programming in Studio 5000 Logix Designer; Wonderware System Platform 1 (Archestra, Application Server); Wonderware System Platform 2 (Historian & Information Server, Intouch for System Platform)

Senior Controls Engineer, Industry 4.0 / STANLEY BLACK & DECKER, Hartford, CT

2018 - 2019

Stanley Black & Decker is a Fortune 500 world-leading American manufacturer of industrial tools and storage, commercial electronic security and engineered fastening systems.

• Performed integration and programming of two automation cells; one presents the work part on a conveyor stopping for the human operator to place parts on a pallet “nest” while also confirming using Cognex image inspection, the part is then moved to the next cell where an Epson SCARA robotic system inserts ten screws to bind the assemblies
• These cells support SBDs Industrial Internet of Things and Advanced Analytics initiative through Ethernet-IP data collection
• Components include Allen-Bradley CompactLogix L320 safety PLC, Guard Master, Elevators powered by Kinteix 2097 servo drives, Armor Stratix 5700 Managed Switch, Armor Block 1732E IO-Link Master, PanelView 5100 and 5510, with RFID READ/WRITE on each pallet, AB industrial microprocessors, safety relays, AB PowerMonitor 500, and multiple camera recording to DVRs.
• Experienced in programming Universal Robots, Omron Techman, Quick soldering robot, and IAI America PCON C/CG position controller for the ROBO Cylinder RCP series actuators. Used AutoCad Electrical to create and maintain electrical drawings
• Authored the department guidelines for Safe Design of Collaborative Robotic Systems, Electrical Design Requirements, Electrical Control Systems Safety Specification, and Safety Design Specification used in design specifications
• Completed training activities including: Universal Robots Core Training with Vision, Robotic Industries of America safety training, Allen-Bradley Servo Motion Mastery, Industrial Robotics - Mathematical Models and Practical Applications, Cognex In-Sight Machine Vision Systems in Easy Builder - PLC Automation SCADA Development HMI

Manufactury Grand Opening April 11, 2019

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Recent Training Activities

Certificate - 211 Electrical Safety in the Workplace - Understanding NFPA 70E v2021
Certificate - GSS - Arc Flash
Rockwell Automation CCN144-A: Kinetix 5700 (CIP) Programming in Studio 5000 Logix Designer
Universal Robots Core Training with Vision Video of training application.
The Complete Guide to Control Valves

Training application which vision team created.

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Wonderware System Platform 1 (Archestra, Application Server)
Wonderware System Platform 2 (Historian & Information Server, Intouch for System Platform)
Robotic Industries of America safety training seminar.
Allen-Bradley Servo Motion Mastery
Allen-Bradley Advanced Servo Motion Mastery
Industrial Robotics, Mathematical Models and Practical Applications
Cognex In-Sight Machine Vision Industrial Development SCADA
National Instruments Data Acquisition and Signal Conditioning

PLC Controls & Automation Engineer / Prysmian Group, General Cable, Wilimantic, CT

2016 - 2018

General Cable is a global leader in the development, design, manufacture, marketing and distribution of aluminum, copper and fiber optic wire and cable products for the energy, communications, automotive, industrial, construction and specialty segments.

• Supported jacketing extrusion systems in the production of various styles of multi-conductor cable used in the energy and telecom sectors
• Responsible for maintaining the controls and automation systems of mission critical production lines, which run three shifts a day, at two plants; Willimantic, CT and Lincoln, RI
• Routinely troubleshot, repaired, and programed nearly 150 separate PLC based control systems, typically Allen-Bradley, and a variety of instrumentation and actuators detailed below
• Backed up the control applications and configuration software of all automation equipment and maintained these files in an organized library the technician’s accessed as necessary
• Developed training material around various technology-based tasks faced by technicians and held training sessions to develop proficiency
• Accepted requirements from Operations and Process Engineering to develop enhancements to the PLC and HMI applications to enhance safety and productivity

• Examples included modifications to recipe systems to better match our process
• modifications to the interaction between line speed and the Zumbach laser based outer diameter control to reduce excursions during line speed changes

• Maintained an inventory of process control equipment and managed availability of critical spare components
• Used AutoCad Electrical to maintain electrical drawings
• Controller equipment routinely troubleshot, repaired and programmed included: Allen-Bradley Control Logix, Compact Logix, Point IO, SLC500, Guard Master, and Flex IO
• HMI hardware included PanelView 600 series, 6181P industrial computers, Parker/SSD DSI3 and DSI8000
• Worked on the following programming development environments: RSLogix 500 & 5000, Logix Designer, PanelBuilder32, RSLinx, PanelView, DriveExecutive, FactoryTalk View, Connected Components Workbench as well as InTouch Wonderware, Historian, Recipe Manager, System Management Console, and Alarm Manager, as well as Control Techniques CTSoft and Parker/SSD DSELite
• Worked with the following motor drives; Parker 590+, 650V, 690+, 890+. Control Techniques Unidrive SP and Allen-Bradley PowerFlex
• Communications protocols I often used, typically through RSLinx, include Ethernet IP, DH-485, DF1, Modbus RTU, RS-232, 422, 485 and ASCII

ELECTRICAL ENGINEER II– PLC CONTROLS PROGRAMMING / EPPENDORF, Enfield, CT

2013 - 2016

Eppendorf is a company that develops, produces, and sells products and services for laboratories around the world.

• Designed the control and electrical systems, including HMI software applications, for the company’s next-generation Sterilize-in-Place Fermentation and Cell Generation Bioreactor product line

• Applications of this product line included bacteria, yeast, insect, plant or mammalian cells, in batch, fed-batch or continuous culture

• Generated P&ID drawings in AutoCad and coordinated quotes with suppliers to meet product cost estimates
• Designed and programed Allen-Bradley CompactLogix PLCs and PanelView panel displays control systems which control the process in the reactor vessel

• Thermal mass flow controllers (TMFC) provide metered additive gasses through sparge and overlay systems. Liquid chemicals are added using up to 5 peristaltic pumps powered by brushed and geared DC pump head motors and measured using scales and load cell processors interfaced to the system over RS-485 Modbus. Heating and cooling of the medium is achieved by a means of a jacketed water circulation system. Real-time pH and dissolved oxygen measurements are achieved via nano-amp sensors and preprocessors. A variety of parameters are available to be configured as user defined cascade PID loops. Agitation of 200 to 900 RPM is accomplished using a motor drive amplifier and small to medium duty permanent magnet motors

• Designed, programmed, and implemented automated test systems in LabView using the PXI hardware line. These systems were used to perform fully automated final test of several product lines manufactured
• Maintained the current product line by processing change orders as well as support manufacturing operations by assisting assemblers in troubleshooting and testing

CONSULTING POSITIONS – CONTROLS AND AUTOMATION

2011 - 2013

ELECTRICAL & SOFTWARE CONTROLS & AUTOMATION ENGINEER

During this period I consulted with four Connecticut firms to design and implement the control and automation projects described below.

• Designed and Programmed IFM Effector based PLC control systems for the LCU-025-CUP, a compact, self-contained, trailer-mounted, Liquid Coolant Supply (LCS) Cart designed to supply chilled polyalfaolefin (PAO) coolant to the aircraft liquid coolant loop for the purpose of removing the electrical heat loads from the avionics of the F-35 Joint Strike Fighter. Mobile computing equipped with CANopen and J1939 to control various components such as the diesel engine electronic control unit and the variable frequency drive (VFD) to drive the compressor
• Designed and programed a National Instruments LabView based test application used in the manufacturing and testing of cerebral tissue oxygen saturation monitoring equipment line. Allows the manufacturing engineer to create a ‘script’ of commands to be issued to the embedded processor of the unit under test over TCP/IP using a Telnet interface. Designed and programmed a Microsoft Visual Studio VB.NET application to read and write 1K and 4K Dallas Semiconductor One Wire memory devices which I accessed over a 1-Wire bus
• Designed, developed, and programed automated test equipment for the aerospace component test industry using National Instruments Lab View Professional Development System. Extensive experience implementing state machines, event driven programming, multiple PID loops, VI Server automated script-based testing and reporting. Real time XY plotting display with bounded pass/fail regions
• Designed, developed, and programed automated Verification & Validation (V&V) systems via embedded systems programming of Texas Instruments F28335 Digital Signal Processor (DSP) using Object Orientated Programming (C++), in conjunction with National Instruments Lab View (LV) and Test Stand (TS)

• Programmed a test application running on the target hardware (TI F28335) to accept a hex coded command over the serial component interface and in turn switch in the various integrated circuit hardware components via the serial peripheral interface (SPI) to analysis the requested sensor input through the analog-to-digital converter (ADC) and send the result back to the requesting system, in this case the LabView test application. In other cases, the LV/TS system is running automated scripts which exercise the control system and actuator to the system requirement

Consultant: SENIOR SYSTEMS ENGINEER / SIKORSKY AIRCRAFT, Stratford, CT

2008 - 2010

United Technologies Corporation (UTC) is an American multinational conglomerate. In 2004, UTC acquired the Schweizer Aircraft Corporation which planned to operate as a wholly owned subsidiary under their Sikorsky Aircraft division.

• Participated on teams designing and developing flight control system components such as Built in Test (BIT) modules, warning, cautions, and advisories (WCA), redundancy management architecture, and data bus communications all of which were components of the USMC CH-53K heavy lift replacement troop and weapons helicopter airframe
• Participated in the design of redundancy management architecture (hardware/software interface) for input signal module (ISM) and output signal module (OSM) signals of the flight control computer implemented in Matlab/Simulink
• Lead engineer authoring the flight control system data bus interface control document (ICD) for the CH-53K heavy lift replacement program
• Participated in design of various aspects of built in test (BIT) modules
• Participated in warning, cautions, and advisories (WCA) working group bringing together all stakeholders of the data concentrator unit, aircraft management system, warnings, cautions, & advisories CSCI, and flight control computer (FCC) and reaching a consensus regarding the processes and tasks associated with each

SENIOR SYSTEMS ENGINEER / GOODRICH CORP., PUMP & ENGINE CONTROL SYSTEMS, West Hartford, CT

2004 - 2007

Goodrich Pump & Engine Control Systems, prior to its acquisition by UTC, manufactured aerospace fuel control systems.

• Designed, programmed, and implemented the Matlab/Simulink and Control Desk/dSpace based Hardware-In-Loop (HIL) test system for the Electronic Control Unit (ECU) of the PWC-210 turboshaft engine used on the commercial Sikorsky S76 helicopter
• Integrated the engine and airframe Matlab models with two dual-channel full authority digital electronic control systems (FADEC) and full real-time ARINC-429 implementation and CAN bus cross channel interface, used in verification and validation of the PWC210 turboshaft engine control system
• Completely automated unattended m-file script-based testing. Full test environment data capture, including all data bus traffic and open/short fault injection, for post-test analysis
• Designed and implemented the signal conditioning hardware which interfaced the HIL simulation circuits and control software to the FADEC units under test

SENIOR CONTROLS ENGINEER - ADVANCED CONTROL SYSTEMS / EMHART GLASS RESEARCH CORPORATION, INCORPORATED, Enfield, CT

1999 - 2004

Emhart Glass is the world’s leading supplier of advanced technologies for manufacturing and inspection of glass containers.

• Performed 100% of design, programming, implementation, testing, and field trial of 840 Advanced Forehearth Control System control application for up to 20 PID control loops per processor including software support for voltage, current loop, thermocouple, and discrete IO boards (hardware) as well as valve motor driver interface
• Programmed in KW MultiProg IEC 61131-3 PLC programming environment the program solved PID loops, acquired and processed signal IO over an Open Process Control (OPC) interface
• Designed and programmed the human machine interface application using Iconics Genesis 32 Active-X for up to 20 control loops per processor cabinet and indefinite cabinet interfaces per plant console, user configurable distribution of control loops, trending, alarms, reporting, data logging to MSDE/JET SQL database, varying access level security and acceptance of job downloads from supervisory controller

CHIEF EE & SW ENGINEERING, CONTROL & HMI SYSTEMS / TURBOMOTIVE, INCORPORATED, Hamden, CT

1992 - 1999

Turbomotive was an OEM turnkey test cell manufacturer who largely automated the aerospace engine overhaul industry in the 1990s.

• Designed, programmed, and implemented custom PLC and microprocessor-based controls and human-machine interfaces (HMI) using Intouch Wonderware for a wide variety of aircraft turboprop, turbofan and APU engines, as well as aircraft components
• Software systems included real-time data presentation and mathematical corrections, step-by-step procedures for engine testing, alarm monitoring, custom data logging, real-time engine test pass/fail evaluation, and custom reporting
• Experience with a variety of sensors including thermocouples, RTDs, LVDTs, RVDTs, charge amplifiers and accelerometers, pressure sensors, current loops, RS-232, 422, 485, IEEE-488, HP-GPIB and inverter-based motor drives
• Completed more than 100 complete test cell applications over seven years

Nuclear Control Systems Engineer / ABB COMBUSTION ENGINEERING, INCORPORATED, Windsor, CT

1990 - 1992

ABB Combustion Engineering is an engineering firm and leader in developing both fossil and nuclear steam supply power systems.

• Engineer responsible for all aspects of Plant Limiting and Supervisory Controller (PL&SC) on DOE New Production Heavy Water Nuclear Reactor contract
• System accepted approximately 1500 inputs from reactor core and reactor support systems
• Responsible for achieving optimal neutron flux distribution

FIELD ENGINEER – SHIPBOARD & FIRE CONTROL SYSTEMS / UNISYS CORPORATION, Bloomfield, CT

1987 - 1988

Unisys Corporation is an American global information technology company that provides IT services, software, and technology.

• Participated in prototype development, integration, and testing of “North Warning” land based unattended short-range radar and “NEXTRAD” Next Generation Doppler Weather Radar
• Completed project to bring aboard Advanced Tactical Systems' prototype remote radar interface

US ARMY INTELLIGENCE & SECURITY COMMAND, Fort Devens, MA

1979 - 1983

The United States Army Intelligence and Security Command (INSCOM) is a direct reporting unit that conducts intelligence, security, and information operations for U.S. Army commanders and national decision-makers.

• Participated in Guardrail precision SIGINT collection/location system, at the time one of the most technically advanced platforms military wide. Sergeant – E-5, grade awarded in just over 3 years
• Instructor at Army Intelligence School
• Held Top Secret Sensitive Intelligence security clearance

Arc Flash Electrical Safety NFPA 70E

Adult First Aid

Universal Robots Core Training

Servo Motion Mastery 1

Wonderware InTouch HMI & InControl

Wonderware InTouch Comprehensive

Wonderware System Platform 1

The Complete Guide to Control Valves

National Instruments Compact RIO & LabView (view sample here)

Iconics Genesis 32 Introduction

Iconics Genesis 32 Advanced

Imagination Systems Real-Time QNX (Unix)

KW Software MULTIPROG for IEC 61131 programming

Linux Administration

Design for Six Sigma, Black-Belt

DO-178B Software Aspects of Certification

DO-254 Hardware Aspects of Certification

DOORS Requirements Management Software