Engineer Design

Brad Carman

Email: *********@********.***

Address: **** ****** ****

City: Dundee

State: NY

Zip: 14837

Country: USA

Phone: 607-***-****

Skill Level: Experienced

Salary Range: $156,000

Willing to Relocate

Primary Skills/Experience:

See Resume

Educational Background:

See Resume

Job History / Details:

BRAD CARMAN, Ph.D.

*********@********.***

607-***-**** (cell)

4280 Locust Road, Dundee, NY 14837

410 Beechwood Drive, Columbia, SC 29212 (winter home)

SUMMARY:

Ph.D. in Mechanical Engineering. 27 years experience in PC system integration and programming for machinery automation and Test & Measurement applications. Certified 1998 by National Instruments as a LabVIEW instructor. 35 years machinery experience, including vibration analysis, stress analysis, troubleshooting, repair, maintenance, and design. Licensed 1990 as Professional Engineer in Ohio. Certified by the Vibration Institute as a Level II Vibration Analyst. Taught vibration certification review courses and proctored certification exams. Formerly a Certified Flight Instructor with instrument & multi-engine ratings and aerobatic experience. My wife & I own Nautical Nights Bed & Breakfast (NauticalNights.com).

EXPERIENCE:

1/1993 - Present: Owner / Engineering & Software Consultant (CREATE, L.L.C.)

Software projects for T&M and Automated Test Equipment (ATE) applications have included the following (LabVIEW unless otherwise stated).

ACR Electronics - Automated testing of search & rescue radio beacons. Supported relocation of one product line from Canadian factory to the Fort Lauderdale facility, and incorporated new product features. Software mix included C#, C++, LabWindows/CVI, Visual Basic & SQL, in addition to LabVIEW.

Zimmer Corp. - Motion control application for fatigue testing materials to be used for joint replacement surgery. Utilized PID, Visual Basic programming & NI-Compact DAQ.

UTC Power - Control systems & LabVIEW support for Fuel Cell test stands, using PXI & SCXI for Real-Time (RT) control, plus the Data-logging & Supervisory Control (DSC) module. ModBus communication was employed at one of the test stands for automotive applications. Documentation using PDMLink.

Stryker Instruments - NI-TestStand application for testing surgical power tools during various stages of manufacture. Both parallel & sequential process models were utilized.

Triumph Gear Systems - PXI & SCXI RT control application for testing aircraft gearboxes. Reprogrammed & enhanced another PXI & SCXI RT application for testing aircraft hydraulic actuators.

Corning Inc's Sullivan Park Research Center - LabVIEW PID & SCXI control software for diesel truck exhaust filter test stands measuring fatigue under operating conditions and measuring filtration efficiency.

Silicon Carbide Products - Compact FieldPoint application with serial communication to controller.

Corning Inc's Sullivan Park Research Center - Motion control & IMAQ vision software for LASER-sealing frits in OLED display glass. IMAQ vision application for measuring shape of glass sheets.

RJ Reynolds Tobacco Co. - Provided Real-Time inspection & shutdown for machine which applied self-extinguishing safety feature to cigarette paper. Synchronous sampling was a key technique because of the machine's variable speed drive.

Tyco Healthcare - DAQ of EKG traces for device testing.

Corning Inc's Erwin Manufacturing Plant - Motion control & IMAQ vision software for manufacturing & testing fiber optic lenses; both the manufacturing and beamscan inspection stations interfaced with the plant`s PI database and Camstar Insite Manufacturing Execution System (MES). Fiber optic splicers were controlled using ActiveX. The 2 years of lens sales from this plant were the successful outcome of the R&D at Sullivan Park described below. Manufacturing operations were then contracted to an Asian plant, using the above software & equipment.

Corning Inc's Sullivan Park Research Center - Test stand software (FieldPoint & SCXI) for fiber optic coupler development.

Corning Inc's Monroe Park Photonics Plant - Control systems maintenance & support to all -Mercury Draw- machines for manufacturing fiber optic couplers. Developed software for improving fiber feed.

Corning Inc's Sullivan Park Research Center - Developed motion control & IMAQ vision software for manufacturing fiber optic lenses. Developed another motion control application for 6-axis alignment between Light Emitting Diode (LED) and fiber lens.

Corning Inc's Photonic Technical Division - DOUBLED the manufacturing speed of fiber optic couplers, by taking advantage of LabVIEW's inherent parallel processing capabilities. Motion control, Statistical Process Control (SPC), GPIB & DAQ software for manufacturing fiber optic couplers. Developed Visual Inspection software for fiber optic couplers. Developed DataSocket software to allow remote monitoring of all coupler manufacturing machines. Provided software support for -Aries-, -Auto Funnel Form- & -Thermal Chamber- stations.

Corning Inc's Photonics operation at -Ceramics Corridor Innovation Center- - Developed GPIB software to measure Insertion Loss for fiber optic couplers.

Pratt &Whitney Aircraft Engines - Developed software for spin pit testing rocket engine & turbomachinery rotors using Barbour-Stockwell TC2A controller; used serial & GPIB communications, DAQ.

Pratt &Whitney Aircraft Engines - Instrumentation setup, calibration, data-logging, and report generation using strain gages, accelerometers, thermocouples, voltage sources, etc. with National Instruments data acquisition boards, HP3852, Fluke2400, trig-tek Model 1000 strain gage amplifier, and E Square data acquisition chassis.

Precision Measurement Systems - Provided LabVIEW LASER alignment report-generation software with DDE interface to MS-Excel and AutoCAD.

"DBA Spectrum Analyzer" - Years before NI introduced its "Sound & Vibration" module, I developed software for machinery vibration analysis which, when coupled with a DAQ or DSA board, yielded a PC-based spectrum analyzer. Both LabVIEW and LabWindows (C language) versions were written, and the LabVIEW version was updated to include some features from NI's S&V module after NI released it. It also included the Gabor Spectrogram. Customers included Pratt & Whitney Aircraft Engines, McCulloch Corp., Glaxo Chemicals, Emerson Motor Co., Dynacor, Inc., and Dong Am in Seoul, South Korea.

Miscellaneous - Developed prototype system for measuring alignment of rotating shafts using image processing, LaPlacian-of-Gaussian edge detection algorithm, C and C++. Taught several LabVIEW courses.

Machinery Alignment Consulting:

Numerous shaft alignments using dial indicator or LASER measurements. Numerous alignments of roll parallelism for steel, aluminum, paper, and plastic film plants using LASER & detector. Plants serviced include: AGA, GE Aircraft Engines, Sumitomo, Logan Aluminum, Commonwealth Aluminum, Meade Paper, AKG, AK Steel, Beckett Paper, Champion Paper, and Appleton Paper. For some of the alignments, I designed & machined my own fixtures.

Engineering Consulting:

Buckingham Manufacturing - Measured natural frequencies of drop test structure used to certify safety harnesses & designed modifications required for stand to meet standards. Used my own "DBA Spectrum Analyzer" application for performing measurements & analyses.

Proctor & Gamble - Preliminary design of vibration isolation system for process machinery.

GE Aircraft Engines - using my own LabVIEW application, acquired vibration data for spin pit test.

GE Aircraft Engines - Stress analysis of 4 test cell piping systems; recommended design changes necessary to satisfy ASME piping codes.

Miscellaneous - Vibration analyses of various machinery ranging from printing presses to aerospace test rigs.

2/90 - 12/92: (contract) Test Facilities Project Engineer @ G.E. Aircraft Engines.

Vibration analysis, troubleshooting, balancing, alignment, and repair of rotating machinery. Commissioned telemetry/strain-gage inline torque measurement system for gas turbine test cell. Designed test fixture for testing exhaust nozzle actuators and associated controls. Failure analysis, repair, finite element stress analysis and design (mechanical and thermodynamic) of high temperature, high pressure air supply systems.

6/82 - 9/86: (contract) Turbomachinery Design Engineer @ G.E. Aircraft Engines.

Developed peening and coating processes for eliminating in-flight high cycle fatigue failures of CT7-5 compressor stage 2 blisk. Mechanical design and project management to develop the following T700/CT7 components: compressor rotor, cast diffuser, cast impeller shroud, diffuser case, Curvic coupling seals, and erosion-resistant airfoil coatings. Included were ANSYS finite element stress analyses, and the issue of casting, forging, ultrasonic and machining drawings.

6/81 - 6/82: Senior Maintenance Engineer for Mobay Chemical Corporation.

Troubleshooting, vibration & signature analysis, alignment, and balancing of rotating equipment. Supervised repairs and overhauls of critical rotating machinery.

1/80 - 6/81: Plant Engineer for Exxon Chemical Americas.

Vibration analysis, field modifications, and mechanical startup of various rotating machinery. Specified and purchased: compressors, gear-sets, pumps, motors, couplings, vibrating dryers, conveyors, dust collectors, star feeders and cyclones for major plant expansions.

7/79 - 1/80: (contract) Value Process Manufacturing Engineer @ G.E. Aircraft Engines.

Member of 4-man task force to reduce raw material & manufacturing costs for all engines designed & manufactured in Evendale. Millions of dollars were saved by incorporating modern manufacturing techniques & tolerances when issuing the forging, ultrasonic, & casting drawings.

7/78 - 7/79: (contract) Turbomachinery Design Engineer @ G.E. Aircraft Engines.

Failure analysis and development of repair procedures for eliminating in-flight high cycle failures of CF6-6 & -50 stage 9 compressor blade dovetails. Rotor-dynamic and finite element stress analyses for various CF6 compressor components.

4/78 - 6/78: (contract) Analytical Design Engineer @ P&W Aircraft Engines.

Dynamic analyses of JT3D second turbine outer air seal and JT9D low pressure rotor. Finite Element stress analyses of JT9D mount rail and of JT8D-9 turbine blade attachment.

5/76 - 4/78: Structures Design Engineer @ P&W Aircraft Engines.

Multiplane balancing of rotor-dynamics test rig. Critical speed, forced response, and maneuver load analyses of the P&WA F-100 and the GE F-404. Developed numerical techniques to predict rotor-dynamic response to nonlinear bearing dampers and supports. Transient modal analyses of F-100 lateral surge deflections. NASTRAN finite element stress analysis of development turbine blade.

1/76 - 5/76: Taught 2nd semester Engineering Calculus course. Lectures to small group of graduate math students, based upon my independent study of Topological Groups.

PUBLICATIONS:

"Using a Data Acquisition Board and a Notebook Computer for Vibration Analysis". Variations of this paper may be found in:

Proceedings of the Seventeenth Annual Meeting of the Vibration Institute, 1993;

Proceedings of the 1993 Predictive Maintenance Technology National Conference;

P/PM Technology magazine, 12/93;

P/N 360446-01, available from National Instruments.

"Alignment of Rotating Machinery Using Computer Vision", Proceedings of the Thirteenth Annual Meeting of the Vibration Institute, 1989.

EDUCATION: 1989 Ph.D. in Mechanical Engineering from University of South Carolina, with emphasis on solid mechanics (including dynamics, vibration and stress analysis), computer vision, and mathematics. Eastman Kodak fellowship. 4.0 G.P.R.

1975 B.S. in Engineering Analysis from Clemson University (coursework consisted of undergraduate M.E. and graduate-level math courses). J.C. Higgins and Rayonier Foundation scholarships. 4 year degree obtained in 2.5 years with 3.7 G.P.R.

Contact this candidate