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Automation Project Manager Engineer

Denver, Colorado, United States
January 25, 2018

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Wendell Hutchings

Aurora, CO

*** - ***-****

An Electrical Engineer working with process and automation control applications since 2004. With a degree in Electrical Engineering and Chemistry, an engineer that capitalizes on breadth of inter-discipline engineering experience to design complete automation control systems. Experience in the full development cycle from initial conceptual design, manufactured released product to field support. An active Integrator of HMI (SCADA) using PCs and peripheral touch panels with PLC control systems. As a team leader over the control software, corroborate regularly and direct other engineers of other disciplines, IT and 3rd party software developers in implementing and completing combined discipline control projects.


3 Phase power Analysis

oPower Factoring

oTransient Analysis (Short Circuit and Noise)

oCE & UL Panel Control Engineer

oPower Spectrum Mitigation

Electrical Cad design of power panels and machinery controls

Programed Automation

oAllen Bradley ControlLogix, CompactLogix, MicroLogix, SLC 500 using RSLogix 5000 and Studio 5000

oIEC 61131-3 standards PLC Integrator

Ladder Logic

Function Blocks

Sequence Diagrams

PLC C Script

oSiemens S7-1211, 12,14, 15, 17 PLC using TIA portal

Embedded controllers

HMI/GUI design panel software of

oAllen Bradley (PanelView Panels)

oSiemens WinCC (Comfort Panels)

o3rd party Maple Systems Panels

oNational Instruments LabView HMI and SCADA Daq applications using RSLinx OPC and TCP/IP communications

Machine Instrumentation including thermocouples (within 1C), accelerometers (within 1grms, pneumatic and cryogenic valves

Remote Automation Networking


Principal Automation Controls and Project Manager

Qualmark Inc - 2004-06 - Present

Lead ongoing projects of machine automation and remote control using Allen Bradley and Siemens PLCs control solutions with 3rd party PC HMI LabView developers.

Designed major custom control applications for use of large manufacturing corporations both domestically and internationally. This gave a higher valued added perception to new potential customers.

Lead engineering and software team to define and realize a 40 channel data acquisition product with power spectral analysis to market.

Designed Custom PID control Allen Bradley and Siemens PLC code for thermal and vibration test equipment for local multi-million dollar international manufacturer.

Improved thermal control accuracy from 2.5ºC to less than 1.0ºC and vibration control from 2.5 Grms to better than 0.5 Grms variations.

Developed custom PLC to Embedded controller communication and remote control

Approved $12 M annually of manufactured product for five years as final test manager.

Reduced cost of system controls by 20% without effecting functionality.

Integrated PLC to Embedded control using RS-232 while interfacing to PC running a LabView application using TCP/IP

Improved accuracy and precision of input values by 50%.

Work and collaborate with ME, ChemE, IT, Software Developers and other EE engineers to stream line product development.

Design all control panels to the specifications for onsite UL approval and CE certification.

Provide Schematics for all manufactured goods:

oPoint to point diagrams

oLadder diagrams

oWiring diagrams

Perform transient and harmonic analysis on system affected by unknown power qualities.

Increase company value to new customers by providing power usage and LN2 usage analysis.

Designed and implemented pseudorandom licensing to protect company the intellectual property of the software products.

Provide custom thermal and thermodynamic mass flow analysis.

Awarded corporate US Patent (Shared) and a submitted international Patent for automated test equipment multi-zone control algorithms.

Part time Night Adjunct Professor

Eco Tech Institute Inc - Denver, CO - 2016-09 - Present

Teach the following courses

oPLC Automation (Allen Bradley)

oInstrumentation and Process Control

oDigital and Analog Electronics

o3 phase power theory

Part time Night Adjunct Professor

ITT TECHNICIAL INSTITUTE - 2012-03 - 2016-08

Teach the following Associate Degree Level Classes:

Digital, Analog Devices, PLC programming, Basic Embedded Programming, Basic Analog and Digital components

Teach the following Bachelor Degree Level Classes:

oAdvanced Embedded Systems using Microcontrollers and PICS

oAdvanced Automation Systems, Power Systems

oElectric Machines and Energy Conversion,

o Power Electronics including FFT and power spectral Analysis,

o Advanced Digital and Analog Communications

Field Support Electrical Engineer

Hutchings and Associates - Denver, CO - 1988-03 - 2004-06

Installed and repaired industrial manufacturing equipment for Fuji Film, Prime Source and XPDEX (Electronic, mechanical, pneumatic, and chemical systems)

Organized and presented training sessions for operators using equipment.

Diagnosed and submitted electrical and electronic changes to manufactures based on field failure.

Designed procedure (accepted by Fuji Film) eliminating failure of computer controller boards from effects of improper power (floating neutral)

Designed custom power supply specifications (Carnfeldt USA machine) to improve stability of 12V+ power of a Z80 processor controller board.

Improved efficiency and productivity through custom designed digital controllers.

Designed custom power amplifier for machine controller output. Reduced current load of controller by factor of 50 and increased productivity by 60%.

Designed and installed custom digital controller for State of Colorado Central Services and Colorado Highway Department. Increased productivity of machines from 1000 units per hour to 5000 units.

Designed changes in finishing equipment control wiring to improve overall performance and processing capacity. Capacity increased from 25 to 40 sheets. Performance increased 25% and accuracy 90%. Implemented for two state of Colorado agencies and numerous commercial applications.

Saved hundreds of hours of production time by making custom controllers to temporarily replace damaged control or sensor boards as original boards were being repaired. Saved thousands of dollars by repairing boards versus replacing with new.

Drafted hand drawings for custom machine parts for improved


Bachelor of Science in Electrical Engineering

University of Colorado at Denver - Denver, CO

Bachelor of Science in Chemistry

Metropolitan State College of Denver - Denver, CO


APQP, TRAINING, WIRING, CONTROL PANELS, PID, Schematic Layout (Point to point, cable, ladder, etc.), Customer Support and Service, Engineering Management (Process and Revision Control)




Engineer in Training exam. Preparing to take Control Systems PE exam in October.


Method and apparatus for thermal control of a multiple chamber test system (#8616063)

A multiple chamber test system is provided. The multiple chamber test system includes a plurality of test chambers that each include a vibration table. In addition, each of the test chambers is provided with thermally controlled air from a common source. An output plenum for providing thermally controlled air to the test chambers may include a flow control device, to provide the same or similar thermal conditions in each of the test chambers. Where pneumatic actuators are used to impart movement to the vibration tables, the exhaust air from the actuators can be prevented from mixing with the thermally controlled chamber air.


Passed Engineering in EIT Exam (Colorado)

Implement custom 600, 480, 400 Volt power control panels of up to 150kVA

Design and integrated independent redundant safety relay logic for PLC systems.

Design proven PLC automation with process thermal and vibration modeling

Setup and configuration of PCs for use as HMI interfaces with PLCs including TCP/IP settings.

Integrate mechanical, pneumatic, mechanical refrigeration and cryogenic systems in control solutions.

Apply PID non-linear adaptations for precision tolerance control systems

Devise AC and DC motor controls

Release custom remote control communication protocol for remote integration of automation controls

Draft Schematic and Wiring diagrams using Orcad CAD Software

Create and release to manufacturing wire, ladder, flow and component state diagrams and schematics

Meet and exceed CE, CSA, NFPA and UL regulations in control panel and system designs

Prepare designs for ECO Processing

Write and specify technical manufacturing and end user procedures and manuals.

Manage full life cycle of control designs including refitting.

R &D Design and Prototyping

Material Acquisition

BOM creation

Release of project to manufacturing

Customer Field Support

Lead and manage as Project Manager of 3rd developer software contractors.

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