PROFESSIONAL RESUME

Mark T. Fruehan

412-***-**** cell

Aliquippa,Pa

aczpm1@r.postjobfree.com

Education: West Virginia University

BSEE

University of Pittsburgh Graduate School of Engineering (EE Controls Class)

Objective:

To obtain work as either a contract or direct hire controls engineer. Expertise in the design and programming of control systems specifically PLCs, HMIs, Scada systems, and drives. Also have electrical design (control Panels) and AutoCad experience

AREAS OF EXPERTISE

1.Programmable Logic Controllers

Allen Bradley Controllogix,CompactLogix, Softlogix (Ethernet,DeviceNet,ControlNet)

Allen-Bradley PLC5 series

Allen Bradley Micrologix

Allen Bradley SLC5 series

Allen Bradley Connected Components –Micro 800, PowerFlex 525 drive, Prog Safety Relay

Allen-Bradley PLC3

Reliance AutoMax PLC

Siemens S5 PLC

Alstom VME-based PLC

Omron PLC

Motorola VME-based PLC

GE Innovation Series PLC

Toshiba V-Series PLC

Automation Direct DL205 PLC

2.Drives

AB DC Powerflex

AB AC Powerflex

AB Kinetics Servo

AB/AMC 3904 Stepper

AB AC 1336

GE DC 300

3.Operator Interfaces

Allen Bradley Panelview

4.PLC Development Software

Rockwell RSLogix 5000, 500, 5., Connected Components Workbench

5.Operator Interfaces Software

Rockwell Factory Talk SE/ME

GE IFIX

Wonderware

6.Programming Languages

C, C++

Visual BASIC

7.Drawing Packages

AutoCad

AutoCad Electrical

Patents

Design of a no - motion detection door control system for which I have received the patent - #4,679,508

DETAILED WORK EXPERIENCE

Employer :Patriot Technical Services

Client :Bridgestone Tire, Muskatine, Ia

May 2016- Present

SENIOR CONTROLS ENGINEER

Developed a control system for a roll press which extrudes rubber into long strips.. System includes AB Connected Components micro 820 processor,2 Powerflex 525 AC drives,a Panelview HMI, and an AB prog safety relay.. Selected all electrical components, Programming was done using AB Connected Components Workbench. Drawings were done using ACAD Electrical. .Also was responsible for resolving ECN’s generated by the factory

Employer :Patriot Technical Services

Client :ATS Rock Hill, South Carolina

Nov 2015- March 2016

SENIOR CONTROLS ENGINEER

Wrote code for an automation system which produces medical parts. A web system which used a servo chain drive to index the material was used. The material was cut (inner diameter) at the first station, A plastic wafer was added at the 2nd station with a pick and place system using vacuum grippers The 3rd station cut the outer diameter and offloaded the parts to a robot which delivered them to the next zone.. System includes 5 AB Kinetics Servo Drives and 2 Kollmorgan DC drives. Also wrote code to command the Yamaha Scara Robot through a large pick and place sequence.The PLCs were AB Controllogix,. The HMI was AB FactoryTalk ME on Panelview 1000’s. The system also had various stations on an ATS SUPERTRAC (linear motor) where various tooling functions were performed ie., Heat welding etc. .

Employer :Kelly Services

Client : Heomonetics, Leetsdale,PA

Sept 2015- Oct 2015

SENIOR CONTROLS ENGINEER

Maintained an automation system that manufactured medical parts for the blood collection/distribution industry

Monitored and logged alarms on the HMI,determined what the problems were, and proposed/implemented fixes.Wrote an Excel macro to extract alarms from the HMI database and show the top 5 alarms on bargraphs which were presented at the daily meetings The PLCs were AB CompactLogix. The HMI was AB FactoryTalk ME on Panelviews. The system had various stations on an ATS SUPERTRAC (linear motor) where various tooling functions were performed ie. Ultrasonic welding,pressing parts together, etc.

Employer :Black Peak

Client : CSD Baltimore, MD

May 2015- June 2015

SENIOR CONTROLS ENGINEER

Wrote code for a large conveyor system which inspected bottles of blood plasma.Robots de-palletized the

cartons of plasma. They were inspected, re-palletized, and returned to a large freezer The PLCs were AB Controllogix and CompactLogix. The HMI was AB FactoryTalk SE and Schneider Magellan

Employer :TechniPower

Client : Plastpro, Ashtabula,Ohio

April 2015- May 2015

SENIOR CONTROLS ENGINEER

Re-designed some safety circuits for a wood saw system in a Door manufacturing facility The current safety circuit design allowed a person to open the gate and walk into a dangerous area Also replaced all batteries for the AB SLC PLCs.

Employer : Superior Staffing

Client :L3 Communications, Pittsburgh, PA

March 2014- June 2014

SENIOR CONTROLS ENGINEER

Worked on the thermal control system for a solar telescope using a Rockwell CompactLogix

PLC and RSLogix 5000 Used PID loop to control the temperature of the mirror Wrote Modbus master driver to read temperatures from slave devices using RS-485 serial interface.

Employer : TechniPower

Client: ElectroPrime, Toledo, Ohio

Feb 2014 to March 2014

SENIOR CONTROLS ENGINEER

Worked on a GM Fender line using PLC5 (RSLogix 5) Interfaced with ABB and Fanuc Robots. Made software changes to the line

Worked on a welding machine which welded nuts to a car fender using a ControlLogix controller . (RSLogix 5000) DeviceNet. was used to interface to the welding machines.

Employer : Stroud Engineering Services

Client: Rockwell Automation,Mayfield Heights,Ohio

June 2013 to Jan 2014

SENIOR TEST ENGINEER

Re-designed a test bed for a ControlNet network consisting of Controllogix racks, CompactLogix racks, FlexIO rack, PointIO, PLC5 rack, 1771 IO rack, SLC rack, 1747 I/O rack, SoftLogix rack, Panelview Plus using Factory Talk ViewME, and Factory Talk View SE HMI.. The Controllogix racks were a redundant Chassis pair.The testbed focused on testing the capabilities of a 1756-CN2R CNET module.in the redundant racks..Testware was written using Rockwell RS5000 ladder logic development system. A Controllogix rack was used to generate disruptions to the racks such as Power cycle, cable breaks, etc. Communication to the test racks was done using produce/consume over Ethernet. Responsible for selecting all supporting components: breakers, fuses, power supplies,etc. and isuring correct ratings

Employer : Adecco

Client: ATW, Dayton,Ohio

April 2013 to June 2013

SENIOR CONTROLS ENGINEER

Worked on a car oil pump automation system using CompactLogix (RSlogix 5000)

Worked on a 3 axis robot for a pick and place operation (Catepillar engine heads)

using Compactlogix .

Employer : Stroud Engineering Services

Client: Rockwell Automation,Mayfield Heights,Ohio

Sept 2011 to March 2013

SENIOR CONTROLS TEST ENGINEER

Designed a test bed for a ControlNet network consisting of Controllogix racks, CompactLogix racks, FlexIO rack, PointIO, PLC5 rack, 1771 IO rack, SLC rack, 1747 I/O rack, SoftLogix rack, Panelview Plus using Factory Talk ViewME, and Factory Talk View SE HMI.. The Controllogix racks were a redundant Chassis pair.The testbed focused on testing the capabilities of a 1756-CN2R CNET module.in the redundant racks..Testware was written using Rockwell RSLogix5000 ladder logic development system. A Controllogix rack was used to generate disruptions to the racks such as Power cycle, cable breaks, etc. Communication to the test racks was done using produce/consume over Ethernet. Responsible for selecting all supporting components: breakers, fuses, power supplies,etc. and isuring correct ratings

Employer : K.A Hamilton

Client: Westinghouse Electric Corp, Commercial Nuclear Div.

Aug, 2010 to July, 2011

SENIOR CONTROLS ENGINEER

Wrote and tested software for nuclear power plant safety systems. ABB AC160 was the controller used Extensive testing of the system was done.

Employer : T-Mark Consulting Inc

Aug, 1998 to Feb, 2010

SENIOR CONTROLS ENGINEER

Client: Gruber Industries, Aliquippa,PA

Contracted to design and write software for the control of a plastic thermoformer machine. Machine has a sequence and is run with pneumatics. It also has an 18 zone furnace The control system used was an OMRON PLC and HMI. Responsible for all the electrical as well as software design. Turnkey project

Client : Internal development

Development of animatronics for use in Halloween exhibits. Used embedded controllers (Parallax Basic Stamp) and HITEC Servo motors. Programming was done in PBASIC

Client: Jet Plastica, Hatfield, Pa

Worked on a sorting/singulating conveyor system for plastic utensils. Used Allen Bradley Controllogix as the controller . Stepper motor control was done using the AMC 3904 card.

Client: Crown ESA, Portage IN.

Worked on Arcelor Mittal Caster in East Chicago, IN. Responsible for hardware /software design and testing/installation.. PLC used was Allen Bradley Controllogix and Drives were Allen Bradley DC Power Flex.Reponsble for the design of 43 drive panels including selection of all components: breakers, fuses,contactors,drives,controllers, etc.. Responsible for all ACAD dwgs.

Worked on problems with strip steering on a Stitch / Push Pull Pickle line at Worthington Steel in Delta Ohio. PLC’s used were Allen Bradley PLC5 and Reliance AutoMax

Client: TXI Cement, CA

Participated in the startup of a cement factory. PLC used was the Allen Bradley Controllogix

Client: Crown ESA, Portage IN.

Solved problems on the #5 Pickle line at East Chicago In.. Including Diameter calculation inaccuracies,

Entry, Process and Delivery speed problems, and wrote thermal overload code for 4 bridles. PLC used was Allen Bradley Controllogix, Allen Bradley PLC5, and Reliance AutoMax.

Worked on problems with strip centering devices (Scan-a-line and Fife) on several inspection lines at I/N Tek I/N Kote in New Carlisle, PLC used was Reliance AutoMax. .

Wrote a spec to make several safety improvements in the Water Treatment Plants including E-stop Pull cords, and mixer drive control etc. Produced the schematic and layout drawings, spec’d out the parts and produced a bill of material. I designed the programming changes and HMI changes

Client: TMGE Automation Systems Inc, Salem, VA.

Wrote code for a coil handling system for Erdemir Steel in Turkey using GE Innovation series VME - based system . Toolbox was the development software. Successfully completed the startup of a downcoiler for a hot strip mill for Erdemir Steel in Turkey using GE Innovation series VME - based system. Also worked on the Steckel Mill.

Completed design and commissioning of the Severcorr Pickle line. PLC used was Toshiba V-Series HMI was I-FIX. Wrote design spec.and code for the pickling,rinsing,drying and auxiliary equipment.

Commissioned a Coil Handling area for Anyang Iron & Steel In Anyang,China PLC used was Toshiba V-Series . HMI was I-FIX.

Client : Darlington Metalizing, Darlington, Pa

Designed a new servo drive system for the print roll. See Darlington Metalizing below

Client: Pittsburgh Tubular Shafting Inc., Monaca PA.

Made code modifications to a lathe which used an Allen Bradley Micrologix controller. Taught a class covering the lathe program as well as Micrologix RS500 programming in general.

Client: Timken Steel Company,Canton,Ohio

Contracted to develop HMI screens for a steel bar mill using Visual Basic Developed a Recipe Download Screen which queried an SQL 2000 database, retrieved recipe data and downloaded it to an Automax PLC through a Modicon Momentum PLC using ModBus Protocol.

Client: Gruber Industries, Aliquippa,PA

Designed and wrote software for the control of a plastic thermoformer machine. The control system used is an OMRON PLC and HMI. First machine is working. Started working on another.

Client: IAS., Aliquippa, Pa

Developed HMI screens for a shaper control system using INTELLUTION iFIX HMI software.

Client: Oklahoma Steel and Wire, Madill Oklahoma

Contracted to design and program a control system for a rod mill. The control system was Reliance AUTOMAX. Breakdown mill, 7 stand roughing mill, 6 stand Intermediate Mill, and Morgan Pre-finish, No-Twist, and Finishing mill as well as Laying head and,Stelmore Conveyors make up the facility. Reliance DC drives using a UDC to PMI fiber optic link were used. . Developed HMI using Reliance SIGMA which uses VB as the development language.

Client: Scotts Fertilizer, Columbus, Ohio

Troubleshooting of a new batch control system for fertilizer.. Control system consisted of Allen Bradley PLC5’s on a ControlNet network. The HMI was Wonderware

Client: Darlington Metalizing Inc. Darlington, Pa

Startup up of a vacuum metalizing system. This was a WEB system with unwind and Re-wind Rolls. Tension control was done with Load Cells. Control system consisted of an AB SLC 5/04 using a DeviceNet Flex I/O system.

Other controllers used include a Direct Logics DL-205 PLC with a D2-240 processor

This was used for the waste water treatment system which cooled,filtered,and added chemicals to the water.

Made some hardware and software changes to this system and documented these changes in the drawings.

There was also a Siemens S5 U95 PLC used to control the water Chiller system.

The HMI was Intellution FIX 32.

Client: Graveyard Productions, Middletown, Conn

Built and installed 3 animated props (animatronics) installed 5 additional props at a large Halloween exhibit. Design and build animated props using Z86 embedded controllers, pneumatic valves and actuators, ac motors, starters,etc.

Provide programming for the controller

Install the animated props at the customer site.

Specify, purchase, and install compressors and air lines to operate 5 additional props.

Client: AK Steel, Rockport, IN

Provided assistance and make enhancements during the startup of the HMI system which I developed for AK while at Cegelec. ( see Cegelec below)

Make improvements/enhancements to the system

Training of AK personnel on the HMI system

Troubleshooting of network and PC hardware/software problems

Build new HMI’s(install Win NT and FIX) and add them to the network.

Make enhancements to other areas such as DIS coil handling system HMI and the water treatment HMI system.

Develop a new IFIX- based data logging system which can be queried using MSQUERY

Make changes and enhancements to the plant control logic (Alstom PLCs) using the Alstom ladder logic development system

Client: Danieli Inc. Pittsburgh, PA.

DOFASCO Caustic Cleaning Line (Allen Bradley PLC5 and Panelview)

Develop and test Panelview screens

Develop and test PLC5 software

Develop and test Wonderware HMI screens

NUCOR Bar Mill Finishing Area ( STACKER Removal System) (Reliance PLC and Wonderware HMI)

Develop and Test Reliance PLC code

Develop and Test Wonderware HMI

Take to field and startup

Employer : ESA

May, 1997 to Aug, 1998

SENIOR CONTROLS ENGINEER

Client:Cegelec,. Pittsburgh, PA

CEGELEC is an automation systems integration house which designs control systems for steel facilities using VME-based control systems. They were designing an anneal/pickle line and a continuous pickle line for AK steel. I was given the lead engineer responsibility for the Intellution Fix HMI system. I had 6 other people helping me. Over 1500 HMI screens have been produced running on 16 view nodes. Data from the PLC’s was obtained using 3 SCADAs (2 for normal data and 1 dedicated to alarms).

HMI System Configuration

HMI Standards Development (Interface with the PLC’s)

Design of the HMI graphics

Real-time trending/historical trending

Alarming

Security

Provide guidance, leadership, and assignments to the other 6 people working on the HMI.

Client: Lukens Steel, Massillon,.Oh

Built a new anneal/pickle line to produce stainless product. I was hired to troubleshoot existing problems with the line as well as make enhancements to the current PLC/HMI software.

Troubleshoot and fix existing problems with the line

Make enhancements to the current Allen Bradley PLC software for the line and the water treatment system and documented in drawings

Make enhancements to the current FIX HMI’s

Training of operators/maintenance personnel

Employer : Peak Technical Services

March, 1995 to May, 1997

SENIOR CONTROLS ENGINEER

Client:Tippens, Pittsburgh, Pa.

TIPPINS is an automation systems integration house which designs control systems for plate and coil steel mills using PLCs and VME-based control systems.

My Duties included:

PLC/VME Hardware Configuration

I/O schematics development

Flowcharting of the process per the sequence of operations

Development of a built -in simulator to test the code

Layout of the HMI (man - machine interface) graphics

Writing the PLC Ladder Logic and VME macro code

Perform in-house testing using the simulator

Start-up system in the field

Training of operators/maintenance personnel worked on the Finishing area /Downcoiler for a coil/plate mill for OREGON STEEL IN PORTLAND, OR.

Equipment automated included a leveler, dividing shear, rotary shear,transfers and all associated tables. A downcoiler was also commissioned. (7 months in the field)

Employer :Davy International, Automation Services Div., (now Siemens)

Dec, 1989 to March, 1995

SENIOR CONTROLS ENGINEER

DAYY AUTOMATION SERVICES is an automation systems integration house which designs control systems using PLCs (programmable logic controllers), HMIs and DCS's (distributed control systems)

Responsibilities included: PLC Hardware selection/configuration

Design of PLC panels

I/O schematics development

Writing the PLC Ladder Logic

Start-up system in the field

Perform in-house testing using the simulator

Development of the HMI (man - machine interface) graphics

Development of a simulator (PC based software package)used to test the PLC code

Flowcharting of the process per the sequence of operations

Training of operators/maintenance personnel

Jobs included:

1.. Ladle Metallurgy Facility (LMF), USS GARY WORKS, GARY IN. (3 months in field) (Allen Bradley PLC 3 & 5)

2. Ladle Metallurgy Facility (LMF), USS MON VALLEY WORKS, ET, BRADDOCK, PA. (1 1/2 years in field for startup and warranty) (Allen Bradley PLC3 & 5)

3. Aluminum Pusher Furnace, EgyptAlum, Egypt (Siemens S5)

4. Steel Reheat Furnace, Xiangtan, China (Allen Bradley PLC5)

5. Refrigerator Assembly, Whirlpool, Evansville, Ind. (Allen Bradley PLC5)

Additional Training

WEST VIRGINIA UNIVERSITY, B.S. ELECTRICAL ENGINEERING

Emphasis was in electronics, both digital and analog. A course was taken in which an 8080 microprocessor system was built. Senior project involved designing and building a video and keyboard interface for the 8080 microprocessor board. A course which covered operational amplifiers in great depth was also taken. A broad knowledge of systems, fields, and power was gained.

E.I.T (ENGINEER IN TRAINING) test PASSED.

HEATHKIT MICROPROCESSOR COURSE

This course taught Motorola 6800 hardware and software.

NRI COMPUTER COURSE

This course taught computer hardware and software using the RADIO SHACK MODEL III as a basis for learning general computer fundamentals.

UNIVERSITY OF PITTSBURGH GRADUATE SCHOOL OF ENGINEERING

Course was taken in Digital Control Systems. Design of a computer controlled camera (automatic tracking of a subject) was done using Z transform theory.

MODICON 984 PLC COURSE

ALLEN BRADLEY PLC3 SCHOOL

EATON IDT HMI (HUMAN-MACHINE INTERFACE) SCHOOL

VISUAL BASIC COURSE University of Pittsburgh Computer Center

C COURSE University of Pittsburgh Computer Center

C ++ COURSE University of Pittsburgh Computer Center

Rockwell / Allen Bradley Motion Control Course CCN 142

SERCOS and Analog Servo Modules and Drives were used Ladder logic motion commands were used. Module/Drive configuration was presented A 3 Axis gluing machine was developed

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