Highly Experienced Controls Engineer/PLC Programmer
Resume:
Michael Smith
***B Mockingbird Lane
Lockhart, TX 78644
Profile
Highly Experienced Controls Engineer with an extensive background seeks a challenging position with opportunity for advancement. Willing to relocate.
Skills
• PLC Programming using Siemens Step7, Rockwell/Allen Bradley Logix 5, 500, and 5000, Omron CXOne, Modsoft, PLC7 Pro, and others
• HMI programming using Siemens WinCC Flex and Protool, RsView, Panelbuilder32 and others
• Visual Basic programming
• Fieldbus technologies including Profibus, DeviceNet, DH+, Ethernet, and others
• Vision system integration using Cognex/DVT Intellect and IN-Sight, Dataman, Banner Presence Plus, and Effector
• Fanuc Robot programming with or without vision guidance
• Servo motion control programming on Siemens, Allen Bradley, Modicon and GE PLC platforms
• Automation Electrical and Pneumatic hardware design/schematics from a sequence of operations, including 480VAC, 220VAC, 120VAC and 24VDC distribution, I/O layout, electrical panel layout, device wiring, wire sizing and fuse/circuit breaker sizing, network/fieldbus layout, Remote I/O layout, satellite junction box layout, pneumatic valve/piping sizing and layout, and BOM’s using Autocad12, 14, 2000 and Electrical
• High speed data acquisition on PLC, Sciemetrics, National Instruments, and PC based platforms using a variety of sensors such as vibration sensors/accelerometers, flow sensors, pressure transducers, torque transducers, temperature transducers, and more
• Nut runner/Tightening system programming using Bosch and Rexroth platforms
• Automation/electrical, pneumatic and hydraulic troubleshooting using a variety of equipment such as hand tools, soldering irons, multi-meters, ammeters, oscilloscopes and more
• Autonomous and team based Automation Start-up, debug, and installation
• Process improvement and troubleshooting
• Mechanically adept with a variety of tools including hand tools, power tools, band saws, lathes and mills Able to troubleshoot most mechanical problems without assistance
• PC troubleshooting and repair of both hardware and operating system issues
• Experienced with Microsoft Windows, Linux, Mac OSX, Word, Excel, Pages, PowerPoint, Numbers, Photoshop, OpenOffice, and many other software packages.
Career History and Achievements
Durr Ecoclean, Controls Engineer 2007 - 2009
Volunteered for an assignment in Ramos Mexico integrating and installing 9 material handling conveyors. These systems were built, started up, and debug in a temporary facility in Mexico before installation at the GM Ramos facility. The lines were controlled using Siemens PLC’s and HMI’s and included RFID tracking, SCADA integration, and vision part identification. During the installation of this project, I also took the lead on the installation of several robotic part washers, which had fallen behind schedule. I interfaced with the customer to develop open issues lists and directed our local contractors as well as reprogramming a majority of the software to get the project back on track. I also developed several process improvements, which I sold to the customer improving their quality and generating additional revenue for Durr. This assignment was accomplished with a heavy load of Step 7, ProTool, WinCCFlex, and vision programming as well as electrical, pneumatic, and mechanical troubleshooting.
Programmed, started up, debugged and installed 4 nut runner stations for GM Flint, St. Catherines, and Ramos Mexico. These stations were controlled using Omron PLC’s and HMI’s.
ATI Systems, Controls Engineer 2002 – 2007
Designed, programmed, started up and debugged a 7 station automated battery assembly and test machine. This highly complicated machine was controlled via an SLC-500 processor and used a variety of ancillary devices to perform vision identification, leak testing, force monitoring, bar code reading, and data tracking and monitoring. This assignment was accomplished using RSLogix500, RSStudio, and other programming packages to configure the vision, bar code reader and robot.
Designed, programmed, started up and debugged a seat frame tester. This machine was controlled via a ControlLogix PLC and programmed in RSLogix-5000 with RSStudio. The machine utilized extensive Cognex vision system coupled with 2 servomotors to perform a variety of quality checks including weld position of components and range of motion/force detection.
Designed and commissioned two brake module testers. These testers were controlled using PC and National Instruments’ compact field point hardware. The program was written using LabView and Visual Basic. The testers also incorporated vision checks for quality control, which was handled with a DVT camera.
Designed, programmed, started up, debugged and installed a speaker grill pick and place station, as well as installation support for 2 end of line electrical door panel testers. These stations were controlled via an SLC-500 PLC and programmed using RSLogix-500 and Panelbuilder32.
Accepted the position of Controls Engineer for the company. I was responsible for everything electrically related to the design of new equipment. As the only Controls Engineer at the company, my duties included interfacing with customers, developing quotations, electrical design, software programming, field installation, equipment purchase, project management, and anything else they needed me to do.
Commissioned several test stations, a press station and material handling upgrades. These systems were controlled via an SLC-500 and PC. Responsible for programming the PLC using RSLogix-500, and modifying the PC programs using Visual Basic. These installations and upgrades were accomplished under a very tight schedule, and required several 20 hr days to complete within the customers time frame.
Commissioned over 20 of ATI’s standard End of Line seat testers, airbag testers, and weight detection calibrators at various locations in the US and Mexico. These testers were PC based and required Visual Basic and XML programming, as well as electrical, pneumatic and mechanical troubleshooting.
Schenck-Turner, INC, Field Service Engineer 1999 – 2002
Commissioned 3 prop shaft balancers. These balancers were controlled via an SLC-500 and a proprietary balancing computer that ascertained balance correction information. The installation required programming with RSLogix-500 and Medar weld unit configuration as well as electrical, pneumatic, and mechanical troubleshooting.
Commissioned a seat and guide press machine. This machine was controlled via a PLC-5 and utilized a Sciemetrics unit for press force monitoring. This required extensive reprogramming and rework using RSLogix5 and configuration of the Sciemetrics unit using IDE.
Reprogrammed a troubled seat and guide press machine, and was appointed to oversee and program the eventual retrofit of this machine. This machine was controlled via a PLC-5 and utilized a Sciemetrics unit for press force monitoring. This required extensive reprogramming and rework using RSLogix5 and configuration of the Sciemetrics unit using IDE.
Commisioned and installed several other types of balancers, including Torque Converter and Crankshaft. These machines were controlled via a variety of PLC’s and balancing computers and required field programming, electrical, pneumatic and mechanical troubleshooting.
PICO, Controls Engineer 1996 -1999
Designed, programmed, started up, and debugged a 7 station testing line. This line was controlled via a PLC-5 and utilized a variety of ancillary devices to obtain test results such as Daytronic, Sciemetrics, bar code reading and generation. Heavy use of AB 6200 and Panelbuilder as well as Visual Basic and Sciemetrics IDE programming was required.
Completed the installation of a camshaft assembly tester. This tester was controlled using a Modicon 885 processor and Sciemetrics for data acquisition. The installation required programming with Modsoft and Sciemetrics IDE.
Designed, programmed, started up, debugged and installed 5 in process test stations. These stations were controlled via PLC-5 and Sciemetrics for data acquisition. Programming was accomplished using AB 6200 software.
Balance Engineering, Field Service Technician 1994 -1996
Commissioned several variety of balancers similar to the product produced by Schenck-Turner above. The installations consisted primarily of PLC debug using AB 6200 and electrical, mechanical, pneumatic, and hydraulic troubleshooting.
United States Navy, GSE3 1990 – 1994
Formally trained as an electronics tech/ electrician for a gas turbine power plant. Served two years aboard a Perry Class Guided Missile Frigate, receiving several Captains commendations for my work and technical ability. Granted an Honorable Discharge in 1994.
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