Costa Automation
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BELOW IS VIDEOS OF THE PROJECTS I WORKED ON
This video showed the Process Control Room Upgrade I did at Detroit Renewable Energy.
Installed wireless pressure transducer to monitor the N2 in the dies
The above video shows the operator and the HMI Live
I designed and built the panel in my office first, tested it, made it turn-key, and installed it.
This shows the HMI & the PLC Live
The Gripper Testing Cart I created consisted of a Click PLC, Pressure Transducer, DIN Power Supply, DIN Industrial PC, DIN Network Switch, and HMI, which I made using LabVIEW DSC. This LabVIEW program will open and close the gripper and test the sensor. It will also allow you to input and log the data, save the data to Excel, and you can open the Excel file and view it. (Once opened, you can save it to another location). On the other tabs are information about the gripper and sensor.
We upgraded the transfer from WayneTrail to Arisa. I had to rewire the sensors on all four gripper bars, each bar having seven sensors. I had to completely rewire and label all of them.
This shows a simulation. I actually installed everything, and it works great.
I installed this SMI 2 on the side of the Arisa Press, then installed inputs and outputs to stop the press if it was idle for more than three minutes. The operator would then have to pick a reason why it was down. This was all logged. I also configured it to display along with all the other presses on the Wintriss Shop Floor Connect.
This is the Wintriss Shop Floor Connect on a large screen in the plant. You can also access it on a web portal.
I designed and constructed a robot tending cell utilizing a Fanuc S-12 robot. Unfortunately, I didn’t complete it before my employment ended. "The press controls required an upgrade to enable seamless interfacing with the Wintriss controls. "
Installed a Zebra FS20 Fixed Industrial Scanner. I set it up so that when the press was stopped because of a fault, a supervisor needed to come and scan his employee ID badge to reset the Wintriss so the press could run. We did this because the operator would reset the press without looking to see why the press stopped. The dies were being damaged, and bad parts were being shipped to the customer. I also provided them with a logbook to log why it stopped. This created accountability and showed why it stopped so the die repair person could fix the die. When scanned, the card would send a digital output that would energize a relay that would simultaneously put the Wintriss in program mode and do a remote reset.
At times, it was challenging to do troubleshooting on the press. This picture shows they typical enclosure on 90 percent of the presses. The documentation was never in the best shape, and for some of the presses, there was no documentation at all.
This shows the 500 TON HPM press that I designed and installed all the controls from a bare press frame
ABOVE I AM DEMONSTRATING HOW TO USE THE CMORE HMI I PROGRAMED
3 Duel Screen HMI's
I created these HMI's using LabVIEW DSC & Diadem
(Maximize the YouTube video below)
Below is my work area at home. I would VPN in and use a remote desktop to work remotely.
Below is my common work space
While working at Detroit Renewable Energy in Detroit
On a typical day I was connected to a remote machine using Dameware with a wireless headset doing IT support, programming & Testing applications with LabVIEW, doing data acquisitioning, analysis and creating reports with DIAdem, working in the Active Directory creating or modifying users, working within the ReflectionX software connected to the MOD 300 SCADA environment doing data management, controls development & Tech Support , in Project Management I was developing the architecture for a complete fiber optic, CAT6 and their hardware interface, servers, upgrade for 50 users, getting 3 competitive quotes, writing purchase requisitions, coordinating & managing several vendors, developing and creating HMI’s for Fuel Process Control “both hardware & software”, monitoring, troubleshooting, repairing & doing inventory of the network using 10-Strike software, keeping track of my Tech Support requests & tasks using a IT Management software, answering to Paul M., the CEO of Michigan Waste Energy…I kept a daily task by task log that I created in Excel, made available Paul via a mapped network connection on his computer in his office to a directory I created on the file server, developed and maintained a html remote panel so Paul and other managers could view, monitor and with a click get a pdf report from the SCADA system that I created in Fuel Process to show live production and history reports of production. Over the years I developed these work schemes/habits and bring them to the companies that I have worked for. None of this was here when I started. I worked from 7: AM to 5:30 PM, “30% I worked to 10:PM” onsite and remotely via VPM from home.
ABOVE IS THE ACTUAL REACTOR I DID MY RESEARCH ON AT GENERAL MOTORS R&D
The catalytic performance experiments that I did were carried out in a vertical stainless steel tubular reactor of either 1” OD for ¾” diameter samples or 2” OD for 1.5” diameter samples. Samples were held in place using a compressible ceramic paper wrap that also ensured that reactor flow passed through the catalyst channels. Volumetric space velocities between 50,000hr-1 and 2,000,000hr-1 were achieved by varying the reactor flow rates and catalyst size.
Reactor flow conditions were controlled using independent MKS 1179 Series, MKS 1479 Series, and Brooks 5850 Series mass flow controllers for all gaseous species, a Thermo Separation Products ConstaMetric 4100 HPLC pump for water, and a Cole-Parmer 74900-10 syringe pump for diesel fuel. The full range of feed concentrations for C3H6, CO, NO, and H2 were achieved by using two concentration levels of BOC certified compressed gas bottles. Nominally, these were 20% and 1% C3H6 in N2, 2.5% and 2500ppm CO in N2, 2% and 2000ppm NO in N2, and 15% and 1.2% H2 in N2. Control of which gas was supplied to the mass flow controller was done with electric solenoids.
Heating of the catalyst was achieved by flowing air, N2, CO2, and vaporized water through two inline heaters and the inline heater set points were used to control the catalyst temperature. Water was vaporized using a length of coiled ¼” stainless steel tubing immersed in liquid tin. The heated feed stream was mixed with the remaining gaseous species via a stainless steel Koflo tube into the feed stream after the inline heaters to prevent reaction over the heater elements.
At any space velocity the gases are mixed 16 times before they exit.
Diesel fuel was introduced into the system by passing the heated feed stream over a high-temperature fiberglass wick attached to the syringe pump.
A V&F H-Sense for H2 Spect
And a Horiba hot Flame Ionization Analyzer (HFID) for total hydrocarbons.
No measurable quantities of N2O or NH3 were detected during any of the experiments. Conversions were calculated using the difference of the inlet and outlet concentrations for each of the species. Inlet concentrations of all species were tuned to within 2% of the desired inlet concentration for each test point using the analyses feedbacks. This was done to ensure reproducibility between tests.