Projects
Below is a sampling of some of the projects that we have done.
2D Barcode Printer System
System to read barcode from a work order sheet and retrieve information from the customers MRP system. This information is then used to generate a 2D barcode that is printed onto the door lock.
Automated Door Lock Tester
Multi-axis servo system integration with vision and pneumatic systems to test commercial door lock functionality.
HMI developed in C++.
Motion/Machine control developed in IEC61131.
Torque monitoring on servo axes to determine if lock handle rotation is within torque limits per industry standards.
User configurable test sequences.
Inspection Robot System
Automated robotic vision inspection system to inspect injected molded parts.
This system integrated a SCARA robot and a servo controlled linear mechanism to perform multiple vision inspections on the injection molded part.
The operator placed the part on the linear mechanism for inspection.
The robot picked the part after inspection and placed good parts into a shipping tray.
‘Flying’ TV Systems
System to control 15 – 3 monitor columns to create a variety of video wall patterns.
System consists of a master computer communicating via Modbus TCP to 15 cell controllers that control the linear travel and rotation of a column of 3 high resolution monitors.
Each column can be positioned as the customer desires to create video walls and other configurations for environment simulation exercises.
Two TV Positioning System
System to move and rotate independent TV’s that can be positioned as needed.
Silicon Wafer Lathe
A machine to x-ray a silicon cylinder and then machine the cylinder to dimensional shape and cut a flat and/or a notch to mark crystal alignment.
Oversaw software team to develop SECS/GEM interface between lathe and production line.
Developed custom designed embedded PC to execute SECS/GEM interface software.
Developed interface software between PLC and PC for SECS/GEM protocol
Silicon Wafer Robot
Aided startup company developing a wafer handling robot using advanced kinematics.
Assisted in control algorithm development.
Pump Tester
Developed two separate test systems to test dispense pumps.
The system monitored pump position and discharge pressures as well as collected statistics.
Pump Tester
Developed control software in C++ for pump testers.
Two systems were developed; one for 90 pumps and one for 180 pumps.
Strapping Machine
Developed networked control system of separate “smart” motors to control the feed and crimping of a steel strap material to band a coil of wire manufactured at a steel mill in Germany.
This system comprised four strapping heads with four “smart” motors per head.
Also developed control software for a similar single head strapping unit in China for the same company
Vacuum Cleaner Test Fixture
Developed the control software and system design for a test fixture to evaluate the performance of home vacuum cleaners.
This system collected position, force, and other data while pushing and pulling the vacuum over various surfaces.
Guitar Sanding Vision System
Developed control software that interfaced to a vision system to identify the wood species and other properties to determine the proper sanding program to run on a guitar sanding machine.
Some of the guitar models sell for over $100,000. Accuracy was very important.
Telemetry Probe Tester
Project Management, control system design, software developement for a large system to test a 300 pound telemetry probe that is used to signal the position of the drill head in oil well drilling operations.
Carton Folding Machine
Developed control system, software and HMI application to control a carton folding machine in Taiwan.
System controlled a flame sealer as well as several electronically geared servo axes.
HMI supported both English and Traditional Chinese languages.
AUV Launch and Recovery System
Developed control software and hardware design for a multi-axis autonomous underwater vehicle launch and recovery system that will be installed on an autonomous vessel.
Cryogenic Pump Controller
Developed embedded pump motor control system per customer specs to control cryogenic pump system. UL and CE marked.
Consumer Appliance – Pasta Cooker
Developed electronics design, software, and built prototype of a consumer kitchen product to automatically cook pasta. The design consisted of an alpha-numeric display, keypad, microprocessor, power supply, 1500W heater control, AC motor control, H-Bridge DC motor control and associated electronics for a cost of $9.00 per unit.
Consumer Product
Developed control software and control concept to control the “card” machine that pulls raw cotton into a smooth sheet of cotton.
Telescope Shutter Doors Control System
Developed control software to coordinate two motors per shutter door to raise/lower the shutter door without cocking the door and causing a jamb.
Developed HMI software to control shutters with special consideration to brain functioning at the high altitude of the telescope.
Cymbal Hammering Machine
Developed control system and software to hammer a pattern onto the musical cymbal for cold forming of the metal for sound parameters.
Updated the control system with new controls after over ten years of operation to take advantage of new capabilities of hardware.
System was developed in C++ with the Linux operating system.
ECM CNC System
Developed multi-axis CNC control system for ECM machine in C++.
Developed Modbus interface to high power power supply used in the ECM process.
Developed custom M and G codes to control power supply and other accessories of the machine.
IMM Sprue Picker Robot Controller
Designed electronics and circuit board to control sprue picker robot.
Design included an LCD display, custom keypad, custom hand held enclosure, 24V inputs and outputs, communications and power supplies.
Developed control software in JAVA.
Developed automatic diagnostics for testing controllers after assembly.
Hundreds of robots are still in use today.
Microwave Wave Guide Positioner
Developed electronics design, circuit board and software for embedded controller to control the position of a microwave wave guide for selecting power from microwave transmitters.
System was used on mobile TV trucks to select power from two transmitters.
System was adopted for use on aircraft carrier as part of the missile defense system. Design passed mil-spec testing on first pass.
Small Transformer Assembly
Over $1 million dollar automation work cell to construct transformers.
Responsibilities included project management, chief engineer (mechanical and controls), and robot software development.
System included interfacing to high power LASER welder/cutter system.
Work cell constructed two sizes of transformers.
System was complex with many parallel operations, so software was developed with some artificial intelligence to have the robot make decisions about what work was required next to successfully construct the transformer.
Crayon Packaging System
Packaging work cell to load crayons into a moving pocket conveyor at the rate of 60 boxes per minute.
Design and development of the control system and software for the work cell.
Installed and started up the workcell on site in PA.
Plastics Extruder
Plastic extruder control system and software. System controlled two extruders, over 60 heat/cool PID loops, gear pump PID loops, logic control, auto start, and HMI.
Plastics Thermo-former
Control system and software development for companies thermo-former machines.
Production SQC System
Developed multi-user / multi-tasking computer system to collect production data on plastic cup manufacturing. The system interfaced to four workstations that included a digital scale and a handheld pendant with keypad and display. The software would prompt the user for information about the product being run and then read the weight of the ten count of the product from the scale. The system produced production reports and statistical analysis of the data. This data was also stored for future use.
Too many to list here…
Contact us with your project.
