Wednesday, March 10, 2010

Robot Piston Assembly and Piston Stuffer



This is a machine for Volvo and Mack truck. The first robot picks up the parts from the pallet and cleans the bottom of the casting for burrs. The parts are then placed into the stuffing machine and the part get "handed-off" to robot number two. Robot number 2 takes the finished piston and inserts it into each cylinder of the diesel engine block sequentially. During the Pistons assembly process, the piston rings are checked and compressed into the cylinder sleeve.

Customer: Volvo / Mack Truck
Processor: Allen-Bradley ControlLogix
Software: ControlLogix
HMI: Allen-Bradley Panelview
Robot: ABB IRC5
Conveyor: ABB

Robot RTV Axle Housing





Here is a robot picking up a part and presenting it to an RTV (Room Temperature Vulcanization) unit. The RTV dispenses the material (which is like a glue) or liquid gasket. The robot then flips the cover over and places it on to the axle. There are two spindle units (Powered-screwdrivers) on the robot and gets two bolt rundown to a specific torque. The project was to replace the robot with a newer version, a new RTV unit, and re-use an existing Atlas Copco spindle unit. The robot end-effector had to be re-designed. The entire sequence had to be re-done and new HMI screens were made. 

Customer: Chrysler
Processor: Telemecanique
Software: PL7 pro
HMI: Magelis
Robot: Nachi AX
Nutrunner: Atlas Copco
Conveyor: ABB

Friday, March 5, 2010

Project History

Engine assembly and test:
Ford / Jaguar V6 DAMB Engine, Brooke Park, OH
GM Northstar V8, Robot installs Hydraulic Lash Adjusters. Livonia, MI

Axle assembly and test:
Dodge Dakota 2nd gen 1997-2004 (AN) Detroit, MI
Dodge Ram 1500 2007-2008), (DR) Detroit, MI
Durango 1st gen 1998-2003 (DN) Detroit, MI
Jeep Grand Cherokee 2005-UP (WK) Detroit, MI
Jeep Liberty 2008-UP (KK) Detroit, MI
Dodge Nitro 2008-UP (KA) Detroit, MI
Chrysler 300, Charger, Magnum 2006-UP (LX) Detroit, MI

Transmission:
Ford Focus Transmission assembly and test (FN) Sterling Heights, MI

Front and rear suspension systems:

Ford Econoline Van 2009-UP Front end wheel build (VN127) Avon Lake, OH
Jeep Grand Cherokee 2011-UP Front Supsension (WD) SMW, Port Huron, MI

Glass Robot Urethane applications:
Ford Focus 2008-UP (CW170) Wayne, MI
GM Pontiac G6, (Webasto OEM) Rochester Hills, MI

Rob Bodnar - Project Controls Engineer

15 YEARS CONTROLS ENGINEERING EXPERIENCE.

•PLC’S: ALLEN-BRADLEY RSLOGIX5, RSLOGIX5000, CONTROLOGIX, RSLINX, RSNETWORX, DEVICENET, PLC5-6200. TELEMECANIQUE UNITYPRO, PL7PRO. TAYLOR PROWORX.
•HMI’s: PANELBUILDER32, RSVIEW, MAGELIS, PANELMATE PLUS
•COMMUNICATIONS: DEVICENET, RSNETWORX, RSLINX, RIO, DH+, PROFIBUS, UNITELWAY, FIPIO, FIPWAY, PROFIBUS, INTERBUS-S.
•CONVEYORS: ABB, COMAU-PICO, DURR, WEBB, I-R, BOSCH.
•ROBOTS: ABB-IRC5, ABB-S4C, NACHI-AX, NACHI-AW.
•POWERTRAIN ASSEMBLY, PRESS, TRIM, FINAL, BIW, WELDING, HOT/COLD TEST, URETHANE, RTV, FLUID FILL.

Employment History

2/2009 – Present Electradyne LLC Warren, MI
Project Controls Engineer
•Contract consulting for tier 1 and tier 2 automotive suppliers, controls engineering, process analysis, managing factory information systems.

10/2008 – 2/2009 Durr Ecoclean / G-Tech Wixom, MI
Controls Project Engineer – Assembly and Test
•Contract Controls Engineer for a diesel engine program. Designed controls for machining, assembly and test stations.
•Created controls designs per customer specifications and standards.

11/2006 – 8/2008 Kuka Corporation Sterling Heights, MI
Controls Project Engineer – Automotive Trim, chassis and final assembly
•Designed control systems for new and re-tooled automotive assembly systems. Supervised electrical installations. Estimating projects.
•Designed electrical, pneumatic, and hydraulic drawings per customer specifications. Customer approvals, documentation control, ordering material. Root cause analysis, problem solving.

1/2006 – 10/2006 Electradyne LLC Warren, MI
Controls Engineer – Automotive Robot Welding Systems
•Contract position designing controls for body-in-white robot welding systems.

6/1997 – 12/2005 ABB Inc. Auburn Hills, MI
Controls Project Engineer – ABB Powertrain Assembly Division
•Lead Project Engineer designing control systems for assembly lines, axles, engines and transmissions. Created software standards for customers.
•Supervised engineers on projects, installations, buy-offs, maintaining schedules and budgets. Estimating and quotation duties.

6/1992 – 6/1997 Controls Systems International Warren, MI
Controls Engineer
•Designed control panels for new and re-tooled assembly machines. Supervised the Autocad department. PLC/HMI programming.
•Panel building, wiring and troubleshooting of control panels.

1984–1990 Jervis B. Webb Company Farmington Hills, MI
Engineer – Webb Electric
•Designed field wiring and conduit layouts for automotive conveyor systems, commercial buildings, and mining operations.
•Duties included estimating, project quotation, supervised and trained CAD department personnel.

1983–1984 J.I.C. Electric Detroit, MI
Detailer, Engineer
•Detailer for electrical ladder diagrams, engineering and blueprinting.
Education Kendall College of Ferris State University Grand Rapids, MI
•Bachelor of Arts in Industrial Design, Six Sigma green belt, 5s trained.

Skills

•Responsibilities in Project Management, cost reduction of electrical and controls project budgets of + 3 Million USD.
•15 years programming PLC’s and HMI’s.
•10 years electrical design and troubleshooting of machinery, PLC hardware, communications, power distribution systems, robotics, pneumatic and hydraulic systems.
•5 years integrating servo and VFD drives.
•Started in the industry field wiring, panel building, and panel wiring.
•Awarded “Supplier of the Year” for three consecutive years.
•NEC, CSA, ANSI, NFPA, OSHA, ISO Standards.