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Guy Williams

PLC Controls Engineer

Southington, CT

hguywilliams@gmail.com

860-426-0460



Skill Highlights

A partial list of hardware and software I work with on a regular basis.

Hardware

Allen-Bradley: SLC 500, ControlLogix, CompactLogix, Point IO, FlexIO, Guard Master

Software

Samples of HMI applications here.

Allen-Bradley: RSLogix 500 & 5000, Logix Designer, PanelBuilder32, RSLinx, PanelView, DriveExecutive, FactoryTalk View, Connected Components Workbench

Intellusion, Archestra, InTouch Wonderware, WindowMaker, WindowViewer, Historian, Recipe Manager, System Management Console, Alarm Manager/Logger

Drives

Allen Bradley: Kinetix, PowerFlex, Ultra

Emerson/Control Techniques: CTSoft, Unidrive SP

Parker/SSD Drives: DSELite, DSI3, DSI8000, 890 Plus



Objective

Electrical Controls & Automation Engineer seeking a position with the opportunity to best utilize and further develop my ELECTRICAL AND SOFTWARE CONTROLS & AUTOMATION ENGINEERING capabilities. Trained Design for Six Sigma Black Belt.

Work Experience

Senior Controls Engineer, Industry 4.0 / Stanley Black & Decker
2018 - Present

Based out of Stanley Black & Decker’s 23,000-square foot Manufactory facility at One Constitution Plaza in Hartford, CT I lead design and implementation of plant-floor machine connectivity and data acquisition across SBD’s network of global manufacturing locations. SBD has created this state-of-the-art manufacturing incubator to accelerate its global Industry 4.0 “smart factory” transformation across 30 manufacturing facilities in the U.S. and to serve as a hub for the latest advancements in IoT, cloud computing, artificial intelligence, 3-D printing, robotics and advanced materials.

I propose future state solutions, drive implementation of data-acquisition between shop floor equipment and systems and software, design the processes and standards of data collection from equipment, hardware selection, and implementation model for the Industry 4.0 program. I also write, modify, and troubleshoot ladder logic, PLC and HMI programming written by outside suppliers and extract key piece data from equipment. Manage contingent/contract labor resources and coordinate their deliverables. Research new equipment types, sources, costs and delivery times to assist in maintaining/deploying global equipment. Provide technical leadership and training to operations team members and operational safety programs. Accountable for instrumentation & controls wiring design, system commissioning & startup. I use AutoCad Electrical to maintain electrical drawings.






Recent Training Activities
Universal Robots Core Training with Vision
Robotic Industries of America safety training seminar.
Allen-Bradley Servo Motion Mastery 1
Industrial Robotics, Mathematical Models
and Practical Applications


PLC Controls & Automation Engineer / Prysmian Group, General Cable
2016 - 2018

At General Cable I support jacketing extrusion systems in the production of various styles of multiconductor cable used in the energy and telecom sectors. Reporting directly to the Facility Manager I am responsible for maintaining the controls and automation systems of mission critical production lines, which must run three shifts a day, at two plants; Willimantic, CT and Lincoln, RI. In this role I routinely troubleshoot, repair, and program nearly 150 separate PLC based control systems, typically Allen-Bradley, and a variety of instrumentation and actuators detailed below. I also backup the control applications and configuration software of all automation equipment and maintain an organized library the technician’s access as necessary. In addition, I develop training material around various technology-based tasks faced by the technicians and hold training sessions to develop proficiency. I accept requirements from Operations and Process Engineering to develop enhancements to the PLC and HMI applications to enhance safety and productivity. Examples include modifications to recipe systems to better match our process and modifications to the interaction between line speed and the Zumbach laser based outer diameter control to reduce excursions during line speed changes. I also maintain an inventory of process control equipment and manage availability of critical spare components. I use AutoCad to maintain electrical drawings.

Controller equipment I routinely troubleshoot, repair, and program includes Allen-Bradley Control Logix, Compact Logix, Point IO, SLC500, Guard Master, and Flex IO. HMI hardware includes PanelView 600 series, 6181P industrial computers, Parker/SSD DSI3 and DSI8000. I work on these systems with, and am proficient in, the following programming development environments: RSLogix 500 & 5000, Logix Designer, PanelBuilder32, RSLinx, PanelView, DriveExecutive, FactoryTalk View, Connected Components Workbench as well as InTouch Wonderware, Historian, Recipe Manager, System Management Console, and Alarm Manager, as well as Control Techniques CTSoft and Parker/SSD DSELite. I work with the following motor drives; Parker 590+, 650V, 690+, 890+. Control Techniques Unidrive SP and Allen-Bradley PowerFlex. Communications protocols I often use, typically through RSLinx, include Ethernet IP, DH-485, DF1, Modbus RTU, RS-232, 422, 485 and ASCII.


ELECTRICAL ENGINEER II– PLC CONTROLS PROGRAMMING / EPPENDORF, Enfield, CT
2013 - 2016

I design the control and electrical systems, including HMI software applications, for the company’s next-generation Sterilize-in-Place Fermentation and Cell Generation Bioreactor product line. Applications of this product line include bacteria, yeast, insect, plant or mammalian cells, in batch, fed-batch or continuous culture. Working to internal customer specifications I generate P&ID drawings in AutoCad and coordinate quotes with suppliers to meet product cost estimates. I design and program Allen-Bradley CompactLogix PLCs and PanelView panel displays control systems which control the process in the reactor vessel. Thermal mass flow controllers (TMFC) provide metered additive gasses through sparge and overlay systems. Liquid chemicals are added using up to 5 peristaltic pumps powered by brushed and geared DC pump head motors and measured using scales and load cell processors interfaced to the system over RS-485 Modbus. Heating and cooling of the medium is achieved by a means of a jacketed water circulation system. Real-time pH and dissolved oxygen measurements are achieved via nano-amp sensors and preprocessors. A variety of parameters are available to be configured as user defined cascade PID loops. Agitation of 200 to 900 RPM is accomplished using a motor drive amplifier and small to medium duty permanent magnet motors. Additionally, I design, program, and implement automated test systems in LabView (view sample here) using the PXI hardware line. These systems are used to preform fully automated final test of several product lines manufactured at the Connecticut facility. I also maintain the current product line by processing change orders as well as support manufacturing operations by assisting assemblers in troubleshooting and testing.


CONSULTING POSITIONS – CONTROLS AND AUTOMATION
2011 - 2013
ELECTRICAL & SOFTWARE CONTROLS & AUTOMATION ENGINEER

During this period I consulted with four Connecticut firms to design and implement the control and automation projects described below.

Working closely with systems designers, I design and program PLC based control systems for the LCU-025-CUP, a compact, self-contained, trailer-mounted, Liquid Coolant Supply (LCS) Cart designed to supply chilled polyalfaolefin (PAO) coolant to the aircraft liquid coolant loop for the purpose of removing the electrical heat loads from the avionics of the F-35 Joint Strike Fighter. The system makes use of IFM Efector PLCs for mobile computing equipped with CANopen and J1939 to control various components such as the diesel engine electronic control unit, the variable frequency drive (VFD) to drive the compressor, and to interconnect PLC components.
Working from engineering design specifications I designed and programed a National Instruments LabView (view sample here) based test application used in the manufacture and testing of the company’s cerebral tissue oxygen saturation monitoring equipment line. The system I created allows the manufacturing engineer to create a ‘script’ of commands to be issued to the embedded processor of the unit under test over TCP/IP using a Telnet interface instructing the embedded system to run a particular test and respond with the PASS/FAIL status. I also designed and programmed a Microsoft Visual Studio VB.NET application to read and write 1K and 4K Dallas Semiconductor One Wire memory devices which I accessed over a 1-Wire bus.
Design, development, and programming of automated test equipment for the aerospace component test industry using National Instruments Lab View Professional Development System. Extensive experience implementing state machines, event driven programming, multiple PID loops, VI Server automated script based testing and reporting. Real time XY plotting display with bounded pass/fail regions.
I designed, developed, and programed automated Verification & Validation (V&V) systems via embedded systems programming of Texas Instruments F28335 Digital Signal Processor (DSP) using Object Orientated Programming (C++), in conjunction with National Instruments Lab View (LV) and Test Stand (TS). For instance, I program a test application running on the target hardware (TI F28335) to accept a hex coded command over the serial component interface and in turn switch in the various integrated circuit hardware components via the serial peripheral interface (SPI) to analysis the requested sensor input through the analog-to-digital converter (ADC) and send the result back to the requesting system, in this case the LabView test application. In other cases the LV/TS system is running automated scripts which exercise the control system and actuator to the system requirements.

Consultant: SENIOR SYSTEMS ENGINEER / SIKORSKY AIRCRAFT, Stratford, CT
2008 - 2010

Participated on teams designing and developing flight control system components such as Built In Test (BIT) modules, Warning, Cautions, and Advisories (WCA), Redundancy Management Architecture, and data bus communications all of which were components of the USMC CH-53K Heavy Lift Replacement troop and weapons helicopter airframe. Participated in the design of redundancy management architecture (hardware/software interface) for Input Signal Module (ISM) and Output Signal Module (OSM) signals of the flight control computer implemented in Matlab/Simulink. Lead engineer authoring the Flight Control System Data Bus Interface Control Document (ICD) for the CH-53K Heavy Lift Replacement program. Participated in design of various aspects of Built In Test (BIT) modules. Participated in Warning, Cautions, and Advisories (WCA) working group bringing together all stakeholders of the Data Concentrator Unit, Aircraft Management System, Warnings, Cautions, & Advisories CSCI, and Flight Control Computer (FCC) and reaching a consensus regarding the processes and tasks associated with each and establishing rules as to how data are consumed.


SENIOR SYSTEMS ENGINEER / GOODRICH CORP., PUMP & ENGINE CONTROL SYSTEMS, West Hartford, CT
2004 - 2007

Designed, programmed, and implemented the Matlab/Simulink and Control Desk/dSpace based Hardware-In-Loop (HIL) test system for the Electronic Control Unit (ECU) of the PWC-210 Turboshaft engine used on the commercial Sikorsky S76 helicopter. I integrated the engine and airframe Matlab models with two dual-channel full authority digital electronic control systems (FADEC) and full real-time ARINC-429 implementation and CAN bus cross channel interface, used in verification and validation of the PWC210 turboshaft engine control system. Completely automated unattended m-file script based testing. Full test environment data capture, including all data bus traffic and open/short fault injection, for post-test analysis. I designed and implemented the signal conditioning hardware which interfaced the HIL simulation circuits and control software to the FADEC units under test.


SENIOR CONTROLS ENGINEER - ADVANCED CONTROL SYSTEMS / EMHART GLASS RESEARCH CORPORATION, INCORPORATED, Enfield, CT
1999 - 2004

This company designs, develops, and manufactures equipment and controls system electronics for the glass container industry. I preformed 100% of design, programming, implementation, testing, and field trial of 840 Advanced Forehearth Control System control application for up to 20 PID control loops per processor including software support for voltage, current loop, thermocouple, and discrete IO boards (hardware) as well as valve motor driver interface. Programmed in KW MultiProg IEC 61131-3 PLC programming environment the program solved PID loops, acquired and processed signal IO over an Open Process Control (OPC) interface. I also designed and programed the human machine interface application using Iconics Genesis 32 Active-X for up to 20 control loops per processor cabinet and indefinite cabinet interfaces per plant console, user configurable distribution of control loops, trending, alarms, reporting, data logging to MSDE/JET SQL database, varying access level security and acceptance of job downloads from supervisory controller. The system used Open Process Control (OPC) based data acquisition. I was trained in our vender’s vision inspection system and programmed the Veritas Inspection System to perform various vision-based tests. I also programmed an 11-axis stepper motor conveyor and test station system in the Veritas line including an automated calibration routine for all eleven axis which avoided collisions and saved operators from having to perform this complicated task.


CHIEF EE & SW ENGINEERING, CONTROL & HMI SYSTEMS / TURBOMOTIVE, INCORPORATED, Hamden, CT
1992 - 1999

Designed, programmed, and implemented custom PLC and microprocessor based controls and human-machine interfaces (HMI) using Intouch Wonderware for a wide variety of aircraft turboprop, turbofan and APU engines, as well as aircraft components. Software systems include real-time data presentation and mathematical corrections, step-by-step procedures for engine testing, alarm monitoring, custom data logging, real-time engine test pass/fail evaluation, and custom reporting. Hardware interfaces included. Experience with a wide variety of sensors including thermocouples, RTDs, LVDTs, RVDTs, Charge Amplifiers and Accelerometers, pressure sensors, current loops, RS-232, 422, 485, IEEE-488, HP-GPIB and inverter based motor drives. The office I lead delivered more than 100 complete test cell applications over seven years.


Nuclear Control Systems Engineer / ABB COMBUSTION ENGINEERING, INCORPORATED, Windsor, CT
1990 - 1992

Engineer responsible for all aspects of Plant Limiting and Supervisory Controller (PL&SC) on DOE New Production Heavy Water Nuclear Reactor contract. System accepted approximately 1500 inputs from reactor core and reactor support systems. Responsible for achieving optimal neutron flux distribution.


FIELD ENGINEER – SHIPBOARD & FIRE CONTROL SYSTEMS / UNISYS CORPORATION, Bloomfield, CT
1987 - 1988

Participated in prototype development, integration, and testing of “North Warning” land based unattended short range radar and “NEXTRAD” Next Generation Doppler Weather Radar. Took on project to bring aboard Advanced Tactical Systems' prototype remote radar interface.


Military

US ARMY INTELLIGENCE & SECURITY COMMAND, Fort Devens, MA
1979 - 1983

Participated in Guardrail precision SIGINT collection/location system, at the time one of the most technically advanced platforms military wide. Sergeant – E-5, grade awarded in just over 3 years. Instructor at Army Intelligence School. Held Top Secret Sensitive Intelligence security clearance.


Education

UNIVERSITY OF NEW HAVEN, West Haven, CT
1983 - 1987

Bachelor of Science Electrical Engineering


UNIVERSITY OF CONNECTICUT, Storrs, CT
1988 - 1990

Completed 27 Credit Hours toward MSEE


UNIVERSITY OF CONNECTICUT, Storrs, CT
2007 - 2010

MASTER of BUSINESS ADMINISTRATION, FINANCE

    Companies I visited in China here.
    Two of my research papers on doing business in China:

Training

Formal training in the following.

Arc Flash Electrical Safety NFPA 70E
Adult First Aid
Universal Robots Core Training
Servo Motion Mastery 1
Wonderware InTouch HMI & InControl
National Instruments Compact RIO & LabView (view sample here)
Iconics Genesis 32 Introduction
Iconics Genesis 32 Advanced
Imagination Systems Real-Time QNX (Unix)
KW Software MULTIPROG for IEC 61131 programming
Linux Administration
Design for Six Sigma, Black-Belt
DO-178B Software Aspects of Certification
DO-254 Hardware Aspects of Certification
DOORS Requirements Management Software
Rational Rose Object-Oriented Analysis & Design
Rational Rose 2000
Veritas iB Introduction