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Leak Test Module


This is an interface and database logging system I designed. The ARM CPU with a minimal Linux OS is running a lightweight database for storing time series data. The OS also handles the touch screen display and device drivers. GTK is implemented for user interface to the attached flow meters which communicate via RS-232 commands. WebKit2 is running an embedded browser as a kiosk for database query and trend visualization. This interface is used to enable the user to configure device and testing parameters of the attached flow controllers, as well as start tests and log to a database for later review. This data is also exposed via OPC/UA to allow integration into other systems and databases.
This is a project which involved mostly Linux application programming and OS configuration.

GNU/Linux - GCC - GTK3 - ASCII serial

Husqvarna Sewing Machine Cam


Husqvarna sewing machine cog. Modeled after original as a repar



- OpenSCAD

691 Stack Press/Welder.

Commonwealth Automation Technologies, Inc


This custom build machine was designed for a fuel cell manufacturer in China. The designed function of the machine was to precisely compress a stack of graphite cells to a set force and retain a tolerance of 10 micro-Newtons. While under compression, three lateral axis' would move across and form banding over the cells followed by a resistance weld module to hold the straps in place. Following each weld sequence deflection and force data was packaged and distributed via OPCUA server for further processing. Being a custom prototype machine, the configuration of the machine components, the desired sequencing , as well as user interface was updated frequently. My experience and foresight of possible last minute design changes from the customer helped me to meet the deadline and deliver a good product.
My contribution included design, coding, and testing of the software for the user interface, motion, and logical systems.

- Beckhoff/TwinCat3 :: PLC/HMI/Motion/Safety

659 Pleating machine.

Commonwealth Automation Technologies, Inc


This custom build machine was ordered by an alternative energy company in Burnaby BC. The designed function of the machine was to "pick and place" graphite cells and overlay a membrane material. Being a custom prototype machine, the configuration of the machine components, the desired sequencing , as well as user interface was updated frequently. By keeping the code as modular as possible I was able to efficiently update the logic to suit the evolution of the machine. Programming the motion controller on this build was also a great experience, It was a very low level system with regards to interfacing with the logic. Reading and writing of data registers and parameters all required manually coded functions.
My involvement included design and coding of the software for the user interface, motion, and logical systems. Selection, configuration and installation of electrical and electronic components. Design and wiring of the control cabinet. Developing schematic.

- Omron/Sysmac :: PLC/HMI/Motion/Safety

476U Fuel Cell Leak Testing Unit

Commonwealth Automation Technologies, Inc


This custom build machine was ordered by an alternative energy company in Burnaby BC. The designed function of this machine was to compress stacks of cells and test for integrity by applying pressurized gas to simulate hydrogen passing through the cells during use. This machines code was a mod kit on an old press. The control system, drive and motor were updated to Beckhoff.
My involvement included design and coding of the software for the user interface, motion, logical, and safety systems.

- Beckhoff :: PLC/HMI/Motion

653 Fuel Cell Leak Testing Units

Commonwealth Automation Technologies, Inc


This custom build machine was ordered by an alternative energy company in Burnaby BC. The designed function of this machine was to compress stacks of cells and test for integrity by applying pressurized gas to simulate hydrogen passing through the cells during use. This machines code was similar to 672A. The extension of the drive was mechanically adjustable which required some new features and changes to the code. I programmed it using Visual Studio IDE and some API's from Beckhoff Engineering.
My involvement included design and coding of the software for the user interface, motion, logical, and safety systems.

- Beckhoff :: PLC/HMI/Motion

662 Fuel Cell Leak Testing Unit

Commonwealth Automation Technologies, Inc


This custom build machine was ordered by an alternative energy company in Burnaby BC. It was then extensively tested and exported to a customer in China. The designed function of the machine was to compress stacks of cells and test for integrity by applying pressurized gas to simulate hydrogen passing through the cells during use. Being a custom prototype machine, The configuration of the machine components, the desired sequencing , as well as user interface was updated frequently. By using some structured text functions I was able to easily change the compression algorithms to suit changes in design and tune for efficiency during commissioning.
My involvement included design and coding of the software for the user interface, motion, logical, and safety systems. Selection, configuration and installation of electrical and electronic components.

- Omron/Sysmac :: PLC/HMI/Motion/Safety
- Keyence :: Safety

672/672A Fuel Cell Leak Testing Units

Commonwealth Automation Technologies, Inc


This custom build machine was ordered by an alternative energy company in Burnaby BC. The designed function of this machine was to compress stacks of cells and test for integrity by applying pressurized gas to simulate hydrogen passing through the cells during use. This machines code was similar to 662 but had entirely different hardware and software specifications. It utilized Windows 7 Embedded with an Intel Atom Processor for all controlled systems. I programmed it using Visual Studio IDE and some API's from Beckhoff Engineering.
My involvement included design and coding of the software for the user interface, motion, logical, and safety systems.

- Beckhoff :: PLC/HMI/Motion

656 Lithium Cell Conditioning Cabinet

Commonwealth Automation Technologies, Inc


This custom build machine was ordered by a customer in the USA. The designed function of the machine was to test and verify lithium cell battery packs to be installed in pacemakers. Tuning the temperature controller was interesting. The controller would adjust its output by differing excitation frequency of solid state relays. The machine was initially designed with excessive voltage and I had to install step-down transformers to limit the voltage to a suitable range for tuning. After the voltage was decreased, I was able to tune and commission the unit using some integrated PID algorithms in the controller.
My involvement included design and coding of the software for the control system. Configuration and installation of electrical and electronic components.

- Watlow

622 Fuel Cell Stack Press/Welder

Commonwealth Automation Technologies, Inc | Knight Industrial Services


This custom build machine was ordered by an alternative energy company in Burnaby BC. It was then extensively tested and exported to a customer in China. The designed function of the machine was to compress stacks of cells, secure and weld strapping to complete the process of manufacturing Fuel Cells. I selected and allocated all electronic hardware and devices as well as worked in conjugation with Glenn Harrison from Knight Industrial in the role of commissioning and wiring. It was a great experience, with many updates and changes in the design through-out the project.
My involvement included Interfacing the welding control module. Selection, configuration and installation of electrical and electronic components.

- Omron/Sysmac :: PLC/HMI/Motion/Safety
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