JIM GALLAGHER CONTROLS ENGINEER 904 Reba Place #1, Evanston, IL 60202 937-216-3219 jgallagherjr@outlook.com Over ten years of equipment design, programming, assembly, and installation experience. Hands-on experience with web handling machines, laboratory test equipment, air-handling machines, water treatment systems, media converting machines, convection oven conveyors, high speed packaging equipment, heavy industrial bale packaging equipment, and robotic vision & control systems. Equipment installed in research & development, food & beverage, high speed packaging, heavy industrial, and automotive manufacturing facilities. TECHNICAL SKILLS Control System Design Panel Layout & Assembly AC Motor Sizing Servo Motor Sizing PLC Programming Robot Programming Motion Programming Hydraulic/Pneumatic System Design Conveyor System Programming Vision System Development AC Drive Programming UL508A/NFPA 70E, 70, 79 P/DFMEA Lean Manufacturing Reverse Engineering SOFTWARE PACKAGES Digital Design Solution o Solid Works 2014 Autodesk o AutoCAD 2007 o AutoCAD Elec. 2014 Microsoft o MS Office Suite o MS Project o MS Visio o MS Excel VBA Rockwell Automation o RsLogix 500/5000 o Studio5000 o PanelBuilder32 o Factory Talk View Studio ME o CCW 8.0 o Motion Analyzer Mitsubishi Electric Automation o GX Configurator DP o FX Configurator FP o MR Configurator2 o GT Work3 o GX Works2 Fanuc Robotics o Handling Pro o ArcMate o irvision Denso Robotics o WincapsIII Cognex o InSight 4.7.0 o DataMan 4.2.1 National Instruments o Labview 8.5 Parker Hannifin o Interact Express Manager Schnieder-Electric o Twido Suite 2.0 o SoMove 2.2 Mathworks o Matlab R2007a B&R Industrial Automation o Automation Studio 4.0.2 Yaskawa America Inc o Motion Works IEC 3 Pro o Sigma Win Plus 7 o Drive Wizard Industrial
o Sigma Select EXPERIENCE Signode Industrial Group LLC, Glenview, IL Sr. Electrical Engineer 10/2015 Current Responsible for the safe operation, design and debugging of packaging equipment and automation control systems. Investigate mechanical and electrical equipment and controls with the ability to effect necessary repairs. Project(s): Ginfast Cotton Baling Machine: This machine was in development for more than five years. During the 2016 season the machine control system was redesigned to implement coordinated motion utilizing Camming Instructions to implement a modified sine profile. o Machine Controller Compactlogix L18ERM o Carriage VFD axes: PowerFlex 755 Carriage axis PowerFlex 755 Fork axis In Cabinet IO Cube20 On Machine IO Cube67 o Hydraulic Power Unit In Cabinet IO Cube20 o Auto Sampler In Cabinet IO Cube20 On Machine IO Cube67 Peumatic Valves Mack o Bag Assist VFD Axes: PowerFlex 525 Bag Assist axis In Cabinet IO Cube20 On Machine IO Cube67 Ginfast Cotton Bag Sealing Machine: This machine takes the baled bags of cotton, folds the flaps, and heat seals the bag. It is included as a part of the product offering for a cotton bale packaging system. o Machine Controller Compactlogix L18ER o VFD Axes: PowerFlex 525 Conveyor o In Cabinet IO Cube20 o On Machine IO Cube67 o Pneumatic Valves - Mack
Ginfast Cotton Baling Packaging System: This system consists of 4/5 machines with four different line configurations. The control system redesign also contributed to the plug and play feature for the system to be integrated utilizing standard equipment to minimize recurring engineering charges for potential custom installs. o Cotton Bagger Ginfast Cotton Baling Machine o Discharge Conveyor: Machine Controller Ginfast Cotton Baling Machine VFD axes: Amorstart LT - Conveyor o Bag Sealer Ginfast Cotton Bag Sealing Machine o Scale Conveyor Machine Controller Ginfast Cotton Bag Sealing Machine VFD axes: Amorstart LT Conveyor Load Cell o Flipper Tipper Machine Controller Ginfast Coton Bag Sealing Machine VFD axes: Armorstart LT Inlet Conveyor Armorstart LT Outlet Conveyor o Upender On Machine IO Cube 67 Corrugated Bundler: This machine was developed to introduce a new packaging material to the corrugated market. It runs at faster line speeds as well as offering side squaring and at least two different machine sizes to accommodate different market needs. o Machine Controller MP3300iec o Servo Axes: SGDV Mechatrolink III Pusher Horizontal SGDV Mechatrolink III Pusher Vertical SGDV Mechatrolink III Sealer Slide SGDV Mechatrolink III Side Square Left SGDV Mechatrolink III Side Square Right SGDV Mechatrolink III Upper Dispensor Feed SGDV Mechatrolink III Lower Dispensor Feed o VFD Axes: V1000 Conveyor V1000 Upper Dispensor Payoff V1000 Lower Dispensor Payoff o Ultrasonic Welder iq Auto-Plus
ISM Machinery, Grayslake, IL Sr. Electrical Engineer 06/2015 10/2015 Responsible for the safe operation, design and debugging of metal working machine and automation control systems. Investigate mechanical and electrical equipment and controls with the ability to effect necessary repairs. Project(s): Horizontal Decoiler: This machine was a prototype that went to a customer site and didn t work. The modifications made to get the machine to a functional state are stated as follows: o Repaired all damaged mechanical and electrical components. o Redesigned dancer arm angular sensor mount and implemented different angular sensor for rugged environments. o Implemented Category 1 stop circuit to engage DC braking. o Reprogrammed VFD to enable dynamic braking function for two second acceleration and deceleration of 6000lbs. load. o Machine Controller Tube Forming Machine o Dancer Arm Position - Novotechnik RSM2800 Series o VFD axes: Lenze SMD Center-Driven Decoiler B&H Labeling Systems, Ceres, CA Sr. Electrical Controls Engineer 02/2013 05/2015 Responsible for designing and engineering electrical systems and components for B&H Labeling machines. This includes executing engineering calculations, creating schematics and drawings, compiling bills of materials, and identifying and qualifying vendors. The position also includes writing, installing debugging equipment programs, and monitoring the build-up of equipment on the shop floor to verify functionality and overall quality. Project(s): Glue Extrusion System (GES): Developed high speed Hotmelt and pressure sensitive glue extrusion system for linear and rotary turret roll-fed labeling machine. A maximum machine speed of 850cpm (containers per minute) was achieved during beta testing. o Machine Controller Controllogix L71 CPU o HMI Panel View Plus6 1000 o Servo Axes Kinetix 5500 - Vertical Adjust Kinetix 5500 - Hotmelt Pump. o High Speed Output - 1756-OB16IEFS Control System Retro-fit: Field retro-fit kit to completely and/or partially replace legacy control systems. o The team continuously refined the development of the Camming control sequence for the material feed. o Machine Controller - Compactlogix L18ERM o HMI Panelview Plus 6 Compact o Servo Axes Kinetix 350: feedback only Kinetix 350: Material feed axis. o VFD Axes: PowerFlex 40P - Main Drive
Electrical Controls S.O.P. s: o Developed electrical controls design package standard utilizing AutoCAD Electrical 2014.
Marathon (All Models): This machine is the all electronic version of the older mechanical roll-fed labeling machines. It would run from 400-600 containers per minute (cpm) with a maximum burst of 750 cpm. o Integrated GES system as an option in to the base machine package utilizing backplane CPU communications. o Reprogrammed base machine platform to incorporate new product option. o Implemented the machines kinematic relationships with output Camming to refine the machine timing algorithim. o Machine Controller Controllogix L71 o Glue System Controller Controllogix L71 (optional) o HMI Panelview Plus 6 1000 o ITW Dynatec Dynamelt Hotmelt System o Servo Axes: Kinetix 6000 Cutter Kinetix 6000 Feed Roller Kinetix 6000 Vacuum Drum Kinetix 6000 Star Wheel Kinetix 6000 Feed Screw (optional) Kinetix 5500 Vertical Adjust (optional) Kinetix 5500 Hotmelt Pump (optional) o VFD Axes: Powerflex 40P Infeed Conveyor Powerflex 40P Discharge Conveyor (optional) Powerflex 40P Center-driven Unwind Powerflex 40P Glue Wheel (optional) Powerflex 40P Secondary Roll-on Belt (optional)
ATW Automation, Dayton, OH Controls Engineer 11/2011 02/2013 Prepare control systems designs and utilizing AutoCAD prepare drawings which include power distribution, PLC, main and station panel layouts, console layouts, pneumatics, hydraulics, and instrumentation. Write and document software. Review and take ownership of budgets and schedules. Work with the Controls Engineering Group Leader to develop cost to completes and release dates. Coordinate with the Controls Assembly Department during the build phases of the project to provide efficient and timely solutions to problems. Participate as a team member during the installation phase of the project. Project(s): GM E-Motor Line: This line was for three models of stator and rotor combo kits that would feed into the transmission assembly line. ATW was contracted to complete the stator assembly line. The I/O network was standardized as Profibus, Plant network as Ethernet, and all safety was done over Ethernet as well. o OP450: Programmed and integrated a vision guided TIG welding robot. Robot Fanuc Arcmate 50 Robot Controller R30iA Vision Fanuc irvision System Welder Lincoln Electric Cell Controller Compactlogix L68S HMI PanelView Plus CE 1000 o OP10A: Programmed and integrated a multi-robot cell containing four material handling robots, CNC wire forming machine, and an electrical testing unit. Robot Fanuc LRMate 100 Robot Controller R30iA CNC Custom AIM CNC Wire Bending Machine Cell Controller Controllogix L61S HMI - PanelView Plus CE 1000 o OP300 OP350: Programmed and integrated a multi-robot cell containing three vision-guided material handling robots and two non-vision guided material handling robots. Developed product recovery routines for multi-robot cells to track part status during production. Robot Fanuc R2000 and LRMate 100 Robot Controller R30iA Vision Fanuc irvision System Cell Controller Controllogix L61S HMI - PanelView Plus CE 1000
Crown Solutions Inc., Vandalia, OH Electrical Controls Engineer 3/2011 11/2011 Develop scopes of work, systems operations, electrical and controls designs of equipment. Review/red lining of P&ID s, general arrangement drawings, detail mechanical drawings, and controls ladder diagrams. Design electrical schematics and panel layouts utilizing AutoCAD Electrical 2010. Develop PLC & HMI software for custom water treatment equipment. Perform factory testing and UL panel inspection for a UL508A certified panel shop. Project(s): Twin Softener SAGD Plant: This system consists of two softeners and an automated brine maker. It was commissioned in a Class I Zone 2 hazardous classified location. o Machine Controller Compactlogix L31 o HMI PanelView Plus 1000 o Softener Instrumentation: Proline Promag Tank 1 Outlet Flow Proline Promag Tank 2 Outlet Flow o Brine Maker Instrumentation: Liquiphant Salt High Level Switch Liquiphant Salt Low Level Switch Cerabar Liquid Level Transducer Micropilot Tank Level Transducer CLARCOR CORPORATE FILTRATION RESEARCH CENTER, Cincinnati, OH Controls Engineer 1/2009 3/2011 Design, build, install, and commission all electrical control and data acquisition systems for test equipment and custom paper converting equipment. Provide all electrical maintenance support for a 15,000 sq-ft. facility. Layout and install all MEP runs for all equipment. Project(s): Batch Mixer: This machine takes polymer pellets and proprietary acid formulations to create a polymer slury. It was commissioned in a Class I Div 2 hazardous classified location. o Temperature Controller Watlow 93 Series o Batch Tank Instrumentation Machine Controller Micrologix 1500 HMI Parker XPR Power Station 10 Load Cell - Hardy Floor Scale o Batch Heating System: Watlow 93 Series Main Temperature Controller Watlow 93 Series Overtemp Controller Batch Transfer Cart: This machine stores the polymer slurry and pumps it into a coating machine. It was commissioned in a Class I Div2 hazardous classified location. o Machine Controller SLC 505 o HMI - PanelView Std 6 Nano-Fiber Spinning Machine: This machine takes a proprietary polymer slurry mix and uses it to coat web material with a nanofiber polymer. It was commissioned in a Class I Div 2 hazardous classified location. o Machine Controller Micrologix 1500 o HMI - Parker XPR Power Station 10
o KBMM SCR Drive Nanofiber Spinning Conveyor Multi-Axis Unwinder: This machine has six center-driven rolls that are controlled by a laser dancer sensor. o Unwind Axes PowerFlex 700
Crane Pumps & Systems Inc., Piqua, OH Manufacturing Assembly Engineer 11/2005 11/2008 Design, build/procure, and implement manufacturing equipment and/or tooling as needed. Develop, maintain, and/or modify manual & automated production testing equipment and/or machine control programs. Conduct time studies and develop time standards for assembly, paint, packaging, and fabrication processes. Maintain and/or update plant and equipment layouts and provided daily production support. Develop, maintain, and/or modify process documentation. Lead manufacturing efforts for NPI (New Product Integration). Project(s): Submersible Pump Testing Station: This is a manually operated test machine used in a manual assembly production line. It is used to power and test submersible pumps for factory acceptance testing. The drives were specifically used to test pumps for the European market. o Single Phase Pump Drive Invertek VFD o Three Phase Pump Drive Powerflex 40 Level Control Test Station: This machine was developed to eliminate the need for manual testing. It was designed to test and report level actuation points for a factory acceptance test. o Machine Controller: Panel PC (Windows XP OS) Labview Runtime Environment Multifunction NI PCI Card Data Acquisition Board Telemecanique Zelio Relay Tank Controller o Test Tank Instrumentation: Viatran Pressure Transducer Tank Level GEM Sensor Paddle Wheel Flowmeter Tank Inlet Flow Meter GEM Sensor Paddle Wheel Flowmeter Tank Outlet Flow Meter Proportional Valve Tank Inlet Flow Control Proportional Valve Tank Outlet Flow Control Burks CR Turbine Pump Tank Inlet Pump Burks CR Turbine Pump Tank Outlet Pump
EDUCATION BS Industrial Technology, 12/2004 Kent State University, Kent, OH Major: Manufacturing Engineering Technology Focus: Computer Integrated Manufacturing Minors: Applied Mathematics Minor: Physics CERTIFICATIONS & CERTIFICATES Eaton Corp. - Arc Flash Training Royal Arc Industrial Services: Environmental Enterprises Inc.: - OSHA Ten Hous - HAZWOPER PROFESSIONAL DEVELOPMENT B&R Industrial Automation: - SEM210.4A: Accelerated Basics in Control and Visualization - SEM250.3A: Automation Studio Training: Intermediate Control and Visualization - SEM410.1A: Automation Studio Training: Single-Axis Motion Integration - SEM441.2A: Automation Studio Training: Multi-Axis Motion Programming Mitsubishi Electric Automation: - GX Work3 Basics w/motion Training - GT Works2 Basics Programming Yaskawa America Inc. Drives & Motion Division: - IEC61131-3 Basics with MotionWorks IEC - PLCopen Basics with MPiec Controllers - MPiec and Sigma-5 Application Programming Rockwell Automation: - CCN142: Advanced Motion Programming National Instruments: - Labview Basics 1 - Labview Basics 2 Haviland Consulting Group: - FMECA (Failure Mode Effects & Criticality Analysis) training Crane Co.: - Value Stream mapping - Statistical Process Variation - Standard Work Development - Production Preparedness Process (3P)
Crown Solution: - Water 101 Environmental Enterprises Inc.: - Hazardous Material Contamination, Operator Training (HAZWOPER) * References available upon request.