resume_for_plc_engineering_ july_2015 with graphics

AFIFI GAYED 19573 Colman Street Clinton Township MI 48035 586-850-1170 [email protected] ENGINEERING|MANUFACTURING

SUMMARY Dedicated and technically skilled business professional with a versatile management, manufacturing and communication skill set developed through 10+ years’ experience as a business owner, and highly educated and skilled PLC engineer. My skill set currently focus on controlling, troubleshooting, debugging all devices around and inside robot cells. Using a disciplined step by step procedure as such: 1-Verifying the mechanical, electrical, pneumatic, and hydraulic components of tools per designing engineer, 2- If needed, correcting or modifying what need to be corrected/modified, 3- Setting up the tool manually, 4-logic debugging and conditioning and HMI-Tool interacting setup, 5- Bringing cell components to dry cycling, 6-trouble shooting during final tool development stage and during real production time. During the process I set up and program/condition devices and tools using Rockwell Software like RsLogix and Factory Talk. I also provide needed assistance to robot technicians and help them troubleshoot/debug robot issues during dry cycle and real production time. Along with PLC programming, I have had training in programming robots but I have not done robot jogging on shop floor yet.

SKILLS Fanuc robot controls Automotive mechanicalABB robot controls Automotive electricalPLC engineering Plumbing residential HMI Factory Talk Microsoft OfficeRSLogix5000 Electrical residentialElectrical controls HVAC residentialComau robots EntrepreneurshipAllen Bradley controls Business managementRobotics electrical maintenance Problem solving/DebuggingRobotics mechanical maintenance Other PLC related skills

EDUCATION M-Tec, Control Robotics Technician Macomb Community CollegeAutomotive, Mechanical, General and Electrical Macomb Community CollegeBusiness Management and Accounting Saginaw Valley State UniversityBachelor of Science University of Minia Egypt

PROFESSIONAL EXPERIENCE Robotic PLC Control Engineer, The Paslin Company, Warren MI January 2015 to July 2015

Administering and enforcing Robotic and tool safety procedures Device configuration Tool manual setup

1


Tool auto and dry cycle setup Tool and robotic station programming and control Solving robotic control problems Programming robotic stations using Rslogix5000_standard_ACD Reconfiguring and reprogramming logic for new tool configurations Debugging Tool and Robot logic. Supervising and certifying the final installations of the electrical and the Ethernet connections of production cells. Supervising and certifying the final installation of water, air and gas fittings Supervising and certifying the final mechanical setup per engineering design. Correcting and/or reconfiguring the mechanical, electrical and pneumatic constructions of tool if needed. Assisting robot programming technicians while programming their robots if needed Debugging Estops and provide Teach bypass for robot programmers when needed. Setting up and configuring HMI Uploading and downloading Factory talk to HMI Configuring communication and operations between HMI and other tools Configuring communication and operations between PLC and other tools Coaching and training other employees when needed Designing training manual and training guides if needed Troubleshooting and correcting robotic control errors Other PLC tasks.

Control Robotics Technician, M-Tec, Macomb Community College August 2014 – January 2015Advanced Apprenticeship Program which consisted of in-depth learning through a combination of class work and hands on experience with:

Robotics Operations: robotic safety, controls, operations, part programming Advanced Fanuc Operations and Programming: collision guard, condition monitor function,

executing multiple program multi-tasking, program shift utility and systems operations Robotics Mechanical: disassembly, inspection and reassembly of a FANUC robotic mechanical

unit Robotics Electrical: troubleshooting, electrical repair and maintenance procedures of the

robotic electrical system and robot electrical component identification and function of robot electrical controller

PLC and Communication Devices: understanding of PLC circuits, hardware and applications, PLC instructions, hardware, communication devices, troubleshooting navigation of PLC controllers software and components

Win CC HMI Programming: HMI fundamentals, functions, hardware and applications, HMI graphics, and creating troubleshooting messages displayed on HMI

PROFESSIONAL EXPERIENCE (continued)

Owner and Operator, AG Ranches Real Estate 2004 - 2014 General maintenance, including residential electrical, mechanical, HVAC, plumbing, and carpentry Negotiating for inventory and material Processing and marketing processed inventory Managing setting assets

2


Drafting and sending collection notices Business management Accounting Serving and managing eviction notices when needed Working with city offices, courts and enforcement agencies when needed

Instructor, Highland Park Renaissance Academy High School, Highland Park, MI 2013 - 2014 Curriculum development and lesson planning Teaching Physics, Chemistry, and Physical Science Classroom management and behavior correction Applying intervention procedures and conflict resolution Testing and record management

Instructor, Inkster High School, Inkster, MI 2011 - 2012 Curriculum development and lesson planning Teaching Chemistry, and Forensic Science Classroom management and behavior correction Applying intervention procedures and conflict resolution Testing and record management

Instructor, Detroit Public Schools, MI, Detroit, MI 2003-2010 Curriculum development and lesson planning Teaching Chemistry, Biology and Earth Science courses Classroom management and behavior correction Applying intervention procedures and conflict resolution Testing and record management

PATENT APPLICATION United States Published Patent application # 11/899,160.MTESBhttp://www.google.com/patents/US20090062040

WRITTEN BOOKS

BOOK TITLE: PLC PROGRAMMING AND TROUBLESHOOTING MADE EASYSUBTITLE: A WORK DIARY OF A PLC ENGINEERAUTHOR: AFIFI B GAYED

WORK SAMPLES

Below is a sample of my daily work as a PLC engineer: This sample is taken from my 300-page book I am publishing soon. I may present some in here but in my book there are more than 90 case studies that you may want to see.

Case study1

PLC is shut off.

Course of action

I used my Multimeter to troubleshoot the problem. The 120 volt link on the top right of the PLC cabinet is not giving voltage either before or after the fuse. I figured that the power was disconnected somewhere else outside the PLC cabinet. I checked the distribution box. There was

3


power coming out of CR4 outlet which means the cutoff is between the distribution box and the PLC cabinetThe power problem now is isolated to 60 feet of wire that connect the distribution box with the PLC cabinet. Upon tracing the wire I found that the wire is made out of 2 extensions attached together by a screw at extensions ends. Looking at both links I saw one of them is rapped with electrical tape. I decided to start checking that one. Using the ladder I reached this taped link. The link was poorly attached. The contacts was hardly reaching each other and the two ends of the contacts were not screwed together to establish proper contact. I removed the electrical tape and securely screwed the contacts and power was immediately restored. Problem is solved.

Now back to resume work in programming op720___________________________________________________________________

Case study 2

HMI800 and HMI720 E-stops are not resetting.

Given: all bits in p800_op800_HMI were off…………..see p800_op800_HMI capture. Note the picture in capture is taken after problem was fixed “bit energized”

Case study 2 continue

When checking point IO for the card 0 it gave “Module configuration doesn’t match the manufacturer’s configuration. Notice this capture was taken after problem was corrected. The highlighted dotted line indicates the location of the fault message.

4


All bit settings in faulted Right hand module matched the working module in other left hand setting.

Solution

Program: Main program, Routine: system

Rung 6 GSV, the value set in the GSV didn’t match the value for the EQU of right hand side

See the copied rung below

EQU (Controller_Serial_Number, 11746424) [OTE (TO_SAFETY [21].22), OTE (System_RH)]; “R”

Problem solved

____________________________________________________________________________________

Case study 3:

Operator Box E-stop is not resetting:

Given: all logic conditions are set correctly

Action: checking IO tree, op box Input card “IB” which is card (1).

See “op800 E, fix j box with operator, IO, card 1” capture blow.

5


To correct the problem do the following steps:1- Right click on card 1 “highlighted in capture above2- A drop down box will open. Select properties

1- A window will open. Select Input configuration, “Showing in capture below”2- Check the Test Source column, “highlighted in capture below” and see what wire numbers are

assigned to the test pulse. As you see below they are assigned to test source points 0 and 1.

Upon checking j op box, I found out that t01 was not in the correct slot. T01 connection is fixed and problem is solved

Case study 4:

Robot teachers were complaining that they are having Estop issues.

Course of action:

Check control power to see which tags are turned off.

Robot 710-R1 was experiencing continuous Estops

XIC(Safe_OP710_Robot_WR1.Comm_Ok) and XIC(Safe_OP710_Robot_WR1.EStop.O1) both tags in rung 1 and 2 were off.

To provide immediate help for Robot guys and to get them back to their task, we had to bypass these two tags so we can energize the OTE(Safe_Zone_07.Teach_Bypass) for them.

Case study 4: continue

See two captures below:

6


We were eventually able to limit the problem to the Ethernet link. Since all other robots are fine then the E link is limited to 710-R1. Thinking that the E cable between the R710-R1 and the E switch is bad, we replaced that cable but problem still there.

Now the problem is limited to the R710-R1 box.

We had someone set in front of the robot box and watch the light indicator inside robot box.

We have noticed that the green card light indicators inside robot box was acting upnormal

Now the problem is limited to the green box inside the robot box.

We noticed that the problem comes and go sporadically so we concluded that one of the links could be loose.

We started gently pulling on each individual wire and heaven behold some of the wires easily broke loose.

We had these wires retightened.

Side note this problem also caused the loss of water supply to welders cause of the loss of teach-bypass.

Also upon following rung 10 above, I had to turn gate switches to maintenance to keep water running.

I also changed the prep stand timer from 1000 millisecond to 5000. See capture below:

_________________________________________________________________

Case study 5:

Robot 830MH1 has lost communication and is not resetting.

My conclusion is a permanent switch or power wire was disconnected.

After investigation we found out that the service field block was disconnected by one of the mechanical guys who working on OP 870. The field block that services robot 830MH1 was provided power through the power source at op 870 fixture. The mechanic guy said he had to rotate the fixture and couldn’t reattach the wires because they became too short and couldn’t reach. We attached wires using extensions and problem was solved.

Case study 6:

7


Robot 190R1 is experiencing frequent stops.

After isolating the problem we found out that the Problem is inside the control box. Upon noticing the behavior of the cooling fan we noticed that the fan was producing a high pitch which indicates that it is about to die. We concluded that the control box could be over heating and that fan needs to be replaced.

Case study 7:

Robot tech is complaining that there is no water supply

Given:

Prep stand solenoid is energized for the zone.

All hard valves are turned on

Water meter reads LO and 00

Incoming pressure is reading high and return is low or zero.

Course of action:

Cycle power to logic: meaning turn the water flow solenoid somehow off and back on. This can be accomplished by inserting AFI in front of the water solenoid rung and then remove it. Also changed the timer to read 5000 instead of 1000

See capture below

:

In another case toggling Teach bypass turned water on.

_________________________________________________________________

Case study 8:

Robot 670-R1 is E-stopped

Course of action: I went immediately to the robot control box to check the physical environment surrounding the robot control box. Glancing in the zone near that c box I saw the electrician unplugging Ethernet wires. I asked him if he unplug any of the Ethernet around and he replied yes.

Robot Ethernet Estop was because of the loss of Robot Communication. Plugged back Ethernet cables and informed electrician not to unplug robots while robot in work. Also informed electrician that unplugging specific robots can end up losing robot configuration and result in loss of hundreds of work hours.

We have noticed that Robot 670-R1 communication drops every time there is a high volume of welding activity in its cell. I think that the high activity of high voltage welding is causing an electromagnetic field that interfering with the Ethernet signal of this robot. We discussed the solution could be using a better insulation for the Ethernet cable that may block the electromagnetic field or using wire routes that do not allow or minimize the parallel running of power cables

After more hours of troubleshooting by robot manufacturer technician he found out that WAN and LAN signals inside the robot box were conflicting so he had to set the WAN link to none and

8


Side note:

After more hours of troubleshooting by robot manufacturer technician he found out that WAN and LAN signals inside the robot box were conflicting so he had to set the WAN link to none and problem is solved.

All materials contained in this document are protected by copyright laws, and may not be reproduced, republished, distributed, transmitted, displayed, broadcast or otherwise exploited in any manner without the express prior written permission from Afifi Gayed and other copyright owners. You may download material for your personal and non-commercial use only or for the sole purpose of Afifi’s job application without altering or removing any trademark, copyright or other notice from such material

9

resume_for_plc_engineering_ july_2015 with graphics

Documents

robot logic

plc programming

robot programming technicians

robot technicians

robot cells

robot programmers

dry cycle setup tool

final mechanical setup