Packaging
Machinery
Through a strong association with the packaging industry
for over 15 years, developed a substantial and valuable knowledge in the
design of packaging machinery and associated feeding systems with ongoing
research and
development.
Directed and actively participated in the
multi-skilled team developing the next generation of
bespoke form, fill and seal packaging machines and intelligent feeding
systems. A modular approach was taken for the mechanical, electrical
and software design, resulting in a family of products that could be readily
customised and adapted to meet customers' exact needs. The machine frame was
designed to be manufactured in either mild or stainless steel, allowing
hygienic wash down systems to be built. The control system was based on an
industrial PC running the QNX operating system (real-time variant of UNIX).
The graphical user interface and multi-process motion software was written
in C/C++.
Developed innovative
low/zero pressure inline feeding system
algorithm incorporating intelligent “virtual sensor” software that tracked,
analysed and reacted to the motion of arriving products, minimising the
number of motors/sensors required compared to traditional multi-belt feeder
systems.
Developed real-time motion control software for 4 axis
high integrity (gas tight) sealing machine for Modified Atmosphere Packaging
(MAP) applications. Software was written in assembler for the National
Semiconductor HPC family of microcontrollers. Embedded a kinematical model
of the system in the user interface which analysed the displacement,
velocity and acceleration profiles generated, ensuring that the mechanical
limitations of the machine’s component parts could not be exceeded by
invalid operator input, significantly improving user efficiency.
Audio Speaker Impulse
Test System
Developed a prototype impulse test
system for audio speakers which reduced the test time from 5 minutes to 5
seconds while providing a vast increase in resolution, compared to
traditional frequency scanning techniques. 
The system delivered a series of pulses via an amplifier to excite the
speaker, and its time domain response captured using a microphone connected
to high speed A/D hardware installed in a PC. The captured data was then
mathematically converted to the frequency domain using a Fast Fourier
Transform (FFT) algorithm, and the results compared with the
expected frequency response for the speaker type under test.
Telecommunication Products Production
Test Equipment
Specify, design and build of bespoke functional and
in-circuit (bed of nails) Automatic Test Equipment (ATE) used in high volume
production of telecommunication products. Analysed the technical
implications of production test fallout, to improve yields through modified
manufacturing and test methods, and advising the product design team of
modifications to enhance the economic manufacture and quality of the final
products. Developed production test database software which logged test
results and repair information, allowing the ATE to statistically predict
the repairs required for subsequent products that failing during test.
Soot Blower Control System
Design, installation and commissioning of a prototype
soot blower control system for the coal-fired electricity generating
industry. The system was designed around a PLC (Programmable Logic
Controller) and used solid-state modules to interface to the various 110VAC
input and output signals. the software was developed using the proprietary
PLC language.
Technical/Commercial Marketing
Promote technical aspects of telecom and special function
semiconductor products, supporting customers by preparation and provision of
relevant data sheets, application information and technical seminars.
Provide customers with expert advice on system designs based on the 16/32
bit 68000 processor and supporting peripheral chips, optimising performance
by exploiting the pre-fetch cache memory and floating point coprocessor, and
specific PCB layout techniques for high speed operation. Determine the
available markets for the 68000 family of products, forecasting trends and
emerging opportunities. Control price/volume of orders in balance with
production capabilities. Monitor and report on competitor activities, and
observe customer trends and demands, to control the timely introduction of
new products.
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