Returning to Wrightspeed

R&D Tech

Building Prototypes (200) with microelectronics and optics.Responsible for planning, organizing , supervising, and executing build.Also responsible for inventory and tracking deployment, RMA repair, redeployment of units.Completed build on schedule.

BLACK PROJECT

Fabricating and reworking DUT to 19" Rack Tester harnesses

Prototyping Grid Edge Optimization Technoloy, (including Experimental 1.5 MW Series Power Router), Engineering Test and evaluation of Volt-VAR Technology, Fabrication of Power distribution boxes, inductors, transformers, test fixtures and various other devices used for test and development of grid edge optimization technology for power utility companies.

Data Acquisition for transmission testing in Propulsion Systems, various other technician duties in Power Electronics Modules Dept.

Hired to fill in for a technician on medical leave from PEM (Power Electronics Module) department. Due to the short duration of the assignment, duties excluded working on inverter and charger circuits and were confined to general lab duties such as prototyping, cable assembly, device and PCB testing, repair and rework of chillers, spooling wire, milling IGBTs with CNC machine for thermocouple installation. Eliminated all leaks in all plumbing and chillers in PEM lab. When I started everything leaked, when I left nothing leaked.

Hired to integrate, connect, setup, configure, program and test data acquisition equipment for Model-S transmission test fixture in Propulsion Systems Laboratory. Equipment included $20,000/each HBM T-12 Torque Transducers (100 Nm & 1000 Nm/1 each), $20,000 HBM eDaq data acquisition box, 37kW Fukuta AC Servo Motor, 38kW DanFoss VFD (Variable Frequency Drive), 3-axis accelerometers, including I/O interfacing for auto-shutdown condition using custom designed signal conditioning circuit and relay driver circuit which automatically engaged EMO (Emergency Motor Off), upon detection of catastrophic gear failure in transmission while running at 3000 rpm. When hired, all equipment was either boxed up or unboxed and staged on the floor. When I left, the Danfoss VFD was driving the Fukuta servo motor at 3000 rpm , the eDaq was collecting data from the accelerometers and the T-12 Torque sensors and the auto-shutdown circuit was operational. Designed and implemented two op-amp signal conditioning circuits, (one Proximity Sensor to RPM converter circuit and one auto-shutdown circuit). Duties also included impedance matching to determine required series choke inductance to run Model-S motor with VFD. Matched Roadster and Model-S motors.

Assembly, tesing & troubleshooting of complex robotic capital equipment for factory automation, with special attention to prototyping and testing of end effectors

Assembly, testing, & troubleshooting of complex capital equipment for DLP chip manufacture and testing. Working with one other technician, assembled total of 6 machines (2 each of 3 different types: 3-axis video die inspection machine, a chip sealing machine, and a process chamber machine). One each of the three to remain onsite and 1 each of the three to ship to OEM in Taiwan. Machines were assembled from partial schematics updated daily. Completed all six machines.

Contract Engineering Technician hired to commission three reliability test fixtures and rehired in Feb,2004 to maintain them and collect data. The fixtures were designed and built by a department that was laid off on Nov 4th, 2002 , along with 3700 other employees, (including myself). There was no one left working who had any knowledge of the machines and there was no documentation and it was unknown if there existed any software. I came in and troubleshot them 'cold turkey' with no documentation and got all three machines operational in the 6 week time frame of the assignment. Software was located but one of the three had a bug so the software was replaced with code I wrote in Qbasic for the memory mapped DeviceNet Controller PCB integrated in single board controller found gathering dust in a storage cabinet.The SBCs (there was a whole cabinet full of them) were left over from the old tool design that used localcontrollers for the PVD modules. When the old design was replaced with a single central controller, all of the SBC were stored in a cabinet , where I found them about 5 years later. I reconfigured the CMOS to boot from a HD (which I added, which contained Windows-95). The memory-mapped DeviceNet Controller was then programmed to write Acceleration, Deceleration, Velocity and Target Position, to the appropriate registers in the Sanyo Denki $5000 DeviceNet motor controllers.

Systems Engineering technician hired to become onsite expert in DeviceNet and Motion Control to support Bowers campus (former support person was transferring to CMP , where he later hired me back after the big lay-off) Learned DeviceNet protocol and motion control H/W & S/W unassisted in three months. Created new mobile-response diagnostic station used to reduce costly tool downtime.Resolved wafer-lift issue by submitting SR (Software Request) to add new S/W functionality.Was sole Tool_Owner responsible for maintenance and operation of two multi-million dollar PVD tools.Performed vibration analysis of wafer lifts and servo motor drivers using PC-based data acquisition tools.Provided motion control support for engineers working on new wafer lift designs. Provided support for numerous other projects including 24 hour particle test.

Testing, troubleshooting and repair of GPS based microwave survey equipment.

Engineering evaluation testing of entire surge protection product line. (AC arrestors, Transient Voltage Suppressors and other surge protection devices, including SADs (Silicon Avalanche Diodes)Was hired to collect test data for entire product line in preparation for UL tests. Generated reports for each product test. Prototyped 10 kA SAD using modified 2 kA pcb.