Looking for an industrial design and manufacturing engineer who possesses a wide range of talents and superior leadership and communication skills? A self starter who can take on challenging tasks and quickly learn new skills as required? Someone who can manage their own responsibilities and fill in for others when necessary?
With 20+ years of experience in electrical and electronic product design, development, production and support, I am the person to manage your product design and production from initial concepts to end of life.
I can provide you with the following experience and more:
- 20 years working with Autodesk products to produce 2D & 3D models for conceptual design as well as dimensional drawings for contract manufacturing, production diagrams, user manuals, bid submittals etc…
- 20 years working with graphic design and layout software to produce product artwork, logos, and labeling, user documentation, marketing literature, and web sites.
- 15 years sourcing components and arranging contract manufacturing.
- 15 years using Mentor Graphics PADS PCB design tools to produce schematics and fabrication data for PCBs containing BGA footprints, multiple layers and matched length memory buses.
- 10 years developing embedded hardware and firmware for 32bit ARM based SoCs using GCC in Eclipse environments, as well as uClinux operating systems and hardware drivers.
- Additional skill set in IT management, having built, configured and managed workstations, servers, networks, websites, and databases from scratch.
PROJECT EXAMPLES
DMX Hotspot
SAND Network Systems
Wi-Fi Access Point with DMX I/O (Proof of concept)
- Developed uClinux OS starting with a low cost development kit.
- Configured OS as Wi-Fi Access Point.
- Wrote DMX-512 device driver for the SoC’s integrated UARTS.
- Wrote application to translate Art-Net protocol to DMX-512.
- Verified compliance to DMX-512a standard before proceeding.
- Wrote bootloader to load encrypted Linux image via USB port.
- Wrote HTML and CGI scripts for over-the-air configuration and firmware update via web browser.
- Designed custom I/O circuitry.
- Performed 6 layer PCB layout including matched length external SDRAM and Flash memory bus.
- Selected stock enclosure & machined I/O ports for prototype run.
- Created name and designed logo.
Radia Lighting Control System
AMX Corp
Modular power control system for lighting and AV equipment
- Engineered form, fit and function of modular components.
- Designed sheet metal enclosures, extruded heatsinks, and component placement.
- Performed PCB layout for electronic controllers and high current dimmers and switches.
- Complied with UL Industrial Controller and Switchboard standards.
- Performed electrical and thermal load testing to verify compliance to international standards.
- Wrote construction procedures for UL approval and future verification services.
- Translated graphics into production artwork for product marking and labeling.
- Prepared all fabrication drawings and assembly documentation for contract and in house production.
Sales Literature
Instruction Manual
Translyte LED System
DADCO/Sunray Manufacturing
- Designed enclosure in 3D design software and prepared fabrication drawings.
- Selected ARM CPU and peripherals to design 2 channel 10A dimmer controlled manually and via wired or wireless DMX-512 & RDM RS-485 protocols.
- Used EDA tools to layout and fabricate the PCB.
- Created 4 button menu UI for the 4 x 8 segment display for setup and manual control.
- Wrote bootloader and firmware in C and ARM assembly.
- Wrote utilities to load firmware and UID on each device.
CRMX
Lumen Radio AB
- Produced fabrication data for 6 layer development PCBs with BGA parts, memory bus, and over 6000 connections.
- Ported SandBox OS and Ethernet protocol interpreters to the new hardware.
SandBox / SandPort
SAND Network Systems
Portable & Fixed Installation Ethernet / DMX-512 (RS-485) Interface
This was a redesign of the EMX2, utilizing an ARM7 SoC w/ 100Base-TX Ethernet I/O
- Schematic capture and physical PCB design
- Developed embedded bootloader and firmware
- Reverse engineered and wrote Ethernet protocol handlers
- Designed production tools for firmware installation & final test
EGO Module Prototypes
EGO Control Systems
- Produced 3D CAD models of proposed control surface layouts
- Prepared schematics, layout and fabrication data for control surface PCBs
- Produced graphic art for key cap legends
Modulus Dimmer Rack
Modular Theatrical Dimming System
AVAB America, Inc. Design sold to Acuity Brands in 2010
- Produced 3D models and renderings for conceptual design and marketing review.
- Designed and engineered enclosure, modules, and power I/O bus using stamped and formed sheet metal, sheet insulators, and a few machined plastic insulators.
- Designed and engineered power and control I/O interconnects between modules and enclosure utilizing low cost, off-the-shelf components.
- Plastic parts designed for possibility of future injection molding without redesign of mating parts.
- Designed to comply with UL and CSA Industrial Controller and Switchboard standards.
- Performed electrical and thermal load testing to verify compliance to international standards.
- Prepared all fabrication drawings and assembly documentation for contract and in house production.
- Designed and produced jigs and templates for in house machining and assembly.
- Prepared contractor installation documents.
eSense Connect
Fagerhult/Lumen Radio
- Developed bootloader to load encrypted firmware image via USB memory stick.
- Wrote utility to encrypt and package firmware binary.
EMX8
SAND Network Systems
Industrial PC based Ethernet to 8 port DMX-512 (RS-485) Interface
- Engineered enclosure combining Industrial PC, storage, I/O connectors and power supply.
- Developed Linux based OS.
- Designed parallel port LED controller circuit.
- Wrote LED control driver.
EMX2
SAND Network Systems
Portable Ethernet to 2 port DMX-512 (RS-485) Interface
- Enclosure design and PCB Layout
- Machined prototype enclosures
- Developed procedures for initial firmware loading and test
UMX2, UMX4
SAND Network Systems
USB 2.0 to DMX-512 (RS-485) and MIDI Interface
The UMX2 hardware was rebranded for companies such as Rosco, ESP, Capture, and LTLights to use with their control software.
- Engineered Enclosures and physical PCB design
- Created customized labeling for OEM partners
Prodigy Dimmer System
AMX Corp.
A modular power control system designed for mixed use of 7 different modules designed for dimming or switching of various loads.
- Designed and produced fab drawings of sheet metal enclosure and aluminum heatsinks.
- Performed load thermal testing to verify compliance with UL and CSA Standards.
- Liaison to Underwriter’s Laboratories for approval of new designs and later compliance verification.
- Translated graphics into production artwork for product marking and labeling
- Prepared all fabrication drawings and assembly documentation for contract and in house production
DDII Dimmer
AVAB America, Inc.
This workhorse of a dimmer was in production from 1985 to 2010. Hundreds of systems are still in use today due to it’s conservative thermal design and easily available replacement parts.
- Designed and engineered circuit breaker holder to replace E-Frame circuit breakers with commonly available residential style circuit breakers.
- Designed and engineered new components to double circuit capacity of 2.4kW unit.
- Designed, engineered and thermal tested new components to accommodate larger power inductors.
- Designed and produced custom rolling “flight case” enclosures and I/O panels for touring use.
- Produced tooling jigs and templates for manufacture of machined and formed plastic insulators.
- Made improvements to design and assembly procedures to facilitate manufacture.
- Performed load thermal testing to verify compliance with international standards.
- Liaison to Underwriter’s Laboratories for approval of new designs and later compliance verification.
- Diagnosed and repaired control PCBs at the component level on and off site.
- Redesigned PCBs for improved reliability.