GENERAL MOTORS
- Zackary Roth
- Aug 3, 2020
- 4 min read
Updated: Aug 7, 2020
Wentzville, MO
EXCEL Controls Engineer Intern
(06/15/2020-08/07/2020)
Projects
Cognex camera install in chassis
For this project I had the responsibilities of designing/making the camera I/O box schematic, Wiring/testing, creating a 3D representation of it live on the floor, and working with maintenance and the industrial engineering department to coordinate the installation of this infrared light camera setup in chassis which was taught to detect whether or not the load arms were properly installed before it reached the end of the operators tool range. Moreover, the main purpose my schematic served was to show how to wire the lights and camera to make the infrared lights strobe at a specific intensity whenever the camera was triggered to allow for a brighter/more detailed image.
This is the schematic I made for the Camera I/O box and the modified female to female I/O cable.
This an overview picture of the testing lab where the infrared lights, I/O box, I/O ports, and power supply are all visible.
Develop/Program an HMI screen for Glass Cell.
This project required me to design a more intuitive camera statistics screen for two cells that were responsible for the glass installation in general assembly. I created the graphics on Siemens software, updated/added Rs5000 logic to two Allen Bradley PLCs for the overall functionality of the new additions to the HMIs (Which involved correcting existing computing logic, creating/modifying tags, configuring the address of said tags to HMI, and etc.),and I worked with the GA department to get the new HMIs uploaded to the floor.
These are some sample before and afters of the HMIs. As you can see I added a pass count, bypass count, bypass reset button, total job count, and easy to understand option titles. Note that there are plenty more screens that were added/updated to the HMI this is just two examples. In addition, the pass percentage calculations were off in the logic and needed to be updated as well.
This is a short video of some of the ladder logic that was added for the new HMI screen
This is a video showing the functionality of the bypass reset button (I manually input random values in the logic so I could test this feature).
Upgrading 17 Allen-Bradley PLC5s from Data Highway to Ethernet IP
In the older sections of the factory there were outdated PLC5s that still used the old data highway communication system which is equivalent to using 1Mbps Internet. For this project I was responsible for coordinating with maintenance during lunch break shut down to install Ethernet modules to the processors, configuring the IPs assigned from the IT department in the processor‘s logic, updating the drivers, and communicating with the required personnel to update them on the progress I made which involved me sending updated data sheets stating the completion date and other pertinent information.
Once this project was completed the mean time to repair went down from an hour to minutes because it reduced PLC logic load time, communication with data analysis software was greatly improved, and the 4 hour data backup time went down to 27 minutes.
These are images of the Ethernet sidecar modules that were used with one picture being of an active processor before the sidecar install.
InDepth (Pilot)
I took part in the pilot program of incorporating a data analysis software called InDepth in truck body that will increase the efficiency/optimization significantly due to its predictive maintenance capabilities and data collection. The responsibilities I had was working synchronously with corporate and the plants Industrial engineering department on updates and Information, configuring/calculating target values for the three zones assigned, and verifying opportunities data on the floor and demonstrating to maintenance how they can use this program for predictive maintenance.
This is a video of a problematic cylinder that InDepth was able to detect due to the oscillation of return time. This was an unseen problem that was losing 1-2 jobs at random times and was only detected by the data analysis software proving the capabilities of this tool even in its infancy.
Logic updates to every PLC5 in Body Shop
This project involved me adding an additional rung to every processors program that remapped status bits to their proper locations so correct information can be shown on the global production monitoring and control system.
Resurrecting the plant`s 3D printer
This was the final project I had while at my internship and it entailed creating a slicer profile setting for optimization of throughput on prints, helping calibrate the print bed, help replace extruding nozzle, and finally setting up a tutorial on how to use the printer for specified individuals.
The printer being used was a Delta Printer Wasp 4070 industrial 3D printer that was essentially being a $15,000 paper weight because not a single individual at the plant knew how to fix/use it. With the help of another intern we both were capable to bring resurrect the printer and teach the site engineers how to use it for their advantage.
Here is a video of me testing the printers calibration and slicer profile settings with a part I created for another project.
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