Projects
Laser PCB Trimmer
Project Overview: Deliver a calibration system to be used in production to fine tune a Radar antenna resonate frequency that is used for a motion detector used in a security system.
Jesse's Responsibilities
Design overall system including all electrical and pneumatic systems
Develop and integrate software application
Test and validate functionality and performance
Oversee mechanical design and build
Ensure OSHA safety requirements are met for high energy systems (Electrical, Pneumatic, Laser)
Deliverables
Complete functional system installed in manufacturing plant
Machine Operating Instructions
Detailed Test Descriptions
Complete System Wiring and Plumbing lists
Complete Bill of Materials
Functional and Performance Certification documentation
RF Isolated chamber with Keysight Spectrum analyzer measuring frequency
Green Laser system to make cut through copper PCB trace
Pneumatic lift system to close and open RF Isolated Chamber
All systems integrated and controlled with custom Windows application built in .NET Framework
Machine vision to locate exact position of PCB Trace
Cooling and Fume Extraction systems
Door lock and panel interlock safety system to prevent unsafe pneumatic and laser operation
Internal Cameras for mechanical system monitoring
Explosive Cartridge Sensitivity Tester
Project Overview: Deliver a system that can precisely control voltage, current, or power to 12 individual devices under test simultaneously while data logging for failure analysis.
Jesse's Responsibilities
Design overall system including all electrical and software systems
Design and build power controller PCB
Build electrical system and troubleshoot
Develop and integrate power controller software
Develop user interface and interface with power controllers and data acquisition cards
Test and validate functionality and performance
Oversee mechanical design and build
Manage and document electrical and software system designs
Custom Designed Power Controller PCB
Custom controller communication protocol
External data acquisition
Pneumatic test pin engagement system
Universal Explosive Cartridge Test System
Project Overview: Design a modular system that can perform various tests for manufacturing, ballistics , and research design projects. Tests include 4-wire resistance, insulation resistance, capacitance, diode polarity and voltage drop, bridge-wire thermal increase measurement, explosive sensitivity, and explosive power and energy measurements.
Jesse's Responsibilities
Initial project concept creation
PCB Design, Layout, and Interconnections
Controller software development
User Interface development
AutoFinal Test projects
Jesse's Responsibilities
Support and manage all Auto-Final test systems in use in manufacturing (27 racks and 50+ test heads)
Design and integrate new test heads for complex new products
Mentor and oversee all new test head designs done by junior engineers
Manage and upgrade custom base software in C# .NET framework
Examples of AutoFinal test heads designed and integrated by Jesse
7" Advanced Security Panel
Cognex Machine Vision for LCD, backlight, and printed logo verification
Pneumatic simulated finger for touchscreen verification
Stepper motor driver X-Y slide to move camera and pneumatic finger
Ethernet and PSTN tests
Speaker, microphone, and piezo tests
Robust communication interface with device under test
Advanced system status logging for rapid remote troubleshooting
Security Keypad
Advanced button icon detection with Cognex machine vision (verifies button icon, color, and brightness while being tolerant to manufacturing variances)
Individual pneumatic button presses
Speaker, microphone, and piezo verification
Ethernet and Wi-Fi verification
Wireless sensor receiver verification
4.3" Security Panel
First tester in department designed to test high resolution color LCD with touchscreen
First AutoFinal tester to be developed in C# .NET framework (previous testers had been developed in VB6)
Fixed location pneumatic screen press verification
Cognex Machine Vision for LCD and backlight verification
Improved PSTN tests
Speaker, microphone, and piezo tests