Hybrid Automation, Inc. Automation Control Systems and Expert Witness Services. Projects Page

Hybrid Automation, Inc. is a Diversified Company, specializing in Automation, Control Systems, and Expert Witness Services. Allen-Bradley, Opto 22, AutomationDirect, Yaskawa, and PLC Programming experience.

All projects completed by Tim Rickard, for various customers around the United States, Great Britain, and Canada.

Bio of Tim Rickard - Automation Specialist and Machine Designer

Mr. Rickard has acquired over 30 years experience in electrical, electronic, automation, robotics, bulk materials handling, and mechanical system design. As an inventor, Rickard holds several electronic and mechanical patents awarded in the United States, Japan, Canada, and Great Britain. In various roles that span Vice President of Technology and Operations, Director of R&D, Project Manager, Construction Manager, and Vice President of Plant Engineering, Mr. Rickard has successfully deployed advanced automated systems for companies such as ThyssenKrupp Robins, Krupp Canada, CNRL, Rio Tinto Energy America, Range Fuels, Rentech, Nabisco, General Mills, Coors, ExxonMobil, Sinclair Oil, Ingersoll-Rand, and Honeywell Aerospace. His recent experience within the energy sector; Renewable Energy, Coal to Liquid Fuels, Coal (strip mining), and the Oil Sands in Canada, adds to his expertise. Travel experience spans the United States, Canada, Mexico, Great Britain, Japan and Okinawa.

Technical background includes extensive experience with Allen-Bradley, Delta V, digital logic circuits, vision systems, and laser research involving Co2 lasers (Class 4 100 watt), and laser diodes (Class 3B). Working closely with recruitment agencies, Mr. Rickard has established and managed several engineering, CAD, automation, and field service groups, for deployment of automated machinery in the food, beverage, refinery, coal, oil sands, pharmaceutical, and chemical plant industries. Most of this work carried over to the field, where Rickard managed electrical and mechanical field construction projects as Project Manager, General Manager, and Construction Manager.

Rickard is an active member with ISA (Instrumentation, Systems, and Automation Society), and AEE (The Association of Energy Engineers). Authorships include Whitepapers for RAM (Remote Asset Management), Energy Management, Automation, and cGMP (Current Good Manufacturing Practice) for FDA related validation procedures in lab environments. Rickard’s IP and patent experience includes work as a Technical Expert Witness involving patent infringement and automation related accidents.

Mr. Rickard has earned several technology certificates from Allen-Bradley and Opto 22, and continues his pursuit of a BSB/M degree in management, along with an AST (Associates in Specialized Technology). In addition, he has passed the qualification test, and is scheduled to complete the ISA's "Certified Automation Professional (CAP)" program during 2009. His engineering work collaborating with Scientists at Southwest Research Institute in San Antonio, certainly adds to his experience and education.

Projects Completed

ThyssenKrupp Robins, and Krupp Canada, CNRL Horizon Project – Fort Mackay, Alberta Canada.
April 2008 to present. http://www.cnrl.com/horizon/ http://careers.cnrl.com/media/cnrl/cnrl_video_operation.htlm. Installation and start up of ore material handling equipment for Phase 1 of the CNRL's Horizon OPP Project with respect to ore preparation plants (OPPs). My role is the Electrical and Instrumentation Site Manager to oversee electrical and instrumentation work performed on the job site, as well as to manage Krupp Canada’s Electrical and Instrumentation Team in the completion of its tasks (12 personnel). Overall commissioning and start up management is also included within my responsibilities. Equipment includes (2) hopper/crushers, (2) high speed/high capacity belt conveyors into a common surge bin, (2) high speed/high capacity belt conveyors into (2) separate slurry prep plants consisting of secondary crushers, and large vibratory conveyors and feeders. Oil sand slurry is then pumped to the onsite refinery.

Management responsibilities include (3) electrical construction crews consisting of approx. 100 electricians, Westwood, Pronghorn, and Elite Controls. In addition I worked with and coordinated work for Wabi, Waiward, Motion Canada, Atcon, and Hagglunds (mechanical contractors). I am also a back up for the Construction Manager, and responsible for the entire job site on weekends.

I completed and passed CSTS safety tests under ACSA guidelines, and I am OSSA certified. Passed all medical and drug screening per Canadian standards. Received Radiation Safety Awareness training for nuclear sensors.

Working under a Canadian work permit. Worked closely with CNRL and Krupp safety officers, developing new safety guidelines and bulletins.

ThyssenKrupp Robins, Expansion project for Jacobs Ranch Mine – Gillette, Wyoming http://www.rtea.com/pages/jacobsranch.aspx. October 2007 thru March 2008. This project will increase production yields to 6000 tons per hour of coal, and automate processes. Utilizes A-B ControlLogix PLC and RSView. I was contracted by ThyssenKrupp Robins for electrical and I&C onsite commissioning and supervision relating to coal breaking, crushing, conveyance, and storage. These responsibilities quickly expanded into site Electrical PM, Commissioning Manager, and Start Up Manager. System consists of truck dump and storage from 300 ton load coal haul trucks, Stamler feeder breaker, high speed (1000 FPM) ROM conveyor, Gundlach secondary crusher, 2.5 mile long high speed overland conveyor, surge bins, feeder conveyors, transfer conveyors, silo storage conveyors to top of silos, and finally load out into trains. Medium voltage (4160 VAC) motors ranged in size from 900 to 1500 HP, controlled by Toshiba VFD’s. This project was completed in the middle of winter, with temperatures as low as -40 below zero, high winds and blizzards were common. We maintained six day weeks, 12 hours days, for the duration of the project. I managed two electrical construction crews consisting of 40 electricians (Northern Electric and Energy Electric), and a commissioning team of technicians and PLC programmers. In addition I worked with and coordinated work for Schmueser, TIC, DCT, and AWS (mechanical contractors). I was on site this entire time period, our commissioning team did not miss a single day of work, six day work weeks, 12-hour days. During the last 2-weeks of the project the customer asked that I organize a two shift team, for 24/7 coal production support. Within days I pulled together a plan, spilt up our teams, and managed 24/7 support.

Renewable Energy - Biomass to Energy Conversion – During the 1^st half of 2007, we managed a pilot plant E&I and piping construction efforts as a PM thru a local GC. I kicked off this project with a part time CAD operator. I went on to build and manage a team consisting of CAD personnel, piping designers, 3D modelers, skid constructors, I&C technicians, mechanical engineers, electrical engineers, electricians, fabricators, pipe fitters, and welders. I pulled together this team in less than 8 weeks, and at it's peak, was responsible for a group of 45 personnel of various disciplines, sub managed by five leads in CAD, Piping Design, I&C, Skid Construction, and Electrical Construction. This "cell" of specialized personnel focused on Biomass conversion systems, labs, and reactors. I assisted in design, procurement, and construction efforts, and successfully completed a fully operational lab and reactor skid. In addition, we kicked off the final phase of this project consisting of a complete “Pilot Plant", converting Biomass into Ethanol. This was all accomplished in under 6 months. In addition to our crew, we worked with the Emerson I&C group, and pulled together a top notch team of Emerson I&C technicians, to work under a short term contract. We also coordinated our construction efforts with other electrical contractors, engineering groups, and project managers on site; Merrick, and CH2M Hill to name a few.

Renewable Energy - Coal to Liquid Fuels – During the 2nd half of 2007, we engineered and managed a project Conveying coal from rail and truck storage hoppers, into drag conveyors, and stored in silos. The coal was crushed and sent on to a gasifier. Also included full instrumentation consisting of CO detectors, radar level measurement, Bindicators, and impact weighers (flow meter). Also responsible for P&ID drawings, CAD based 2D and 3D mechanical drawings, schematics, panel layout, and PLC programming. During the course of this project I also managed electrical construction projects in general, and several CAD and 3D pipe designers.

Snack Food Plants - Distribution and packaging of snack crackers. A typical line consists of multiple infeed conveyors from oven to bucket conveyors (with bucket tracking logic), multiple storage systems, vibratory conveyors and feeders, belt conveyors, Ishidi scales, Bosch baggers, Bosch cartoners, Bosch accumulators and Bosch bundlers. Controlled by freestanding multi door control panels, A-B PLC-5/25 processors, adjustable frequency drives, motor starters, etc. HMI consists of remote consoles with message displays, switches and lights. Communicates via the A-B Data Highway Plus to an A-B PLC-3 host computer, and color process control stations using Intellution DMACS software. I have installed control systems in virtually all Nabisco bakeries (including co-packers) within the U.S.

Aerospace Industry - High Speed Test Fixture - Designed and fabricated an 18,000 RPM test fixture for a F-16 jet turbine driven PMA (Permanent Magnet Alternator). Included precision machined parts, special duty high-speed motor, variable frequency drive (VFD), and a complete control panel with software and program. Will go online during February 2003. This project is a good example of our diversity with automation projects, where we coordinate precision fabricated parts along with an advanced control system, in order to deliver a turnkey solution to the customer. One of the best examples of Hybrid Automation philosophy. See photo and video below.

Cereal Product Distribution and Conveying - Various cereal plants thru out the United States and Great Britain. A typical line consists of distribution systems with multiple bucket conveyors, belt conveyors, vibratory conveyors, and storage. Most systems can also "tote off" product to a completely automated tote loader system. A-B PLC-5/40 PLC's are generally used as controllers, with PanelView HMI's.

Convenience Store (C-Store) Remote Asset Management (RAM) - Integrated “Real World” technology into a NOC, for monitoring and control of systems in the field, for a major Oil Company’s C-Store market. This included energy management, high-speed credit card transactions, tank monitoring (fuel), car wash, and digital video. We supplied the “missing link”, and developed an industrial grade control system that can “harvest” field data and send it up to the Data Center, for monitoring, control, and reports. We engineered and fully tested all available connectivity solutions to transport bi-directional Data (TCP/IP) between the field and Data Center. The control system is designed to utilize Satellite, Frame Relay, Wireless, Cell Burst, DSL, Private Networks, or Modem connectivity. Transfer rates vary from 56K to 1 Meg, depending on the technology used and application requirements. Communication Protocols include Modbus TCP, direct SQL calls to SQLServer database, and several proprietary HMI display and trending software packages. We can transport simultaneously over a single connection, “live” digital video, credit card transactions, control logic, and raw data. Field Data is stored and archived at the Data Center and accessed via a browser-based portal utilizing customized reports. Software is not required on the customer side. We utilized Opto 22 B3000 and Ultimate I/O “brains” for the field control system, and communicated with the NOC’s SQLServer alarm database via Wonderware “InTouch” Modbus/TCP driver. The energy management portion of this package alone, will save this Oil Company over $3 million in annual energy costs, when rolled out to all of their C-Stores.

Pasta Plants - Long goods and short goods pasta lines. Controlled by A-B SLC-500/03 PLC's. Conveys long goods or short goods, via bucket conveyors, thru loaders and unloaders, into packaging equipment. Product can be selected for distribution from a single dryer source, to multiple lines.

RF (Radio Frequency) Modem Project – Completed a major project for a fortune 100 Company, involving wireless modems. Because of non-disclosure agreements, I can’t publish the Company name at this time. This project consisted of a pair of modems utilized for converting a RS485 proprietary network to wireless, and a “front end” pair of modems used to convert a hardwired RS232 proprietary software interface to wireless. Both modem pairs are state of the art 900 MHZ and 2.4 GHZ modems.

DNA Research Lab - Chemical and waste handling for DNA manufacturing (lab). Completely re-designed existing system, created new programs, and automated all systems. Controlled by two A-B SLC-500 PLCs and two PanelViews. Supplied various chemicals and gases to reactors within the lab, and then removed byproducts (chemical waste) to waste storage tanks. Utilized pressurized vessels, pneumatic valves, and storage tanks for handling chemicals. Also monitored explosive gases using LEL detectors. This system was completely automated, and could operate off-hours. Interfaced to HVAC system (Johnson Controls), and to automated dial out system to monitor alarms. Established US-FDA PLC validation and compliance procedures, as it applies to the FDA cGMP (Current Good Manufacturing Practice), standards of IQ, OQ, and PQ.

Potato Chips - Omron PLC. This project controlled a potato chip fryer. The potatoes were automatically sliced, fried and seasoned.

Tobacco Plant - Bristol, England. Installation of advanced conveyance systems for handling raw tobacco product. Also deployed a new electronic speed control system, as a result of R&D efforts. Similar conveyance products were installed thru out England during the 90’s.

Clean Rooms - Automation of new semiconductor manufacturing plant, Class 10 clean room environment. This project included automation and control of HVAC systems, humidity, chilled water, process water, scrubbers, exhaust, vacuum, and waste. Interfaced to Foxboro control system. Provided all control wiring, sensors, valves, and analytical instruments. Documentation included a complete submittal package and P&IDs. Also provided calibration, checkout, testing, startup, and training.

Building Automation #1- Satellite Transceiver Station - Automation of two buildings on-site, and add-ons to existing facilities. Automation and control of all HVAC, and satellite dish cooling/heating systems. Utilized Opto 22 controllers with SNAP Ethernet I/O. All systems controlled and monitored by an on-site central station, utilizing Opto 22 “FactoryFloor” software. The control system is also “web enabled”, allowing for access and monitoring via the Internet and standard browsers.

Building Automation #2 - Temperature control for 452-unit luxury "loft" apartment complex. Managed installation, and created program and graphics for HVAC. Each apartment has its own FCU (fan control unit), hot water system for heating, and air conditioner for cooling. Also includes utility monitoring (water, KWH, and heat). Utilized KMD (Kreuter) DDC controllers, networked together via RS-485 comm lines. The entire complex can be accessed, programmed, monitored, and controlled, via remote modem, or by connecting locally with a laptop. Utility data is gathered automatically by the system daily, and provided to on site computers for billing.

Grain Handling System - Automated grain elevator systems. Conveys grain from silos to rail cars and/or trucks. Also off loads grain from trucks and conveys to silos. A-B SLC-500 PLCs, and PanelViews.

Water Project - Completed pumping station project for City Park. A-B SLC-500 PLC with PanelView. Developed a unique dual pump control system, using PID loop control.

Bowling Machine Control - Completed PLC based controller for AMF type bowling pinspotter. Utilized PLCDirect PLC with IDEC touch screen. Also redesigned several other control systems related to the machine.

Micro-controller - Developed microprocessor based conveyor speed control, along with a discrete component speed control. We manufactured this product for the customer.

Customized Circuit Boards - Completed circuit board redesign for their line of security products (detention centers and jails).

Experience

Computers and IT - Extensive use of personal computers, laptops, printers, scanners, digital cameras, and peripherals. Application experience includes: PageMaker, AutoCAD, AutoSketch, AutoSketch for Windows, Visio, Wordperfect, Lotus 1-2-3, DataBase III Plus, FilePro 16+, RealWorld accounting software, Peachtree, WordStar 2000+, Microsoft Windows OS (3.1, 95, 98, NT, 2000 and XP), Logitech and HP scanners, Timeline, Norton Backup, Norton Utilities, Norton Anti-virus, MS Word 97-2002, MS Powerpoint, MS Publisher, MS FrontPage, MS Access, MS Project, MS Excel, Adobe Acrobat, FileMaker Pro 5, Corel PHOTO-PAINT, and many other MSDOS and Windows based single and multi-user software packages. Also have extensive experience developing and managing Internet sites, Internet access, and e-mail, including HTML, XML, and Java development.

Control System Application Experience - PLC experience includes hands on training, application and programming experience with: Allen-Bradley's PLC-5/10 thru PLC-5/60, SLC-500, and MicroLogix 1000 and 1500. I also completed the A-B PLC-5 accelerated training course. In addition I have attended Allen-Bradley seminars on statistical process control, operator interface and color graphics systems, variable frequency drives, vision systems, bar code, radio frequency identification systems and many other areas. Extensive experience with Allen-Bradley's complete line of controllers, VFDs, relays, contactors, sensors, PBs, etc.

PLC Systems - Have extensive experience with Opto 22 PLC’s, AutomationDirect (Koyo), Westinghouse, Foxboro, Gould, GE, TI, and Omron.

VFD (Variable Frequency Drives) - Extensive experience with Yaskawa and Allen-Bradley. Speed control of motors 0-18,000 RPM, vibratory feeder speed control, 0-400 HZ output, and variable voltage applications.

Wireless (RF) Modems – Design and application of wireless modem networks used for RS485, RS422, RS232, Ethernet and USB applications. 900 MHZ and 2.4 GHZ.

Networks, Digital Video, and Satellite (VSAT) Connectivity - Transported bi-directional Data (TCP/IP) between the field and Data Centers. I’ve utilized Satellite (VSAT), Frame Relay, Wireless, Cell Burst, DSL, Private Networks, and Modem connectivity. Transfer rates from 56K to 1 Meg. Protocol experience include Modbus TCP, direct SQL calls to SQLServer database, and several proprietary HMI display and trending software packages. Transported simultaneously over a single connection, “live” digital video, credit card transactions, control logic, and raw data. Field Data was stored and archived at a Data Center and accessed via a browser-based portal utilizing customized reports.

DDC Controllers - Hardware and programming experience includes: KMC (Kreuter) "KMD" controllers, Reliable, Barrington, ESUSA, and Z-World.

PLC programming - Experience includes A-B 6200 series, A-B RSLogix series, Opto 22 FactoryFloor and ioControl, Omron CPT, and DirectSOFT. Also completed advanced programming courses for the A-B and Opto 22 product lines.

HMI (Human Machine Interface) - experience includes: A-B Advisor, PanelView, PanelMate, and RSView. RealFlex, ControlView, Opto 22 OptoDisplay and ioDisplay, CTC Interact, Intellution's "The Fix" and DMACS, Citect, and Wonderware InTouch.

Hardware - Sensors, valves, and dedicated controller experience includes: A-B, Banner, Turk, Microswitch, Rosemont Analytical, Thornton, Modus, Omron, Effector, Gems, Belimo, Keystone, Dwyer, Veris, Weed, KMC, Johnson Control, Kele, Honeywell, Siemens, Brandt, General Eastern, Pyromation, Fluidyne, Signet, Fischer, Baumann, and many others.

Vision Systems - Application experience with the A-B VIM and CVIM vision systems. Also familiar with the COGNEX 2000 and 3000 series machine vision system, Microvision products utilizing the Cognex processor and INEX vision systems.

Lasers - Co2 (Class 4 100 watt), laser diodes, visible and infrared (Class 3B), and helium-neon lasers.

Gas Valves and Controls - PID gas valve controllers, gas valves, temperature controllers, and limit switches.

Digital Logic and Electronics - CMOS, HTL, TTL digital and analog logic circuits for industrial based control systems. Power drivers using MOSFET, TRIAC and IGBT transistors. I/O interfacing of discrete logic, programmable controllers, data processing equipment, relays, sensors, etc., to peripherals. Design of regulated linear power supplies and infrared and visible optoelectronic systems for use in beam break and proximity sensing. Electronic speech synthesis for voice controlled equipment and voice message indication. Sensors: proximity, optoelectronic, Hall Effect, mechanical, etc.

Microprocessors - Microprocessor based controllers using the Intel MCS-48 and MCS-51 8-bit embedded controllers. Blue Earth Research MICRO-440 micro controller. Parrallax BASIC stamp micro controller. Z-World micro controllers.