KELSON

SUTHERLAND
PROJECTS
&
EXPERIENCE

M E CHANICA L S ECTI ONS

D ESI GN
Parametric Solid Modeling using Carbon Fiber Placement Heads
Solidwork, Catia and PTC Creo
Roboic Controls & Programing
Finite Element Analysis using
Ansys End Effector Stands

Documentation

CON TR OLS AN D
S IMU LAT ION
Siemens Portal, Step 7 and
Operate for PLC and CNC
Programming

CG Tech VCP an VCS for

Automated Fiber layup program
creation and simulation

Python, VBA, Labview

D OCU MENTATION
Machine Drawings for
manufacture using ASME
standard GD&T

Assemby drawing and

documentation for manufactuing
and spares orders

Organization using PDM

Software
AUTOMATED
Fiber Placement Heads
An Automated Fiber Placement (AFP) head is a piece of aerospace

manufacturing equipment used to deposit uncured composites onto a mold.

The AFP heads carry spools of material. Ranging from 1/8” wide to 1/2” wide

tapes. Each head contains its own electrical, pneumatic and controls system and

can be mounted to a gantry machine or industrial robot arm.

I worked to design and improve mechanical systems on the creel and the

process ends of these end effectors. I also worked to support legacy AFP heads

used in production facilities around the world.

Because of our customer’s unique requirements each new project involves

a large amount of design changes to these heads. I personally lead a team of

five engineers to create a new AFP head for the National Composite Centre in

Bristol, UK. This project involved adapting our widest format material (1/2”) to

our smallest head format (8-spools).

In addition to design work, I was responsible for some aspects of the

construction and commissioning of AFP systems. Troubleshooting the

problems seen on this equipment requires intimate knowledge of the

mechanical, electrical, pneumatic, and controls systems and how they interact

with each other. Through many cycles of design, testing, delivery and support

I have learned how to better design for the whole life cycle of a product.

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ROBOTICS
Controls &
Programing

AFP systems built by Electroimpact are either based on a custom built, Fanuc

controlled gantry machine or a high accuracy Siemens controlled Robotic arm. The

majority of my experience has been with the latter.

These robotic arms are purchased form Kuka, but then outfitted with Siemens

servo motors and Renishaw absolute scales for secondary feedback. By using the

scale positions in combination with measurements from a laser tracker, the position

error can be compensated for, thereby creating an accurate motion platform.

I have experience in the initial setup and operation of these systems. In general,

setup involves integrating the Robot’s CN C with custom software and a hand full

of programmable logic controllers (PLC) which operate equipment such as the AFP

heads and operator safety equipment.

Programing of the PLCs is done through Siemens automation portal. A

combination of Boolean ladder logic and text based programming is implemented.

Each AFP head has its own on-board PLC which is responsible for controlling

solenoid valves, air pressure regulators, infrared heaters and monitoring a variety

of analog and digital sensors. I have worked to improve the reliability and

consistency of equipment operation though changes to the control system.

For example, each AFP head uses an infrared heater to promote adhesion of the

dispensed composite material to the mold or substrate. This heater was run in open

loop which caused process errors when heat built up in the heater body. A

resistance temperature detector (RTD) was added to the heater body. Using this

RTD feedback I was able to actively adjust the heater output.

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END EFFECTOR STANDS
One important feature of AFP systems is that the end effectors can be

quickly placed into a stand and exchanged for a different end effector. Some of

these stands move or rotate the end effector for operator or maintenance access.

I have designed several of these stands for different end effectors. In

general, the stands consist of large steel weldments which are anchored into

concrete. The sands need to repeatedly locate the end effector for pickup and

drop-off.

For one project I designed a stand which would lift a 1,500lb end effector to

a position where it could be picked up by the machine. The structure was

required to withstand a strong earthquake without falling over. To lift the end

effector a servo driven acme screw was used. Linear rails and bearing cars were

used for accurate and repeatable positioning.

Documentation
One aspect of good engineering is to document one’s designs.

Through the creation of hundreds of machine and assembly

drawings I have learned how to effectively communicate with

vendor and customers. I have also learned how to effectively

communicate my own ideas to my engineering colleagues through

written reports.

The ability to properly dimension and tolerance drawings is

essential for an engineer. I have had the opportunity to work

directly with the vendors who make my parts. I have learned many

lessons about how to ensure that the machinists and I are working

towards the same goals.