Dave_Adams_Projects_2015-06_t
- 1. Dave Adams Recent Projects June, 2015
- 2. Dave Adams- Summary • LinkedIn public profile at: www.linkedin.com/in/dvadams/ • ~ 34 years experience as a Mechanical Engineer • Promoted to Engineering Manager at two firms • 7 US Patents
- 3. Recent Positions Summary List Title Company Dates Mechanical Engineer Contractor Solopoint Solutions 7/13 -- 6/15 Staff Mechanical Engineer Labcyte Sunnyvale, CA 12/09 – 7/13 Mechanical Engineer Contractor Prosource (Optoview, Fremont CA) 02/09- 11/09 Manager, Mechanical Engineering Crossing Automation Mountain View, CA 12/06 – 01/09 Member of Technical Staff Crossing Automation Mountain View, CA 11/05 - 12/06 Mechanical Engineer Contractor ATR (Asyst Technologies, Fremont, CA) 05/05 – 11/05 Principal Mechanical Engineer Aquest Systems Corporation, Sunnyvale, CA 07/04 – 05/05 Manager, Mechanical Engineering Asyst Technologies, Fremont, CA 11/02 – 07/04 Senior Staff Mechanical Engineer Asyst Technologies, Fremont, CA 06/98 – 11/02
- 4. Recent Position –Solopoint Solutions • Mechanical Engineer Contractor July 2013 – June 2015 – Design support for one project at Lathrop Engineering • July-November 2013 – Joined SRI Team focusing on High Efficiency Walking Humanoid February 2013 – Primary Mechanical Design responsibility for Electrical Power and Electronic Control Systems Packaging – System-level Mass Properties Management, Mechanical Vendor Selection and Management, Mechanism debug, Subassembly Test, Creation and management of system- level BOM, Subsystem and System-level Mechanical Build
- 5. Recent Position –Solopoint Solutions
- 6. Recent Position –Solopoint Solutions • Challenges – High-efficiency rolling friction reducer was noisy and exhibited intermittent high friction/interference problems • Established design control of critical lobed cam wheel • Drove fabricator to improve resolution so that CAM profile followed CAD model within 0.8 microns – Definition of Mechanical layout of Electrical/Electronic Systems – Design of modular battery pack • connect/disconnect force was ~100 lbs – Aggressive build schedules • Met! – Aggressive Cost Goals • Built under-budget!
- 7. Recent Position -Labcyte • Staff Mechanical Engineer- April 2010- July 2013 – Transition of POD Automation System into Manufacturing – Design of Access Laboratory Workstation http://www.labcyte.com/products/access-laboratory-workstation • System Layout, Cast Deck and Enclosure design, Robot Pneumatic Gripper • Modular OEM Equipment Installation design • Product transitioned into manufacturing • Marketing Support for Customer Specials – Converted from Contractor (Dec 2009 - April 2010)
- 8. Recent Position –Labcyte Access Beta • Access Plate Handling System Problem Statement – New product line for company – Needed quick (3 month) turn on design for Beta System • Beta System available trade show Demo 6 months after project start • Integrate OEM Robot -operator protection required- • Limited Equipment set – Marketing wanted Light Curtain protection- not feasible • Changeover to transparent polycarbonate window protection – Beta System, built 7 units- on time-SUCCESS! – Led to Pilot System design (see next page)
- 9. Recent Position –Labcyte Access Pilot/Production • Access Pilot System Design – Address serviceability issues identified in Beta Phase • Needed to “flip” (mirror) system geometry around • Add sliding shelf and sliding access doors Stiffness of slides used was an issue- required iteration – Stringent Cost Goals – Expanded list of served OEM devices • New OEM devices identified per customer request ~2 per month • No industry standards; most equipment types designed for manual loading – Pilot Design had to be low-cost and flexible
- 10. Recent Position -Labcyte • Access Pilot System Design – Triggered by successful Beta Introduction – SystemMain and Auxillary Base Plates designed to be symmetric • Both items sand-cast-Sourced both plates at General Foundy • Allowed RH/LH equiment mounting options – Main Base Plate designed with rear access available • Allowed optional Rear Table for more OEM equipment – Safety Enclosure design using extruded frame (80/20) – Safety Panel design allowed inside- or outside mounting – Locking Sliding Shelf with Kinematic mount features – Docking Rear Table – Considered “the smoothest NPI transfer in the history of the company”
- 11. Recent Position -Labcyte • Access Pilot System Design & Project Challenges – Integrating cast part base plate design into production • Achieving buy-in from Operations was critical – Use of standard extruded frame • Achieving buy-in from Marketing was critical – Stiffness of slides used for Door and Sliding Shelf • Scant technical information available; required iteration – Robot Gripper functionality • Vendor-selected actuator subject to “infant mortality” failure • Redesigned and built first seven (working) Grippers; shipped to Robot Supplier for integration – Modular Rack Plate Storage • Robot requirements for precision of placement were initially beyond capability of OEM supplier to measure, much less manufacture
- 12. Recent Position –Labcyte Access System Responsible for Mechanical Design of Access Benchtop Automation System Safety Enclosure Main Base Plate Aux Base Plate Locking Sliding Shelf Dual-Slide Access Door
- 13. Recent Position –Labcyte Access Optional Rear Table with Modular Equipment Mounting system Challenge: Provide Kinematic locating for multiple non-standard equipment types, from multiple Vendors Solution: Adjustable DIN-Rail style mounting rails with adjustable L- shaped foot locating brackets 4 locations
- 14. Recent Position –Crossing Automation • Manager, Mechanical Engineering- – Mechanical Design of two products • Vacuum Transfer Module • System Controller – Managed one employee and two Contractors – Promoted to Manager 12/06 – One US Patent Applied for
- 15. Recent Position – Crossing Automation • Vacuum Transfer Module Design Challenges – Wafer Transfer; needed to be precise (.001”) and Clean – Initially: Company founders wanted piezo-motor drive • Found not to be feasible due to wear, particle and speed issues – Axis Configuration: Founders wanted dual mechanisms each with three independent axes • Independent Extend, Lift and Rotate mechanisms • Lift and Rotate Axes to be common to both devices • Simpler Control software – Ultra low- footprint: 520mm2 • Indentified as a product differentiator
- 16. Recent Position –Crossing Automation Vacuum Transfer Module Designed the dual extension axes and the rotational/vertical drive
- 17. Recent Position – Crossing Automation • Vacuum Transfer Module Design Solutions – Wafer End Effectors stacked vertically – Extension Mechanism- steel band drive with linear servo motor actuation • Negligible wear over millions of cycles • Extension mechanisms side-by-side to minimize chamber volume • Enabled footprint advantage – Vertical and Rotational Drives outside of Chamber • Vertical: dual lead screws with dual guide shafts • Rotation: Frameless direct drive motor • Ferrofluid used for rotational seal • Metal Bellows used for vertical seal
- 18. Recent Position – Crossing Automation • Vacuum Transfer Module Design Challenges – Extension mechanism stiffness • Achieved 4X stiffness improvement using FEA – Steel band tracking • Required 3 DOF adjustment each pulley – Supervision of outside Contractors • Tasked with taking over design of Lift/Rotation – Component selection for vacuum compatibility
- 19. Recent Position –Crossing Automation Responsible for Mechanical Design of the Enclosure and internal positional layout of PCBA’s: Challenges: -Achieving cost targets -Selecting fan and louver design for proper airflow cooling -Ambiguity with OEM PCB layout information
- 20. Recent Position –Asyst Technologies • Manager, Mechanical Engineering – Mechanical Design of two Generations of Conveyor, three generations of Turntable – Managed two employees and one Contractor – Promoted to Manager 11/2002 • System Layout and Customer Liason for installation in Arlington TX • Supported System install in Singapore • One US patent granted
- 21. Recent Position – Asyst Technologies • Design Challenges – Ceiling-Mounted System – Achieving Rail-to-Rail Alignment • Required careful attention to extruded rail geometric tolerancing – Design of two-axis FOUP positioner • Thin height profile; “Dual Worm” mechanism; Included FOUP Gripper – Design of all Turntables used throughout Product Line • Maintain Track alignment for smooth motion on thru-transits • Three-position; sand-cast construction – Design of several configurations of Conveying System with Turntables • Required by various configurations of wafer containers – Direct Customer Liaison including system layout – Created & maintained “System Configuration” documents • Used by Applications, Sales and Field Service
- 22. Recent Position – Asyst Technologies Responsible for System- level design (factory layout) Designed robust FOUP Gripper for X-Z Gantry Robot Responsible for Inter- Floor Elevator Integration Design Responsible for two versions of Conveyor design Responsible for Design of all versions of Turntable
- 23. Older Projects Acuson V5M Transducer- redesigned sculpted ergonomic hand- held control unit Provided Engineering oversight of Endoscope, manufacturer, 64 channel signal cable manufacturer, and molded housing parts manufacturer Applied Materials Epi Centura 200mm - Four generations of design- Concept stage through Pilot Production -Flagship Centura product -4 US Patents -Still in production ~70% of world-wide market -Process used to make 50% of a silicon devices