Addendum to Resume of Kenneth Hamel

Chronologically Ordered

Purdue University


Delco Electronics

(Annual Volumes ~ 3,000)
(Annual Volumes ~ 100,000)


Flxible Corporation

(Annual Volumes ~ 1,000)

Note - an example of a Flxible Transit Bus, similar to the prototype vehicles used in R&D.

Lucent Technologies (then Celestica)

H-Tek, Llc

    • Note - the program written above performs the basic function of a desired result, and is provided in the following  file.  The program uses a communication control called PDQComm for VB that greatly simplified the code necessary for bidirectional communication between the unit and the pc.

    • Note - the program written above performs the basic function of a desired result, and is provided in the following  file.  The program uses a communication control called PDQComm for VB that greatly simplified the code necessary for bidirectional communication between the unit and the pc.

  • The Visual Basic programs written above to interface with the SuperLogics ADC-1 and 8018 modules were written to perform data logging with time stamping, per the following link SuperLogics Data Logging.
  • Jan-2005, Prototyped / Programmed a BS1 Basic Stamp Module with circuitry added to accomplish a standalone control panel:
    • a rough schematic was generated outlining the basic concepts
    • a parts list was generated and purchased
    • big components were laid out physically on a proto circuit board for spacing
    • certain circuits were bread boarded and tested (and modified if necessary) before circuit board installation
    • the circuit board was populated and tested in circuit chunks
    • excess circuit board material was removed
    • the circuit board was powered and tested
    • modifications were made to circuitry based on circuit re-configurations, then re-tested
    • an aluminum box was machined for the proto circuit board
    • support components and proto circuit board were installed in the aluminum box
    • unit was programmed using software written earlier during the BS1 Basic Stamp Module core function testing (above)
    • a programming cable was added allowing the re-programming and debugging of the unit when assembled
    • the unit was tested with the same testing hardware used for current production control panels
    • demonstration of functionality
    • modifications were made to circuitry based on demo feedback, then re-tested
    • a few pictures of the prototype (front label was edited)
    • Noteworthy:
      • Future - output circuitry with current limit and sensitivity selections
      • Changed 9 VDC battery to rechargeable
      • Eliminated 30 minute timer, replaced with software
      • Eliminated relay for buzzer function, replaced with transistor logic circuitry
      • Pushbutton switch can be replaced with much simpler/cheaper unit
      • Lights are controlled with 5 VDC instead of 120 VAC
      • Regulated and short circuit protected 5 and 12 VDC are available for expansion capabilities
      • Communication to computer networks and systems now possible
      • Wiring to sensor probe can be 22 gauge instead of 16 / 18 (possibly even 6 conductor phone cable)
      • 120 VAC neutrals through sensor probe replaced with low voltage, low current inputs to controller
      • Eliminated many wire crimping termination's, simplified wiring interface, and greatly reduced assembly time
      • All six boxes can be effected with one design, both hardware and software
      • A productionized circuit board for this product should measure roughly 3" x 4" (depends on added complexity)
      • A BS2 Basic Stamp Module can be quickly exchanged for the BS1 by routing necessary control signals to appropriate places, then re-programmed with software easily converted from the BS1
      • Possible primary building block for future products (other processor choices exist)
  • Converted the BS1 core function software for all six control panels to BS2 software and tested with a BS2 Basic Stamp Module bread boarded component by component (similar to the BS1 core function testing).
  • Jan-2005, Prototyped / Programmed a BS2 Basic Stamp Module to interface with a KP56LM2 Stepper Motor to perform forward and backward rotation of the motor.  The motor is a 6 VDC motor, but is being supplied with 5 VDC from a PC power supply.  Circuitry was bread boarded one winding at a time (4 total) through 4 switches based on the quick reference sheet provided with the unit.  Once the proper sequence of the four windings was determined, four independent circuits were built up and tested that could be controlled by the BS2.  Finally, a quick program was written and tested, per the following link Stepper Motor Test Program .  Following is a basic schematic of the stepper circuit Stepper Schematic .  Also linked is a torque vs. rpm curve for a similar stepper motor Stepper Torque vs Rpm .
  • Jun-2005, Had Built, Modified, Interfaced, Programmed, Tested a prototype XYZ table to perform certain machining operations.  The CNC machine was put together from plans purchased off the internet and modified for my application.  The machine has increased accuracy and production capability.  I wrote a macro that accesses a spreadsheet I customized to speed the programming of the G Code for the controlling of the table.  This eliminates error prone typing and data entry while also allowing for very quick and accurate programming changes on the fly when desired.  The following link is an example of the G Code program the macro spits out G_Code_Example .  Inside the customized spreadsheet I allow for many variables, while the macro accommodates issues found initially for controlling the stepper motors with one of the control programs.  Much has been learned through experimentation with the machine, while modifications have been required here and there for increased performance.  The programming has been enhanced several times over what's been linked above.  Various demo control programs have been investigated, one of the following snapshots of which is currently being used (Sep 2006) for controlling the table Demo Software Screen Shots .  One DOS version has been used only a little (since the programming structure differs from the two program screen shots linked above).  Fixture offsetting and backlash compensation have been experimented with.  I've used the machine to engrave simple and Complex Lettering on some scrap wood.
  • Apr-2006, Designed, Built, Programmed, Tested a prototype timer module using parts, designs and concepts from earlier prototypes.  A Basic Stamp 1 was used for this function.  A proto circuit board was populated with components chosen similarly from earlier proto designs, while software written from an earlier proto was modified to help turn this more quickly.  This module allows the pumping of a motor for times related to the setting of a dip switch accessible to the user.  30 second increments from 0 up to 15 minutes have been allowed.  Preliminary accuracy measurements are +/- 2 seconds in a fifteen minute timing interval.  The motor being controlled is a 120VAC 5 Amp capacity motor (roughly).  The whole project fits inside an aluminum enclosure ~ 4.5" x 4.5" x 2.25".  The following links are Pictures of the Proto Timer and Dip Switch Settings.  The operation and function can be varied greatly. 
    • Phase 2 - a key switch was added as extra control for a store manager.  The switch provides low voltage power to the box as well as input to the controller.  The software has been improved to provide tighter response and more features were added.  The unit was burned in for appr. 1000 cycles before shipment.
  • Prototyped an automatic fish feeder using common household items.  The project uses a Basic Stamp 2 currently.  Software turns an output on that drives a DC Motor for some specified time interval every 4-6 hours.  PWM control was experimented with.  Life cycle testing resulted in over 250,000 cycles (.5 sec on, 1.5 sec off).
  • Built and experimented with a mini Tesla coil kit.  The operating frequency is around 35 - 40 KHz.  When a spark is drawn from the output (roughly 1/4" to 1/2") nearby electronics are affected.  Working (and burned out) fluorescent bulbs could be brought to some luminance with this low power coil.  It is setup currently to run on 2 9V batteries in series.  This kit is a modification of a Tesla coil using readily available modern components.
  • Feb-2006, Built a Prototype control panel to interface with an ultrasonic sensing device having two NPN outputs for level detection.  Because the sensor needs 12 - 24 VDC a control panel was setup to work primarily on 12 VDC.  Lights are LED's, relays are coiled at 12 VDC, and an inexpensive power supply are now the main components.  A simple transistor circuit was designed/built to provide an inversion for the proper operation of a light, thus eliminating the use of a relay (a simple test circuit was setup that placed 500,000 cycles on this circuit and support system interface).  The demo unit is plug and play alongside the original.
  • Jan-2007, Wrote a Visual Basic program to test students on their US States and Capitals .  Future configuration changes include but are not limited to:  the use of other data sets, data logging with time stamping, running average, live forward/backward scroll through test, graphical map representation, etc..
  • Aug-2007, Built a Prototype control panel using a wireless control system to remotely activate a time delay relay for opening a valve for a  pre-selected period of time.  The time delay relay is a multifunction device that can be wired for varying operational conditions.  Both wired (like keypad entry) and wireless approaches were investigated to accomplish the objective.
  • October-2007, Re-Wrote a Visual Basic program to test students on various subjects.  This is an expansion of what I did earlier.  During this re-write, a testing algorithm was implemented using a macro as the test vehicle to insure that no duplicates were generated in the choices section.  Features include:  different tests can be easily loaded, made and combined; test results are data logged and time stamped to a unique file name so that progress can be viewed over time; forward/backward scroll through test after completion.  The test files below contain:  Multiple Choice Test program with Make Test and Combine Tests button(s), directories, and sample tests.  The following link is a snapshot of a test in progress.  The program provided is as-is, and can be used for a variety of subjects and age brackets.  These *.DLL's may be necessary to place in either your "c:\windows" or "c:\windows\system" or "c:\windows\system32" directory for the program to run.  New tests created will have an exact file format ( refer to sample test ), and will be saved with *.csv extension.  Currently, test length has a range from 6 up to 300 (the upper limit may be more related to the amount of memory on each system and the availability of that memory during run time).  
    • The following zips are the progression of development of the executables:
      •     Added more functionality (ie. Make Test, Combine Tests, auto answer, scroll back through test after completion, entire test now saved in results file, re-formatted to allow run on 800 x 600 screen)
      •     Added the ability to load new test after one was completed without closing down then re-opening the program, miscellaneous enhancements
      • MultipleChoiceTest_R010608.rar     Scroll wraps around, seconds removed from display, added ReadMe button, tweaked response time, miscellaneous enhancements
      • MultipleChoiceTest_R062910.rar     Some screen layout is user selectable, taking test more automated with more visual and audible feedback, test in progress can be saved (next update will allow loading of saved tests)
  • December-2007, Interfaced with a unique compiler for use on a PIC16xxxx microprocessor.  A different processor approach over the BASIC Stamps used earlier is the investigation.  A simple testing program compiled and simulated using a ladder interface, loaded and ran on the breadboarded target processor very quickly.  The current test program runs two outputs opposite each other.
  • Early 2008, Interfaced an Omron Zen programmable relay to function with an ultrasonic sensor to mimic current tank configurations.  The Zen uses ladder logic for it's programming (up to ~100 rungs).

Zen Controller