Expert Details

Expert in Automated Machinery, Machinery Design, Mechatronic Design, Automation, Motion Control Systems

Expert ID: 727429 Wisconsin, USA

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A Registered Professional Engineer, Expert has more than 35 years of experience in engineering designs and solutions. Expert has extensive experience in automated equipment. As president of Klover Products, he oversees the development of products for the broadcast industry and beyond. As president of Innalytical Solutions, he focuses on consulting service relating to industrial equipment. Expert has been awarded 12 U.S. patents for industrial equipment, manufacturing processes, and broadcast equipment. His designs have been used by many major manufacturers, including GM, GE, Ford, Rolls Royce and Caterpillar. These designs have been featured in Machine Design, Design News, Automotive News, Production and HD Pro Guide magazines. Expert has served as an expert witness on multiple cases as well as provided forensic engineering services. He is an experienced report writer, a certified SolidWorks Professional, and certified in fire investigation.

He acted as Engineering Manager for a small special machine builder while they searched for a full-time employee. During this time he implemented a PDM system for the CAD users. He also provided trouble-shooting services and developed proposal concepts for this builder of automated test-stands.He completed the mechanical design for two assembly and test systems for gas struts used in the off-road vehicle industry. He also developed and programmed the motion control system for these two systems.He designed several LEAN assembly cells for a small system integrator.He replaced the entire control system of two CNC plasma cutter / punch press machines. The first was custom built and the control components were no longer supported. The second was updated to be fully compatible with the first. Both machines required the ability to work with the existing CAM post-processor and utilize existing part programs.He developed a spreadsheet that estimated cycle time for CNC cutting / routing machines that generated cutting time estimates based on the HTML code used to operate the machine. He also developed a new, more flexible control system for the cutting machine.

Expert may consult nationally and internationally, and is also local to the following cities: Chicago, Illinois - Rockford, Illinois - Aurora, Illinois - Naperville, Illinois - Joliet, Illinois - Elgin, Illinois - Waukegan, Illinois - Milwaukee, Wisconsin - Madison, Wisconsin - Kenosha, Wisconsin

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Year Degree Subject Institution
Year: 1983 Degree: BS Subject: Mechanical Engineering Institution: Iowa State University
Year: 1999 Degree: Advanced Technical Certificate Subject: Reliability & Maintainability Institution: Blackhawk Technical College
Year: 2001 Degree: MA Subject: Management Institution: Regent University

Work History

Years Employer Title Department Responsibilities
Years: 2017 to Present Employer: Undisclosed Title: Co-Founder Department: Responsibilities: Provides drive-through automatic brake inspection systems used in fleet management, inspection screening, eDVIR, and autonomous vehicles and platooning.
Years: 2012 to Present Employer: Undisclosed Title: President Department: Responsibilities: Was incorporated jointly with an Innalytical Solutions customer to produce unique products for the television broadcast industry. Our first product was the parabolic microphone designed at the request of Fox Sports. We have expanded that product line to three different sizes. These parabolic microphones have been used to broadcast the Super Bowl, World Series, MLB All-Star game, NBA All-Star game, and the NCAA men’s basketball tournament. Klover Products’ second product line is a system of removing moisture and debris from video camera lenses. •
2014 - Created the “Sound Shark Audio” division to expand the parabolic microphone products into the consumer market.
Years: 2004 to Present Employer: Undisclosed Title: President Department: Responsibilities: Providing engineering consulting services to a wide variety of customers including acting as an expert witness in legal matters.
2009 to 2018 - Operated the “Machine Doctors” division to focus on the machinery service area such as troubleshooting, upgrades, and retrofits.
2011 to 2016 - Operated the “Investigative Engineers of Southern Wisconsin” division to focus on forensic engineering services.
Significant projects include:
• Mechanical design of a spacer transport system and gas fill station for an automated assembly system of glass units (dual pane residential window panels)
• Mechanical design of a series of assembly cart for LEAN assembly of tractor axles
• Design of parabolic microphone that began Klover Products
• Mechanical and electrical design, programming, and project management of a tire assembly system for off-highway construction equipment
• Mechanical design, electrical design and programming of two gas strut assembly systems for off-highway dump trucks
• Mechanical and electrical design of an autonomous servo driven mobile television stage – the lift arms from this design were used to lift the roof of the broadcast stage for Super Bowl 47 Expertgame, half time, and post-game shows
• Finite Element Analysis of the roof and roof rack for an automobile-mounted sensor used for laser-driven terrain measurements
• Mechanical design of robotic assembly and packaging system for injection molded plastic parts for the second-tier supplier to the automotive industry
• Replaced the entire CNC control system of two custom built punch press/plasma cutters – larger one capable of stamping and cutting ½” x 4’ x 10’ plate
Years: 2003 to 2004 Employer: Gilman Engineering & Manufacturing Title: Senior R&D Engineer Department: Responsibilities: The entire R&D Department was eliminated due to budget cuts in May of 2003
A patent application was filed for a unique assembly process for clutch plate assemblies
Years: 2001 to 2003 Employer: Gilman Engineering & Manufacturing Title: Director of Research & Development Department: Responsibilities: Responsible for setting the direction of R&D efforts and overseeing those efforts
Responsible for new ancillary modules for the IntelliMove and all servo applications utilized within the SDST diesel fuel injector project
Created two patentable concepts for completing final function tests of rack & pinion steering gears – a patent application has been made for the first of these concepts
Created an adjustable height workstation for LEAN assembly systems which was patented
Years: 1997 to 2001 Employer: Gilman Engineering & Manufacturing Title: Manager of Research & Development Department: Responsibilities: Created two programmable part-handling devices - A patent has been granted for one of these devices called IntelliMove.
Created a unique light duty conveyor system
Created and managed R&D projects for cost reduction and standardization
Prepared proposal and assisted in the sale of a unique fully-automated assembly system for SDST diesel fuel injectors that utilized 80 programmable part-handling devices
Years: 1995 to 1997 Employer: Gilman Engineering & Manufacturing Title: Senior Application Engineer Department: Responsibilities: Prepared proposals and assisted in the sale of assembly systems as large as $40,000,000. Generated sales of over $67,000,000.
Designed and implemented six vision inspection stations for a large assembly project
Created a simplified part inverting mechanism which was patented
Years: 1991 to 1995 Employer: Gilman Engineering & Manufacturing Title: Senior R&D Engineer Department: Responsibilities: Applicated, estimated and sold SmartConveyor transport systems
Project manager for first SmartConveyor transport systems
Controls project engineer for second SmartConveyor systems
Developed control system for SmartConveyor (CAN-bus I/O)
Implemented one of the first real-world Device-Net control systems
Applicated, sold, designed large gantry robot system
Simulated assembly systems using "Witness" software
Designed six-axis (Steward Platform) robot for assembly of automobile transmission component. (The system was modeled in 3D solid geometry using CATIA software.) A patent has been granted for this six-axis robot
Years: 1988 to 1990 Employer: Gilman Engineering & Manufacturing Title: R&D Engineer Department: Responsibilities: Responsible for all control work in R&D (Allen-Bradley, Modicon and GE PLC's)
Created a simulation package for assembly systems (Approximately 6000 lines of “C” code)
Developed new heavy-duty transport system called SmartConveyor
Received two patents on the SmartConveyor
The SmartConveyor design has been featured in Design News, Machine Design, Production, and Automotive News magazines
Years: 1986 to 1988 Employer: Gilman Engineering & Manufacturing Title: Senior Design Engineer Department: Responsibilities: Acted as lead designer and unofficial Project Manager for several large projects including Drill & Mill system for GM APV mini-van and robotic instrument panel assembly system
Years: 1985 to 1986 Employer: Gilman Engineering & Manufacturing Title: Mechanical Design Engineer Department: Responsibilities: Responsible for debugging of several systems
First mechanical designer to use the CAD system (IBM-CADAM)
Years: 1983 to 1984 Employer: AMF-Potter & Brumfield Title: Development Engineer Department: Responsibilities: Designed and implemented a robotic test system
Responsible for debugging of purchased automated equipment
Responsible for all control work on Modicon PLC’s
Years: 1980 to 1983 Employer: Fisher Controls Title: Cooperative Engineer Department: Responsibilities: Gained hands-on assembly and machine shop experience
Implemented a new machining process & developed control valve linkage.

Career Accomplishments

Associations / Societies
He was formerly a member of Mensa and SME.
Licenses / Certifications
He is a licensed Professional Engineer in the state of Wisconsin and Illinois.
Awards / Recognition
His designs have been featured in Design News, Machine Design, Production, and Automotive News magazines.
One of his designs was nominated for Wisconsin Society of Professional Engineer's New Product Award, and the USA Today Quality Cup. This design was also a finalist for the Automotive News PACE award for innovation in the automotive industry.
Publications and Patents Summary
He has been awarded 12 US patents and 3 foreign patents related to automated equipment. He has also been awarded a U.S. patent pertaining to parabolic microphones.
2 more patent applications undergoing currently.

Additional Experience

Expert Witness Experience
In 2004, he was deposed during arbitration between his former employer and a customer. Having been the Director of Research & Development during the development of the assembly system in dispute he was questioned about the product development process and the associated testing process for a product that was used extensively in the construction of the assembly system at issue in the arbitration.

He provided an expert opinion report, in 2011, to the owner of a machine shop related to the potential of a thunder storm causing damage to a computer numeric controlled (CNC) machine tool. This report was used in negotiations with his insurance company.

In 2013, he provided an expert opinion report for litigation between two manufacturing companies. The case related to a patent infringement concerning a food packaging machine and in particular how stress was carried through the frame of that machine. The case was settled before the deposition was to occur.

He provided an expert opinion report, in 2014, for litigation between a Technical College and a supplier. The case related to the ability of the driver simulation (training) system provided by the supplier to meet expected levels of performance and reliability. The case was settled before the deposition was to occur.

In 2015, he was deposed for a case in the Court of Chancery of the State of Delaware concerning breach of contract and the use of trade secrets. He later testified in the Court of Chancery of the State of Delaware with regard to the same case. The technical portion of the case, which he addressed, involved the improper use of SolidWorks CAD models by the defendant.

He provided an expert opinion report, in 2016, for litigation between a manufacturing company and a supplier. The case related to the ability of the steel cutting system provided by the supplier to meet expected levels of performance and reliability. The case was settled before the deposition was to occur.

In 2017 he provided analysis of an industrial machine that was involved in a fatal industrial accident. No case resulted from the analysis.

He has also completed more than a dozen forensic engineering cases. Of these cases, two have required a formal written report.
Training / Seminars
He developed and conducted training programs for automation products developed for use in industrial settings.

He also presented a seminar on effective use of the SolidWorks animation in machine design to SolidWorks user groups.
Vendor Selection
He has located and / or developed sources for components and sub-systems for use within larger systems over the length of his professional career. He has worked with suppliers to develop new products to meet his specific needs.
Marketing Experience
He has been involved in the special machine industry for over thirty years with experience in a broad array of technologies.
Other Relevant Experience
He has developed his problem solving skills in order to apply them to the troubleshooting of industrial machinery. He has also developed in-depth knowledge and experience in the combination of mechanical and control technologies to optimize the design of automated machinery.

Fields of Expertise

patent infringement, expert witness, test equipment, production equipment, manufacturing equipment, heavy equipment manufacturing, equipment manufacturer, equipment safety, equipment design, equipment failure, automatic handling equipment, plant and machinery, machinery specialist, large machinery, Mathcad, mechatronics, assembly, process machinery, controller tuning, stress modeling, capital equipment, Microsoft Office software, man-machine interface, conveying system, automatic handling, numerical control machine, servocontrol, welding machinery, robot arm, mechanical equipment analysis, computer-aided design software, mechanical component, mechanical design automation, robotic end-of-arm tool, solid modeling, machine switch, electrical machinery modeling, electrical machinery maintenance, electrical machinery repairing, electrical machinery, electric machine, mechanical product reliability improvement, ball screw, finite element modeling, mechanical system simulation software, machine capability study, design for cost, control system design, automated manufacturing, computer-aided optimum design, machine condition evaluation, machinery selection, electrical-mechanical accident, forensic engineering, machine mechanical condition analysis, machine diagnostics, control equipment, design for manufacturability, mechanical power transmission, machine-tool control, design optimization, computer simulation, mechanical device design, engineering design productivity, electromechanical actuator, electromechanical device, automatic control, fluidic control system, machine element, mechanical system, equipment, machine, power shaft, computer numerical control, servovalve, robot programming, project management, mechanical fastener, mechanical engineering, mechanical drive, manufacturing, machinery maintenance, machine vision, industrial process, finite element analysis, failure analysis, digital numerical control, Cosmos software, control system

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