(Click the photo to e-mail me)
Okay, so this is an OLD photo...

Engines and controls have changed a lot since this overcarbureted sled made its "T" run... Or HAVE they?? From "Crate Motors" to one-offs, it's still air, fuel, and ignition- now with emissions. Let's see what OEM-quality test gear and knowledge can do for YOUR project. "Home" is Flint, Michigan, but don't let that keep us apart.
Résumé of: David C. Kopin (Powertrain Development / Calibration Engineer)
P.O. Box 597 Flint, MI 48501-0597 (810) 736-8885 < davekopin@aol.com >

Objective: Application Engineer in the field of Powertrain development, calibration, and validation. Although experience is 80% on gasoline engines, I am strongly interested in Common-rail Diesel and/or Hybrid.

Skill Set Includes, but is not limited to the following areas :
Powertrain calibration, testing, and validation (OEM and/or Aftermarket)
Instrumentation (car and dyno cell), data acquisition, analysis and reporting of results
Emission testing (gasoline and diesel) - from "modal" (development) through certification
Driveability development and validation trips in hot / cold / Altitude conditions
Fuel Injection and exhaust aftertreatment systems and components.
Marine/Industrial/Specialty engine controllers (BigStuff, Delphi’s MEFI and other brands)

Education: BSE from GMI 1970 (Mechanical / Materials Science)
MSE University of Michigan, 1976 (Industrial & Operations Engineering)
PE (Ret.) Michigan 1978 (scored 97 & 90 on parts 1 and 2, respectively)
SAE Member – Steward for Monroe College Formula SAE team 2003 and 2004.

Best Career Achievements:
- Invented catalytic converter rapid aging process that is used at several manufacturers worldwide today (2000 hours reduced to <=100 hours).
- Originated new methods of testing O2S (exhaust oxygen sensors)... Developed special engine setup and control, data acquisition items & rate, new data analysis methods.
- Achieved "Impossible" EPA approval for carry–across of durability data from carbureted durability vehicles to TBI engines, saving millions of dollars and many months of program time. "Conventional wisdom" of that era held that such approval was impossible.

Experience / Employment History (Last Update 01 Dec 2004)

Post "Retirement" : Contract Engineer.
- Worked with "Big Stuff" brand Aftermarket Engine/trans Controller (1000+ hp).
- Worked with ETAS/SAM2000 calibration tools (2005 OEM program).
- Served as a Team Steward in the 2003 and 2004 "Formula SAE" competitions).
- Calibrated two niche-market 500 hp "Crate Engine" packages ("MEFI" marine engine controller). Supported dealerships and end-customers. Received spontaneous awards for diligence and recapture of timelines. One program made the cover of HotRod Magazine.
- Managed and supported offsite work at suppliers and OEM specialty departments.
- Worked on several supercharged packages (typically using Magnuson hardware).
- Attend SAE, SEMA, and PRI events to maintain contacts and knowledge of the business.
- Monitor some CARB newsletters, trade publications.

June 1992 until early "retirement" in 1999 to address elder care and family issues : Supported Product improvement and New-Test development for Exhaust Sensors and catalysts. Learned fuel injectors, including Piezo-concept. Invented new methods of testing and analyzing traditional O2S, and "wide range" (UEGO) sensors. Participated in design, build, and commissioning of a new sensor-test facility. Results were factored into USCAR standards.

May 1990-May 1992: Was main interface between lab and product teams for joint venture with Russian car company. Wrote and taught a course in emissions to the client. Coordinated engineers in more than one state. European homologation was part of the responsibility.

Oct 1987-April 1990: Special assignment in AC’s new "Engine Management Systems Center" at GM’s Milford Proving Ground. This was a high-paced, intense organization aimed at producing a center of expertise rivaled by none.
The EMSC provided direct support to GM and Saturn Powertrain calibration and systems groups (Chevy Truck "CPI" fuel injection for the L35 engine was my focus). EMSC’s merging of several disparate GM divisions was a precursor to the formation of Delphi, bringing together the best engineers from formerly independent GM divisions in Michigan, Indiana, and New York. Math models for controls and system components were developed there, too. The job touched injectors, airmeters, EGR valves, crankcase ventilation systems, evaporative emission systems, electronic throttle development, ignition systems, spark plugs, transmissions, traction control… virtually every part of a powertrain control system and their interactions (as well as proper measurement techniques). The privilege of being there gave rare and comprehensive experience in hardware design, variability reduction, extreme weather test, emissions test, dyno test, instrumentation, accelerated testing, and government certification… In a compressed time frame. Trips to GM Proving Ground and Emission facilities in Michigan, Arizona, Colorado, New York, and Canada gave unique appreciation for how theory and laboratory work perform in the real world. Was instituting FMEA and RPN (Risk/Priority Number) methodology at the end of this assignment.

September 1985 to September 1987: Supervisor… Managed group of engineers and technicians responsible for test development, site integrity, data integrity, engine build, and procedure control. Upgraded site documentation and worker’s attitude/productivity, eliminating downtime on 60 dynamometers via higher-quality, pre-built, test setups. Developed hardware and methodology for rapidly aging catalytic converters. The new test accelerated the process from thousand(s) of hours to about three days, saving time, money, and (accident/failure-caused) loss of high-hour samples. Subsequent versions of this test are still used today, and have been accepted by the EPA and CARB as an alternative to running actual durability vehicles.

November 1983 to August 1985: Managed the Vehicle Emission Lab at AC. Earned credibility for that lab’s numbers by establishing low cost lab-to-lab correlation practices and initiating SPC-like internal controls, using VisiCalc spreadsheets on my own Apple][. Further improved the lab’s repeatability by personally re-vitalizing the air handling system, then working with union personnel to get appropriate understanding of reasons for, and scheduling of, preventative maintenance. Adapted leftover equipment and AC products to build better-behaved facilities and easy-to-use quick-check devices for daily quality control practices.

September-October 1983: Worked at Opel PEK (Engineering Center) in Russelsheim, Germany. The purpose was to get autobahn durability data for upcoming catalytic converter application on Opels. The (successful) mission was to work with Opel engineers and technicians to instrument the fleet, using analog tape recorders to capture temperature and engine data while underway, and get past safe shipping of, and reading of, those tapes "back home". Wife and age-9 daughter accompanied, and "school" was held in the hotel room.

July 1981 – August 1983: Test Engineer in AC’s dyno lab, doing competitive engine analysis, FTP emission testing with dyno-mounted engines, multi-bank A/F control, and combustion studies. Learned to see engines in terms of micro-events within cylinder events within overall firing order sequences within vehicles within regulatory requirements. With the collaboration of one very interested tech, eliminated Mainframe computer dependency and got real-time data.

May 1976 - June 1981: Emission Cert @ Milford PG. Completed MSE degree, became a PE. Senior Project Eng’r, Closed-Loop Catalyst Selection fleet. Learned the development side of the powertrain process. Generated vehicle calibrations, did special studies, and correlated vehicle data to catalytic converter design features and noble-metal loadings.

August 1965- April 1976: Buick Motor Division… Co-Op student, Metallurgist, Process Engineer. Assignments covered all areas of Buick’s home, from customer service formletters to the underground pits of the Forge&Spring, foundry, laboratory, machining and assembly plants.