Selected Projects
Bridging the gap between OT and IT. A collection of industrial automation, IIoT, and embedded systems engineering projects.
Hybrid Edge-Cloud Architecture
ExactCure: Mission-Critical Control for Precast Concrete
Architected and deployed "ExactCure V4", a control system balancing cloud analytics with absolute local reliability. Designed a Hybrid Edge Architecture combining an ABB PLC with an Industrial Raspberry Pi.
Challenge
Operations faced the "Connectivity Trap" where internet outages stopped curing cycles, and rigid legacy controllers required rewriting logic for every new plant layout.
Solution
Implemented a Split-Plane MQTT Architecture. The local ABB PLC and Edge Node handle critical control loops autonomously, while buffering data for AWS IoT Core.
Impact
Achieved 100% local uptime with Zero Data Loss. Scaled deployment to multiple plants using software-defined configuration files instead of hard-coded logic.
High-Performance Edge Gateway
639 Solar: SNMP-to-MQTT Bridge for Datacenters
Engineered a production-grade edge gateway to integrate legacy Sentry PDUs with a modern Ignition SCADA system via MQTT, reducing latency from minutes to sub-seconds.
Challenge
Bridging the protocol gap between synchronous, polling-based SNMP v2c devices and a real-time Unified Namespace (UNS) architecture without blocking operations.
Solution
Built an Asyncio Python gateway that fires parallel SNMP requests and publishes normalized JSON payloads to MQTT. Includes intelligent aggregation for daisy-chained units.
Impact
Unified legacy PDU data with modern solar telemetry in a single pane of glass. Enabled reactive alarming via UDP Trap listening.
Industrial Protocol Normalization
WAGO IIoT Gateway: Unifying Field Operations
Designed a "Local Brain" using a WAGO PFC200 to normalize heterogeneous field signals (Analog, RS-485, Digital) into a standardized Modbus TCP interface for SCADA/BMS.
Challenge
Managing a "Babel Tower" of field devices (4-20mA, Modbus RTU, Discrete) created signal chaos and bus collisions on a single RS-485 line.
Solution
Implemented a deterministic State Machine Sequencer in CODESYS to orchestrate polling. Created a self-diagnosing interface that reports signal health alongside values.
Impact
Reduced troubleshooting time by 80% by pinpointing sensor faults (e.g., "Wire Break") directly in the SCADA tag registers.
Safety Systems Engineering
Mitsubishi PLC Rescue: Refactoring Obfuscated Logic
Performed a complete reverse engineering and clean rewrite of a obfuscated OEM codebase for an imported manufacturing machine to meet local safety compliance.
Challenge
The original "Black Box" code was intentionally obfuscated and unsafe. Adding required safety interlocks to such fragile logic posed a severe risk.
Solution
Traced electrical schematics to map I/O and rewrote the logic using a clean State Machine architecture. Separated Safety logic from Process logic.
Impact
Achieved full safety compliance and vendor independence. The client now owns a documented, maintainable codebase.
Secure Remote Control
Secure Edge Gateway: Bi-Directional PLC-to-Cloud
Engineered a lightweight Node-RED gateway to bridge critical process PLCs with cloud SCADA. Implemented secure bi-directional control with Store-and-Forward capabilities.
Challenge
Enabling remote control over the internet without exposing the PLC to security risks, while handling frequent network micro-outages.
Solution
Deployed a Node-RED gateway acting as a secure proxy. Implemented a local SQLite buffer to cache data during outages and burst-sync upon reconnection.
Impact
100% Data Completeness in historic charts and secure, operational agility for remote plant managers.
Precision Process Control
Hatchery Fogger: Simulation-First PLC Workflow
Designed a turnkey disinfection control system for poultry hatcheries using a "Simulation-First" approach to validate logic before hardware deployment.
Challenge
Biosecurity demands extreme precision. Over-dosing kills embryos; under-dosing causes contamination. Standard PWM was insufficient for low-flow pumps.
Solution
Developed a custom Pulse Frequency Modulation (PFM) block on an Arduino Opta (PLC) for linear dosing. Validated 100% of logic via a Python Digital Twin.
Impact
Day 1 deployment was 99% bug-free. The system ensures consistent disinfection cycles with verifiable audit trails.
Robotic Fleet Management
OperaPrima: From Isolated Machines to Cloud Intelligence
Transformed a fleet of standalone robotic pizza machines into a centrally managed IoT ecosystem with real-time telemetry and AI-driven insights.
Project Gallery
Challenge
Machines operated as islands with no visibility into errors or performance. Updates required physical visits, and data was overwritten locally.
Solution
Built a bridge using Weintek HMIs to transmit MQTT data to a Next.js/Supabase cloud. Implemented Row Level Security (RLS) for multi-tenancy.
Impact
Drastically reduced support costs via remote diagnostics and enabled data-driven R&D for future machine iterations.
Open Source Industrial Runtime
ZPLC: Industrial Control on Commodity Hardware
Designed and built ZPLC, an open-source PLC runtime that transforms cheap microcontrollers (ESP32, STM32) into deterministic industrial controllers.
Challenge
Bridging the gap between the reliability of expensive proprietary PLCs and the flexibility of modern open-source hardware.
Solution
Architected a deterministic Virtual Machine on Zephyr RTOS with a Hardware Abstraction Layer (HAL). Includes a web-based IDE for structured text.
Impact
Democratizes industrial control for SMEs and enables rapid prototyping with a modern, developer-friendly workflow.
High-Performance Driver Development
S7Plus Connector: Native TLS 1.3 for Siemens PLCs
Developed a C++ industrial driver for SIA Connect to communicate natively with modern Siemens S7-1500 PLCs using the encrypted S7CommPlus protocol.
Challenge
Modern Siemens PLCs use non-standard TLS tunneling over COTP. Standard libraries fail to connect, forcing insecure "PUT/GET" workarounds.
Solution
Engineered a custom OpenSSL Memory BIO implementation to wrap TLS 1.3 frames inside ISO-on-TCP packets. Built a symbolic addressing engine.
Impact
Enables secure, high-performance data extraction from Protection Level 3/4 PLCs without compromising plant security policies.
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