Hari — Controls Engineer
Hari
Industries Served
Languages
Will Work
Eligibility
Work History on Automate America
Programming Skills (6)
Programmed and optimized ladder logic, function blocks, and structured text in STEP 7 for S7-300/400 PLCs, ensuring efficient and reliable process control. Performed system upgrades and migration from older S7-300/400 models to newer S7-1500 controllers, implementing best practices for minimal downtime and improved functionality. Developed scalable control programs in TIA Portal for S7-1200 and S7-1500 PLCs, using modular programming structures to enhance code readability and maintainability. Designed custom HMI screens in WinCC for real-time data monitoring and control, prioritizing intuitive layouts and alarm management to support operators. Implemented SCADA solutions with WinCC for multi-site monitoring and control, enabling centralized supervision and efficient data logging. Configured Profinet and Profibus networks for seamless communication between Siemens PLCs, HMIs, and third-party devices, ensuring data integrity across distributed systems. Troubleshot and optimized network performance, resolving issues with device connectivity, addressing, and data exchange in complex setups. Integrated Siemens PLCs with various field devices, ensuring proper configuration and signal validation across inputs, outputs, and communication interfaces.
Developed and troubleshot ladder logic programs for SLC 500 series controllers using RS Logix 500, focusing on optimizing logic for system efficiency and reliability. Utilized advanced features such as Add-On Instructions (AOIs) and User-Defined Data Types (UDTs) for reusability and standardization across projects. Conducted testing and validation for ControlLogix applications to ensure robust performance under industrial conditions. Created intuitive HMI interfaces with FactoryTalk View for PanelView Plus and other HMI devices, focusing on operator-friendly layouts for monitoring and control. Configured RS Linx for efficient communication setup between PLCs, HMIs, and SCADA systems, ensuring reliable data flow across industrial networks. Applied control strategies across various Allen Bradley platforms to improve process efficiency, reduce downtime, and enhance system robustness.
Utilized HandlingTool software for configuring and controlling Fanuc robots in complex handling applications, ensuring safe and productive operations. Conducted offline programming and simulation with ROBOGUIDE, verifying robotic paths and cycle times to reduce shop floor downtime. Conducted thorough testing and troubleshooting to ensure consistent connectivity and performance in robotic operations. Executed preventive maintenance to extend the longevity and reliability of Fanuc systems, minimizing downtime.
Programmed and optimized control logic for Omron CJ and CP series PLCs, applying ladder logic and function blocks for diverse automation processes. Configured scalable systems with these PLCs, ensuring flexible expansion for complex manufacturing operations. Developed advanced automation solutions using the Sysmac Studio software with NX and NJ series PLCs, which combine motion, safety, and logic control. Implemented high-speed motion control and synchronized machine operations, optimizing processes for improved efficiency and accuracy. Configured communication using Omron's proprietary FINS protocol as well as Ethernet/IP, Modbus TCP/IP, and Profibus, ensuring efficient data exchange across diverse systems. Integrated Omron PLCs with SCADA and MES systems for real-time data monitoring, increasing operational visibility.
Configured and optimized PowerOn Reliance for real-time monitoring and control of distribution networks, enhancing situational awareness for utility operators. Set up advanced network models that enable accurate load forecasting, outage management, and grid reliability. Integrated PowerOn Reliance with OMS to enable rapid fault location, isolation, and restoration (FLISR) during outages, reducing downtime and improving service reliability. Set up secure access controls and encryption within PowerOn Reliance, ensuring compliance with regulatory standards and safeguarding critical infrastructure. Conducted periodic system audits and vulnerability assessments, protecting SCADA and network integrity.
About Me
Controls Engineer with over 6 years of extensive experience in designing, programming, and optimizing advanced automation and control systems across diverse industries. Proficient in PLC programming with Siemens, Allen-Bradley, and other leading brands, complemented by a solid understanding of SCADA and HMI technologies. Demonstrated expertise in developing robust control logic, integrating complex systems, and enhancing operational efficiency through innovative solutions. Skilled in a variety of programming languages including C/C++, Python, and SQL, enabling seamless data acquisition and process automation. Adept at troubleshooting and resolving complex control issues while ensuring compliance with industry standards. Strong collaboration skills foster productive teamwork and project management, leading to timely and successful project delivery. Committed to leveraging technical expertise to drive continuous improvement and deliver high-quality automation solutions.
Professional Competencies (16)
Applications (8)
My Business
Why Choose Me
<p>I bring not only deep technical expertise but a genuine commitment to understanding and meeting their unique needs. With over five years in engineering, quality, and automation, I've gained hands-on experience across multiple industries. My approach is collaborative I work alongside clients to ensure that solutions aren't just technically sound but also practical and impactful for their business goals.</p> <p>I'm driven by integrity, accountability, and a passion for continuous learning, always aiming to go above and beyond to deliver results. For me, success means making sure my clients feel supported, understood, and confident in the solutions we build together.</p>
Work Experience(3)
Developed and programmed PLCs using Siemens TIA Portal and Allen-Bradley Studio 5000, creating robust control logic for hydrogen-powered systems and ensuring seamless integration with SCADA architecture. Designed and configured HMI interfaces using Siemens WinCC and FactoryTalk View for Allen-Bradley systems, providing real-time monitoring and control of hydrogen production, storage, and energy conversion processes. Extended SCADA system applications with custom C++ modules, using Visual Studio to create plugins and interfaces for additional data processing, advanced analytics, and customized control features. Developed and executed Hardware-in-the-Loop (HIL) simulations using dSPACE and MATLAB/Simulink to validate control algorithms for hydrogen-powered systems, ensuring accurate emulation of system components in real-time. Utilized Opal-RT for fault injection testing within HIL environments, assessing system responses to various failure scenarios to enhance reliability & robustness of hydrogen storage & energy conversion processes. Utilized C++ for enhancing SCADA functionality, developing extensions that integrate with existing HMI/SCADA platforms to automate complex data processing tasks and provide real-time analytics for operational optimization. Programmed OITs to display real-time data for critical energy parameters, including voltage, current, power factor, and load demand, enhancing operator situational awareness. Optimized control algorithms in PLC programs to enhance response times and ensure efficient operation of automated systems, working closely with cross-functional teams to meet project requirements. Created detailed electrical schematics and layouts using CAD software, ensuring accuracy in wiring and component placement for complex projects. Analyzed & optimized electrical circuits through CAD tools, enhancing system reliability and efficiency. Developed reusable PLC function blocks to standardize control logic, ensuring consistency across projects and simplifying future modifications or expansions. Integrated OPC UA and MQTT protocols for seamless communication between control systems and enterprise applications, ensuring connectivity across various industrial devices. Used MATLAB/Simulink for control system modelling & rapid prototyping. Collaborated with cross-functional teams, using tools like AutoCAD Electrical for panel design review and JIRA for project management, ensuring smooth communication between Siemens and Allen-Bradley systems and optimizing control strategies. Configured FactoryTalk View SE and Wonderware HMI interfaces, providing robust visualization and monitoring of hydrogen production and storage processes. Integrated IEC 61850 MMS protocols using Siemens SICAM PAS and Allen-Bradley communication modules, ensuring secure data exchange with Intelligent Electronic Devices (IEDs) and enabling interoperability with substation automation systems. Enabled historical data logging on OITs for energy metrics, supporting usage analysis, compliance reporting, and long-term storage. Extensive hands-on experience with Rockwell FT View SCADA (SE/ME) for configuring scalable, user-centric HMI systems, integrating FactoryTalk View with multiple PLCs for seamless plant-wide visualization and control. Proficient in configuring multiple communication protocols, including OPC DA, OPC UA, Modbus, Ethernet/IP, and MQTT, for seamless integration between control systems and third-party applications. Collaborated with project managers to ensure timely and successful project delivery, assisting with project planning, risk management, and resource allocation to achieve project objectives within scope and budget. Documented SCADA system architecture, configuration details, and operational procedures, creating user manuals and providing training sessions to ensure smooth operation and maintenance by end-users. Used SQL to create custom queries and reports, providing insights into system performance and helping with decision-making processes for maintenance, system improvements, and troubleshooting. Developed and optimized control algorithms for automation systems, enhancing performance and response times for complex industrial applications. Utilized MATLAB/Simulink for control system modeling and rapid prototyping, accurately simulating power electronics and control systems to support design validation. Configured and managed I/O modules for PLCs to ensure accurate data acquisition and control of various field devices, including digital and analog inputs/outputs for seamless communication with sensors, actuators, and other automation equipment. Conducted safety assessments and implemented OSHA guidelines to create a compliant and safe work environment, reducing workplace incidents. Diagnosed and debugged control system issues, utilizing tools like PLC logic analyzers and oscilloscopes to identify and resolve problems in control loops, communication networks, and hardware connections, minimizing system downtime. Conducted end-to-end testing of motor drives, actuators, and servo controls to ensure smooth integration with PLCs & SCADA systems, verifying proper operation under real-world conditions.
Extensive experience in programming Allen-Bradley ControlLogix and CompactLogix PLCs using RS Logix 5000/Studio 5000, developing robust control logic for various industrial automation systems. Proficient in creating and optimizing ladder logic, structured text, and function block diagrams for complex automation processes, ensuring efficient system performance and ease of maintenance. Developed hybrid powertrain control strategies using MATLAB/Simulink and AVL CRUISE to optimize power distribution between electric and combustion systems for fuel efficiency. Integrated Battery Management Systems using Simulink Real-Time, ensuring safe and efficient energy distribution for hybrid vehicles. Developed & configured HMI applications using FactoryTalk View SE/ME, creating intuitive interfaces for real-time monitoring, control, and data visualization. Designed custom dashboards and alarms in SCADA systems, providing operators with critical information to manage production processes effectively. Implemented scalable HMI solutions for site operations, ensuring consistent user experience & data access across different facilities. Deep understanding of Ethernet/IP protocols, configuring and troubleshooting industrial networks to ensure reliable communication between PLCs, HMIs, VFDs, and other devices. Integrated multiple automation components using Ethernet/IP, optimizing network performance for high-speed data transfer and system synchronization. Designed control logic using Simulink and MATLAB for powertrain applications, enhancing system response times and performance in hybrid vehicle systems. Configured HIL systems with LabVIEW and Simulink Real-Time, interfacing with PLCs for seamless hardware integration & realistic operational testing. Conducted system simulation & control analysis using MATLAB/Simulink, accelerating design & validation of control algorithms. Calibrated and configured sensors (e.g., pressure, temperature, proximity, and flow sensors) to ensure accurate measurements and proper integration with control systems, enhancing system reliability and efficiency. Integrated Wonderware HMI with control systems using protocols such as OPC DA and OPC UA, supporting cross-platform communication for plant floor connectivity and enterprise-level data analysis. Conducted SAT/FAT (Site Acceptance Testing / Factory Acceptance Testing) to validate control systems functionality and compliance with client requirements, ensuring readiness for operational deployment. Conducted end-to-end testing of motor drives, actuators, and servo controls, verifying system performance under real-world conditions to ensure reliability and compliance with project requirements. Utilized LabView for developing graphical interfaces and control logic data acquisition and automation tasks, capturing data from sensors and actuators for analysis, troubleshooting and debugging automated test systems, ensuring accurate data collection. Experienced in using Python for data analysis and automation, utilizing libraries like Pandas and NumPy. Developed scripts to streamline data processing tasks and generate reports. Familiar with basic machine learning concepts and building simple models for predictive analysis. Skilled in writing SQL queries for data retrieval and manipulation. Experience with database management in systems like MySQL and PostgreSQL. Able to design and optimize database schemas to support data storage needs. Proficient in using MATLAB for simulations and data visualization. Created simple scripts for analysing system performance & testing outcomes. Proficient in using AutoCAD Electrical to create and modify electrical schematics, wiring diagrams, and panel layouts for control systems. Utilized AutoCAD Electrical for documentation, generating BOMs (Bill of Materials) and reports for manufacturing and installation processes. Utilized electrical diagrams to guide system assembly and testing, ensuring adherence to design specifications and safety standards. Investigate product defects to identify root causes and recommend corrective actions to enhance product quality. Implemented fault detection and alarm functionality on OITs, enabling rapid response to equipment issues and reducing downtime. Configured and integrated high-voltage drives, including programming Variable Frequency Drives (VFDs), to achieve precise motor control and energy efficiency in various applications. Configured OPC UA, Modbus, and IEC 61850 protocols, enabling seamless data exchange and interoperability between control systems and power electronics.
Developed control systems using Siemens S7 PLCs for automated assembly lines, ensuring precise and efficient control of various production processes. Programmed and integrated SCARA robots for high-speed pick-and-place operations, optimizing coordination with conveyor systems to improve throughput. Configured HMI applications using Siemens WinCC for intuitive operator interfaces enabling operators to adjust process parameters and view system status in real-time. Integrated AGVs with Siemens PLCs, implementing communication protocols for seamless operation and synchronization with automated equipment. Tested, debugged, and commissioned control systems both in-house and at customer sites, ensuring compliance with industry standards like NFPA 79. Collaborated with cross-functional teams to align control systems with mechanical and electrical design requirements, ensuring reliable system performance. Implemented IoT connectivity within the PLC architecture for remote monitoring and data logging, supporting predictive maintenance and operational insights. Developed reusable function blocks in the Siemens environment to streamline control logic, enhancing efficiency for future projects.
Education / Training / Certificates(3)
Facilities Worked At(1)
Frequently Asked Questions
- What does a Controls Engineer do?
- A Controls Engineer designs, programs, and maintains automated control systems including PLCs, HMIs, SCADA systems, and industrial robots. They work in manufacturing, automotive, and process industries to optimize production and ensure system reliability.
- What certifications do Controls Engineers need?
- Common certifications include Rockwell Automation Certified Professional, Siemens Certified Professional, FANUC Robot certifications, ABB Robot Programming certifications, and TIA Portal certifications. Industry experience is often valued as highly as certifications.
- How do I hire a Controls Engineer?
- On Automate America, you can search for Controls Engineers by skill, location, and availability. Post a contract with your requirements, review applicant profiles and certifications, then connect directly or use White Glove managed services.
- What does Hari do?
- Hari is a Controls Engineer on Automate America, the global professional marketplace for skilled talent across industrial, commercial, and residential work.
- Where is Hari located?
- Hari is based in S Plainfield, New Jersey.
- What does Hari specialize in?
- Hari works with Allen Bradley / Rockwell, Siemens, Fanuc, ABB, GE as a Controls Engineer on Automate America, the global professional marketplace for skilled talent across industrial, commercial, and residential work.
- Is Hari available for work?
- Availability unknown. Hari has not marked it recently.
- How do I connect with or hire Hari?
- Create a free profile on Automate America and send a connection or contract request from this profile. Hari can then respond and coordinate the work directly through the platform.