Jack — Senior Controls Engineer

I have 12 years of experience with Rockwell controllers, ranging from MicroLogix to ControlLogix platforms. In later generation systems, I implement modern programming practices, including object-oriented structures, Add-On Instructions (AOIs), and structured, reusable logic. My HMI development in FactoryTalk View incorporates parameterized objects, tag-driven displays, and efficient screen hierarchy for scalable interface design.

I have hands on experience developing advanced automation systems using Beckhoff TwinCAT 3, including full integration of EtherCAT I/O, motion control, and custom TCP/IP communication. I've built modular architectures using Structured Text with a focus on maintainability and real-time performance. Projects include implementing a generic TCP server using the Tc2_TcpIp library to interface with external devices such as cameras and scanners, as well as coordinating multi-axis motion using NC/PTP and NC/CAM configurations. My work emphasizes object-oriented design and efficient state machine logic for deterministic control.

I have built and commissioned water systems using both Modicon M241 and Modicon M580 controllers. I am proficient in Ladder Logic and Structured Text programming, and I've worked within both EcoStruxure Machine Expert and EcoStruxure Control Expert (formerly Unity Pro) environments. My projects involved developing scalable, maintainable logic with a focus on modular design, remote connectivity, and reliable field integration.

I have built custom OPC UA libraries for integrating industrial devices and control systems into broader automation architectures. This includes both client and server implementations, enabling secure, tag-level communication with PLCs, HMIs, and external applications. My libraries support node browsing, dynamic tag subscription, read/write access, and structured data modeling. I've integrated OPC UA into real-time systems using platforms like Beckhoff TwinCAT, CODESYS, and Python-based services, ensuring seamless connectivity and interoperability across diverse industrial protocols.

I develop automation solutions using CODESYS across a variety of hardware platforms, including Raspberry Pi, WAGO, and Berghof systems. I've implemented IEC 61131-3 compliant programs using Structured Text, Function Block Diagrams, and Ladder Logic. My experience includes building PID control loops for fluid level regulation, flow control, and pressure systems, tuned for responsiveness and stability in real-time environments. I've also integrated OPC UA communications and built custom libraries for sensor and actuator abstraction, enabling scalable design and remote monitoring. Visualization and control interfaces were developed using CODESYS HMI with parameter-driven screen logic.

I've been building open-source SCADA solutions using Ignition by Inductive Automation, leveraging its object-oriented architecture and modular design to create scalable, maintainable industrial applications. My work includes designing tag-driven UIs, templated views, and parameterized popups that align with modern development practices. I collaborate with a group focused on advancing open standards and reusable components across projects, with an emphasis on clean code, version control (Git), and structured deployment. My experience spans tag historization, alarming, scripting with Python (Ignition's scripting environment), and database integration for both runtime performance and long-term maintainability.

I use C# to build robust, object-oriented applications for industrial and automation environments. My work includes developing backend services, diagnostic tools, and custom middleware to interface between PLCs, OPC UA servers, and higher-level applications. I follow modern design principles including SOLID architecture, dependency injection, and asynchronous programming to ensure performance and maintainability. I've also integrated HTTP/REST APIs, handled structured logging and diagnostics, and built custom data parsers and state machines for real-time industrial workflows.

From control strategy to code documentation to user manuals, almost every job I have had required extensive documentation.

Milpitas California Key Qualifications and Responsibilities: Spearheaded the enhancement of control systems for electrolysis processes utilizing platforms such as Allen Bradley, Schneider Electric, and Siemens. Tailored control algorithms and system code to meet the specific requirements of each custom project, ensuring optimal performance and reliability. Key Achievements and Projects: Developed and implemented a comprehensive overhaul of system programming, introducing modular logic to create a flexible and maintainable codebase by leveraging Object Oriented Principals. Built a Modbus TCP server using C# and Blazor Webserver technology to effectively simulate remote I/O, PLC operations, and system communications, enhancing testing and development processes. Applied machine learning techniques to automate routine tasks, significantly improving efficiency in generating SCADA tables, standardizing variables, and streamlining documentation processes.

Los Gatos California Key Qualifications and Responsibilities: Pioneer the development of a low-code industrial automation platform using C#, streamlining process management and integration in manufacturing environments. Proactively identified and resolved software challenges, enhancing operational efficiency and software reliability in manufacturing settings. Key Achievements and Projects: Designed and implemented a sophisticated C# program that automatically detects all devices connected to a network, dramatically reducing manual search time and eliminating human errors. Overhauled and upgraded a demonstration production line to meet NFPA 70 electrical safety standards, enhancing safety and compliance. Developed versatile programming solutions enabling seamless integration of multiple PLC brands (including Allen Bradley, Siemens, and Beckhoff) with custom software, fostering improved system interoperability. Successfully integrated OPC UA into the developed software, showcasing advanced SCADA capabilities and robust data acquisition functions.

Newark California Led a team of four engineers, fostering the development of methodical troubleshooting skills, promoting safe work practices, and efficiently managing workloads. Responsible for the maintenance and enhancement of an automated conveying and sorting system, leveraging both software upgrades and hardware optimizations. Oversaw project management and cultivated strong collaborative relationships between engineers and technicians to ensure cohesive team dynamics and efficient project execution. Key Achievements and Projects: Engineered an advanced image classifier using Python 3 and TensorFlow 2.8 that automatically detected 10,000 faulty packages daily in real-time, significantly reducing the need for manual inspection and saving substantial labor costs. Identified and resolved numerous logic redundancies and errors within RS Logix 5000 (version 32.0) software, including double Boolean assignments, logical inconsistencies, and duplicated logic blocks, thereby enhancing system efficiency and reliability.

Dundee Michigan Key Qualifications and Responsibilities: Held a leadership role overseeing daily shift operations, including sending comprehensive shift reports, prioritizing tasks, and providing ongoing production support. Specialized in configuring, backing up, and restoring parameters on various drives and PLCs utilizing Human Interface Modules (HIM) and Connected Components Workbench, along with maintaining and updating documentation and files on the maintenance drive. Expert in troubleshooting and programming Allen Bradley PLCs, primarily using Connected Components Workbench, as well as RSLogix 500 and 5000 environments. Performed troubleshooting, repairs, and programming on Siemens S7 PLCs and associated HMI components, particularly in Erema pelletizing equipment. Skilled in diagnosing and rectifying issues in machinery used in HDPE and PET wash processes, including hydraulic bale breakers, metal and rubber conveyors, blowers, augers, grinders, and high-speed sorting machines. Key Achievements and Projects: Successfully designed, installed, and implemented multiple automation systems, notably a belt tracking alarm system employing a Micro 820 controller, which significantly enhanced operational safety and efficiency.