Some of these I built.
The newest ones I didn't.
Selected work, newest first — line recovery, control system design and retrofit, optical sorting commissioning and training platform development. Client names are withheld where confidentiality applies.
High-Speed Downstream Line Recovery
Confidential client · Independent engagement
2026
A downstream packaging line brought back to full working order — tray packer, buffer table, straw applicator and line controller (chain conveyor), all running on Schneider PacDrive3 servo control with Lexium LXM52/62 drives. Combined hardware and software diagnosis: drive faults, controller configuration, motion programme corrections and machine sequence recovery, then run integrated. Together with the aseptic filling machine work, this covered both generations of Schneider servo control — ELAU and PacDrive3.
Aseptic Filling Machine Recovery
Confidential client · Independent engagement
2026
Recovery of high-speed aseptic filling machines and the downstream equipment they feed — tray packer, buffer table and line controller (chain conveyor). Work spanned hardware and software fault diagnosis, including tracing faults on the CoDeSys-based Eaton/Moeller XVC controllers driving the ELAU servo system. The equipment was returned to full working order and run integrated. During the same engagement I designed and deployed site-to-site WireGuard VPN infrastructure, giving the client secure remote access to PLC and HMI systems across geographically separated plants.
McCain Foods Tote Back Room Dumper System Upgrade
Key Technology (Duravant China)
Aug 2025
Independently redesigned the PLC control programme for a hydraulic tote dumper. Replaced a single-cycle full dump with a configurable multi-stage reciprocating sequence — adjustable angle offsets, dwell times and cycle counts, all set from a newly designed HMI — plus manual/auto switching, pump interlocking, limit switch logic and tank level monitoring. Written in Allen-Bradley Connected Components Workbench for the Micro820, with AI-assisted code generation followed by on-site modification and debugging. Delivered and tested on site; production rollout was not completed due to unresolved mechanical constraints.
Aviko China Xilinhot Factory Phase II
Key Technology (Duravant China)
Mar – May 2025
Supported software commissioning and optical calibration of Key Technology optical sorter systems within a large-scale potato processing expansion project. Coordinated with mechanical teams on installation sequencing and assisted with procurement scheduling.
Bosch Automotive Products Diesel Generator Fuel Supply System
Suzhou Reyanmatic Co., Ltd.
2023
Independently designed and commissioned a backup diesel generator fuel supply monitoring system for Bosch Automotive Products (Suzhou) Phase 5 facility. Sole responsibility from hardware selection through to customer sign-off. Key technical challenge involved decoding Modbus RTU communication from liquid level sensors, including RS232-to-RS485 protocol conversion and careful selection of the protocol converter to ensure reliable data acquisition.
SAIC Roewe Oil Supply Control System
Suzhou Reyanmatic Co., Ltd.
Jul – Dec 2022
End-to-end ownership of a non-standard oil station supply monitoring system for SAIC Roewe, from hardware architecture through to software delivery. The core technical challenge was implementing RS232 free-port communication to poll over a dozen liquid level meters simultaneously — requiring deep analysis of each instrument's proprietary message structure and CRC checksum mechanism. Built a WinCC Advanced SCADA interface integrated with SQL Server for data logging and VBScript-driven reporting. Subsequently upgraded the system with OPC-UA connectivity to interface with the factory MES, enabling real-time production data integration.
Huagcc Tech Calcium Carbonate Production Line
Suzhou Reyanmatic Co., Ltd.
Sep 2021 – Jan 2022
Contributed to the automation of a medium-to-large scale calcium carbonate production line using Siemens SIMATIC PCS7 — a DCS platform typical of process-intensive industries. Led hardware selection, OEM coordination for control cabinet manufacturing, and on-site commissioning. Collaborated with a partner engineer responsible for PCS7 software development. Delivered post-acceptance operator training to customer staff.
Schneider PacDrive3 Servo Training Platform
SIG Combibloc (Suzhou) Co., Ltd.
Jul – Dec 2020
Conceived, designed, and built a fully functional PacDrive3 servo controller training platform from the ground up. Covered the complete development cycle: hardware scheme design, electrical schematic, component procurement, cabinet assembly, commissioning, and course material authoring. The platform enabled hands-on servo programming training that was previously unavailable internally. Recognised with SIG Combibloc's 2020 internal innovation award.
TSsb Troubleshooting Simulation Rig
SIG Combibloc (Suzhou) Co., Ltd.
Nov 2014 – Jan 2015
Designed and built a fault-injection training rig from scratch to support troubleshooting skills development for SIG Combibloc's TSsb filling machine. Responsibilities spanned the full build cycle: component procurement, electrical and pneumatic schematic design, assembly, and commissioning. Collaborated with global SIG trainers to develop the accompanying curriculum and delivered the inaugural troubleshooting course on the completed platform.