Some began as a blank drawing.
Others, as an alarm.
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 on Schneider PacDrive3 with Lexium LXM52/62 drives. Diagnosis ran from the drives to the code (drive faults, controller configuration, motion programme corrections, machine sequence recovery) before the whole set was run integrated. Taken with the aseptic filler work, it covered both generations of Schneider servo control, ELAU and PacDrive3.
Aseptic Filling Machine Recovery
Confidential client · Independent engagement
2026
High-speed aseptic filling machines brought back to full working order, along with the tray packer, buffer table and line controller (chain conveyor) they feed. Faults were traced through hardware and software, down to the CoDeSys-based Eaton/Moeller XVC controllers that drive the ELAU servo system, and the equipment was then run integrated. On the same engagement, a site-to-site WireGuard VPN went in, giving the client secure remote access to PLC and HMI systems at plants in different locations.
McCain Foods: Tote Dumper Control Rebuild
Key Technology (Duravant China)
Aug 2025
The control programme for a hydraulic tote dumper, redesigned independently: a single full tip replaced by a configurable multi-stage reciprocating sequence, with angle offsets, dwell times and cycle counts all set from a new HMI. Manual/auto switching, pump interlocks, limit switch logic and tank level monitoring came with it. Written in Connected Components Workbench for an Allen-Bradley Micro820, with AI-assisted code generation, then modified and debugged on site. Delivered and tested; production rollout was held back by unresolved mechanical constraints.
Aviko China: Xilinhot Plant, Phase II
Key Technology (Duravant China)
Mar – May 2025
Supported software commissioning and optical calibration of Key Technology optical sorters on a large potato-processing expansion, working with the mechanical teams on installation sequence and helping keep procurement on schedule.
Bosch Automotive: Standby Generator Fuel Monitoring
Suzhou Reyanmatic Co., Ltd.
2023
A fuel supply monitoring system for the backup diesel generators at the Bosch Automotive Products (Suzhou) Phase 5 plant, designed and commissioned single-handed, from hardware selection to customer sign-off. The hard part was the level sensors: reading their Modbus RTU data meant converting RS232 to RS485, and choosing a protocol converter that would keep the readings reliable.
SAIC Roewe: Oil Supply Control System
Suzhou Reyanmatic Co., Ltd.
Jul – Dec 2022
A non-standard oil station supply monitoring system for SAIC Roewe, owned end to end from hardware architecture to software delivery. The core problem was polling over a dozen liquid level meters at once through RS232 free-port communication, which meant working out each instrument's proprietary message format and CRC checksum. A WinCC Advanced SCADA interface logged to SQL Server, with reports driven by VBScript. A later upgrade added OPC UA, linking the system to the factory MES for real-time production data.
Huagcc Tech: Calcium Carbonate Line on PCS7
Suzhou Reyanmatic Co., Ltd.
Sep 2021 – Jan 2022
Automation for a medium-to-large calcium carbonate production line on Siemens SIMATIC PCS7, the DCS platform common in process industries. Led hardware selection, coordination with the OEM building the control cabinets, and on-site commissioning, while a partner engineer developed the PCS7 software. After acceptance, trained the customer's operators.
PacDrive3 Servo Training Rig
SIG Combibloc (Suzhou) Co., Ltd.
Jul – Dec 2020
A working PacDrive3 servo training rig, taken from idea to finished cabinet: hardware concept, electrical schematics, component procurement, cabinet assembly, commissioning, and the course material to go with it. Before it, servo programming could not be taught hands-on in-house. It won SIG Combibloc's 2020 internal innovation award.
TSsb Fault-Simulation Rig
SIG Combibloc (Suzhou) Co., Ltd.
Nov 2014 – Jan 2015
A fault-injection rig for SIG Combibloc's TSsb filling machine, built from scratch so troubleshooting could be taught on faults set up on purpose. The build ran from component procurement and electrical and pneumatic schematics through assembly and commissioning. Developed the curriculum with SIG's global trainers and taught the first course on the finished rig.