some of my projects
Current employer tasked me to adapt a manual MIG welding process to be done by a collaborative robot, and train the welding technician to now operate said robot. Now all large weldments (from 6" to over 6' in length) are done by robot. The design of torch grips was done entirely on solidworks and the first physical prototype became the final part. Collaborative robots are Industrial robots designed to be able to work alongside human workers with no risk of injury. They’re smaller, handle smaller loads and cost significantly less than their classic counterparts. While they’re extremely popular for simple tasks such as palletizing and pick-and-place, they’re quite capable of undergoing more sophisticated manufacturing tasks such as welding, assisting CNC machinery, gluing, electronics soldering and the like. As of today we're designing a modbus master to interface with the robot and act as a console.
MIG Welding Collaborative Robot with controls through Modbus.
Controller and Data adquisition for Testing equipment
Automatic controller and datallogger for testing equipment. ON/OFF, proportional, and PID Control. Continuous and discrete. It controls parameters and gives time-stamped registers. Data can be visualized in real time through Windows based app developped internally. Once test is configured, controller can operate without connection to app for the duration of the test (usually up to a month) and relay the info for Controller stores data in an sd card and relays it to app once connection is re-established. Controller also stores alarm events, or lack thereof, in order to validate success of test.
These controllers currently opérate each and every Biological environment test chamber manufactured by “J3”, and can be adapted to a myriad of equipment. Currently, a version of this controller with wifi capabilities is being developped.
“3D Prototypes” of electromechanical systems
It is possible to boost the reliability of the design process by building prototypes of each iteration to test if they meet the requirements.
With modern CAD techniques, it is possible to achieve this every step of the way in a digital environment, saving time and cost in the actual prototying. It is a very powerful tool for the systems integrator. As an OEM, the usage of Solidworks or similar software is fundamental for developing special mechanical parts and assemblies for projects. I’ve also rendered my services for clients interested in a versatile version of their product in order to test upgrades and new versions.
Automatic dosaje system for Paint production and packing
I was contacted by a client who produces 300 paint products from a combination of just 5 ingredients. They wished to aquire an automatic system that would quickly serve a desired proportion of ingredients as commanded by a user, in order to do away with the need of constant and large quantities of stock in order to sell on their stores. The objective was to achieve a solution that would only require electricity and small amounts of compressed air, in order to be placed in their stores as well as their factory. They also didn’t want complicated equipment such as peristaltic pumps, which are industry standard.
Stages of development
Design and verification of head loss and necessary flow of the fluid (Paint) throghout the machinery
Design and coding of the “precisión Paint dosaje by weight” PLC routine.
Design of the GUI (Graphics user interface).
Design of a custom 3-position pneumatically actuated Paint valve (rapid dosaje, precise dosaje and closed)
Installation, calibration of the machine.
The system is currently operating at client’s factory and the Project is being commercialized by J2M.
Original Equipment: Automatic paper roll positioning machine, for saw cutting variable length rolls
My client owned a manual paper-cutting saw and saw the need of automating the cutting of the large paper sleeves of variable diametres into rolls in different, programable lengths
Project consisted in:
Design, manufacturing and mounting of a cart, resting on rails, actuated by a pneumatic piston. Cart had opposing, vertical conveyor belts with a manually adjustable separation in order to accomodate for differing diameters and controlled by a single stepper motor through a special transmission system in order to prevent slippage and desynchronization that may damage the sleeve. With this, the stepper could feed variable lengths into the saw, and the piston could make the cutting motion.
Design and manufacturing of the electric panel to power up the PLC, stepper motor and saw motor
Programming of the PLC and HMI routines
Development of SCADA Software
As a collaboration with a software developper, we’ve developped a SCADA software capable of acting as a client in an industrial network through MODBUS TCP/IP or Serial (RS485 RTU) protocols.
SCADA (Supervisory control and data adquisition) softwares coordinate and command the status of process machinery in an industrial plant in such a way that each separate machinery can be made aware of the state of other machines in order to coordinate efforts. As part of this Project, I made ARDUINO and ESP32 microcontrollers to act as servers and clients, which now can be used as components of an industrial network for secondary applications (like quick data display).
Some examples of established SCADA software include Siemens’ Simatic Scada, Rockwell’s FactoryTalk, and Inductive automation’s Ignition. Our development allows us to provide industrial networking and automation services for small and médium factories without having to resort to these softwares and requiring our clients to purchase a license.
PLC & SCADA, Modbus TCP/IP & Serial, Visual Studio .net
PLC programming for industrial hydraulic machinery
As part of my job in a heavy equipment manufacturer for the agricultural industry, i’ve developped programs for the control of the hydraulic systems that power them.
Depending on the product, pistons and rotary motors can be commanded by a set of 4/3 directional valves and a relief valve in an ON/OFF or analogic fashion. In the case of ON/OFF control, proportional valves for smooth acceleration and decceleration.
PLC would take inputs from operators through joysticks and limit switches, and controlled the hydraulic pump and valve manifold to ensure a smooth and responsive operation. It prevented situations that may damage the equipment, such as simultaneous energization of opposed coils and excessive jerk and acceleration.
Valves used: Relief Valves, 5/3 directional valves, ON/OFF and analogic. Proportional flow control valve from different vendors, pressure limiting valves, counterbalance valves, Crossover valves and flow choke valves.
Actuators used: pistons, rotary actuators, motors.
Development of Custom Function blocks and AOI’s for AOIExchange
AOIExchange is a small company that offers user-defined function blocks, AOI’s, Libraries and templates for rockwell and Allen bradley PLC’s and HMI’s.
Since October 2020 I develop PLC and HMI modules for it, which are currently offered through their website. They are inspired and taken from my experience working as a systems integrator in paint dosage systems, hydraulic machinery and general industry.