some of my projects
My current employer tasked me with adapting a manual MIG welding process to be performed by a collaborative robot and training the welding technician to operate the robot. Now, all large weldments ranging from 6 inches to over 6 feet in length are done by the robot. The design of the torch grips was entirely done in SolidWorks, and the first physical prototype became the final part.
Collaborative robots are industrial robots designed to work alongside human workers with no risk of injury. They are smaller, handle smaller loads, and cost significantly less than their classic counterparts. While they are popular for simple tasks such as palletizing and pick-and-place, they are also capable of handling more sophisticated manufacturing tasks such as welding, assisting CNC machinery, gluing, and electronics soldering. Currently, we are continually adding more routines and tasks for the robot to handle.
Automatic welding process with UR-10 Collaborative Robot
Automatic Controller and Datalogger for testing equipment
Our automatic controller for testing machines provides ON/OFF and PID control, along with datalogging of measured parameters. It is compatible with all types of sensors, and tests can be configured and results reported by a windows application. Once configured, the controller can function with full autonomy. Controlled parameters can be a function of time for gradient and progressive tests. The software offers real-time visualization of measured values in graphs, indication of states of alarm, and generation of reports at the end of each test.
Once a test is set up, the controller can work autonomously for months on end, storing logged values and alarm events on an SD card. The data can be automatically dumped once the connection is reestablished. Our controllers are currently operating in every biological test chamber commercialized by "J3 Desarrollos" and can be adapted to meet any testing needs. Soon, we will be adding internet connectivity, allowing you to configure and monitor your tests from anywhere in the world.
Various "3D prototypes" done for local and remote clients.
When manufacturing a piece or an assembly, it is crucial to consider all dimensions and geometries. Sometimes a design can make it to the prototyping stage, only to fail to produce the desired behavior. However, with current CAD techniques, it is possible to create a "virtual" prototype that can be examined for individual behavior and how it fits in an assembly. This virtual prototype can be adapted to multiple production technologies, which can greatly reduce, if not completely eliminate, the physical prototyping phase.
A skilled CAD modeler can simulate kinematic relationships between parts in an assembly to simulate how they would move. I have attached some examples of 3D prototypes and their respective final parts that I have done for various clients, including simple metallurgical devices and parts for automated systems.
PLC commanded Automated dosage system for Paint production
A client contacted me with a request to automate a process of mixing four ingredients in varying percentages to produce around 300 recipes. However, they did not want to rely on pneumatic driving or commands, which is the industry standard. I developed the full project and automated it with a programmable logic controller (PLC). I designed the entire process, calculated pipe and valve dimensions to allow for sufficient flow, and integrated a weight-measuring dosage control system, also controlled by the PLC.
The machine is currently installed and being operated by the client in their facilities. Additionally, my small consulting firm is selling the project as a pre-packaged solution. This project is an excellent example of our ability to provide customized automation solutions that meet the unique needs of our clients.
Original Equipment: automatic positioner, variable feed, for saw cutting
My client needed to automate the cutting of paper sleeves at different lengths according to the production order. They had a saw for this purpose and commissioned the development of an original equipment.
The project involved:
Design and manufacture of a carriage, a system of opposing conveyor belts controlled by the same stepper motor to prevent slippage, and capable of adjusting their separation (for sleeves of different diameters) using a transmission system.
Design and assembly of a power board for the control of a high torque stepper motor, a double-acting pneumatic cylinder with Hall effect limit switches, a single-phase motor (for the saw) with emergency stop, and a graphical interface.
Programming of PLC routines to calculate cutting point coordinates based on the user's input of sleeve length and desired cut lengths, taking into account cuts of the tips or "burrs" to ensure the quality of the cut section.
Programming of the graphical interface.
SCADA Software Development
With the collaboration of a computer science graduate, we developed a SCADA software capable of acting as a client in an industrial network with MODBUS protocol, both TCP/IP and Serial (RS485 RTU).
SCADA software (Supervisory Control and Data Acquisition) coordinates and commands the states of process machines so that the situation of one of them can generate a response in another. They also keep a record of events, notify alarm states via email, SMS, or other means, and allow the control and adjustment of certain operating parameters in each machine remotely. As part of the development, I elaborated and programmed ARDUINO and ESP32 microcontrollers to act as MODBUS servers and clients.
Some examples of SCADA software include Simatic SCADA from...
PLC Programming for Industrial Hydraulic Machinery
As part of my work in an agricultural machinery manufacturing company, I developed programs for the control of the hydraulic system of these machines.
Depending on the model, hydraulic pistons and motors were controlled by a manifold consisting of 4/3 directional on/off valves and on/off vent valve or with gradual control of oil flow through compensated proportional valves.
The PLC programs made for these machines take as input the command of two joysticks by the operator and stroke limits and control the turning on of the hydraulic pump and each valve to provide the oil flow to each actuator. For partial actuation of an actuator, timers were used to provide time...
Development of Functional Modules and Blocks for PLC Programs for AOIExchange
AOIExchange is a company dedicated to the sale of programming templates or "functional blocks" of code for Rockwell and Allen Bradley PLCs.
Since October 2020, I have been developing modules for this company, which are sold on their website. They are generally inspired by solutions that I implement in my work as a systems integrator.
Printed Circuit Boards for industrial applications.
Some clients who manufacture serialized equipment need to produce individual control panels for their machinery. By replacing wired circuits with PCBs, we have significantly reduced costs and man-hours in electrical production while also improving quality standards. Additionally, PCBs provide a more polished image to the end-user compared to just wired circuitry.
Arduino-based Modbus Server & Client devices
Originally designed as a test-bench for software development and robot programming, these devices are capable of interfacing with all Modbus TCP/IP compatible devices. This includes PLCs, DCSs, HMIs, SCADA software, Microsoft CNC machinery, industrial robots, and microcontrollers. The client version can execute polling and writing commands on any register of devices in server-mode. The server version can connect to multiple clients, as well as other copies of itself and other server machines, and report values in real-time. Users can manually input values through keypads, and an internal conflict-solving algorithm sorts between these inputs and client inputs to always keep the latest value up-to-date.
Ramp Valve Calibration System
Ramp valves provide NCG to internal combustion engines adapted to run on it. They inject it to the manifold for each separate piston. They require to be adjusted so they behave equally between the 4, and in mechanical shops, that usually means fitting them into an engine and carefully testing it while adjusting each valve.
I’m currently designing a system that will, using a cleverly designed pneumatic circuit, test each ramp valve’s performance separately with compressed air, and adjust them automatically until their performances are equal. This leaves them ready to be fitted into an engine without the time-consuming process described above.
The final delivery will include a windows-based application that will keep track of each test and print a report to go alongside the calibrated ramp valve.