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Assembly, Programming, and Commissioning of a Dual Incline Automation System

Built and programmed a dual incline automation system as a complete mechatronic setup. The work focused on control cabinet construction, including wiring based on electrical schematics, integrating motors, cylinders, sensors, and actuators, and programming a Siemens PLC using TIA Portal V18. The project was carried out in close collaboration with both mechanical and electrical specialists.

Comprehensive documentation of this work can be found in the Projects section.

Commissioning and Programming of a Test System

Developed and commissioned a servo-driven test system for telescopic rails. Implemented cyclic motion sequences in the PLC and created a full HMI interface for system operation and monitoring. Also carried out detailed fault analysis, partially rewired the system based on updated schematics, and successfully recommissioned it. The system was later expanded with additional components and functionality.

Comprehensive documentation of this work can be found in the Projects section.

Testing of Portable Electrical Equipment in Accordance with DGUV V3

Performed compliance testing on portable electrical equipment using a GT900 tester. This included measuring protective conductor resistance, insulation resistance, and leakage currents, as well as assigning the appropriate protection class (I, II, III). In addition, conducted visual inspections and functional tests, and verified correct wiring. Documented results and approved equipment in line with regulatory requirements.

Manufacturing of Refrigeration Units

Carried out electrical wiring of refrigeration units, particularly large refrigerated display cabinets for both series production and custom builds. All systems were manufactured entirely in-house, from processing sheet metal and individual components through to painting and final assembly. Worked from electrical schematics and performed safety testing in accordance with DGUV V3. Verified and documented system functionality and operational safety prior to commissioning.

Maintenance of Air Cargo Containers

Execution of maintenance, repair, and inspection work on temperature-controlled air cargo containers used for the transport of food and pharmaceutical products. This included complete disassembly and reassembly, systematic fault diagnosis, and analysis of temperature and event data using integrated data loggers (cold-chain monitoring). Evaluation of temperature profiles and diagnosis of deviations. The work also included the supervision and maintenance of the integrated PLC system, including reading out program data, creating and restoring backups, and performing firmware updates as part of maintenance activities. In addition, electrical safety inspections were carried out in accordance with DGUV V3, along with functional and safety checks.

Maintenance of a Bitumen Processing Plant

Maintain a large-scale bitumen processing plant consisting of two multi-level mechatronic production lines, each approximately 300 meters long. The facility includes cooling rollers as well as extensive automation and supply systems handling electricity, compressed air, water, gas, oils, fillers, and additives, all processed according to precise formulations.

Responsibilities include maintaining, troubleshooting, and repairing electrical and control system components such as PLCs, bus couplers, frequency converters, and motors, as well as working on control cabinets and automation systems.

A key focus is ensuring high system availability, particularly within the safety-critical heating system. Regular inspections, preventive maintenance, and continuous fault analysis and resolution are essential parts of the role.

Mechanical Engineering / Assembly of Drilling and Milling Machines

Assembled and wired high-precision, PLC-controlled drilling and milling machines for printed circuit board (PCB) manufacturing. The machines were mounted on solid granite base plates to ensure maximum precision. Carried out extensive wiring based on electrical schematics and supported commissioning by integrating preconfigured control programs.

Control Cabinet Construction and Control Engineering (Hardwired / PLC-Based Systems)

Built and commissioned electrical circuits and control systems as part of vocational training. Implemented classic control systems such as star-delta starters, reversing contactor circuits, and motor starting controls. Worked with both hardwired control systems and PLC-based solutions using Siemens S5 and S7 platforms. Gained hands-on experience in wiring, system functionality, and analysis of control processes.

Assembly of a Transfer System

Assembled, wired, and commissioned a transfer system for training purposes. Combined mechanical assembly, electrical installation, and PLC programming. Focused on precise installation, accurate alignment of components, and safe handling of heavy equipment. Worked closely within a team throughout assembly and commissioning.

PLC Programming (IL, FBD, LAD)

Independently developed and expanded a PLC-controlled pick-and-place and inspection system featuring a gripper, drilling station, rotary indexing table, and conveyor belt. Implemented automated part handling, inspection of defined characteristics, as well as sorting and process recirculation. Programmed using Instruction List (IL), Function Block Diagram (FBD), and Ladder Logic (LAD), and extended the system across multiple PLCs to enable more complex process sequences.

Packet Filtering, Routing, and Firewall Systems

Designed and implemented security solutions at both network and system level. Set up and configured packet filtering, routing, and firewall systems on Linux platforms. Developed and optimized custom rule sets to secure LAN and WAN infrastructures, in some cases down to kernel level, and hardened systems to minimize attack surfaces.

Comprehensive documentation of this work can be found in the Projects section.

Servers, Databases, and Administration

Set up, configured, and administered server environments based on Linux (Ubuntu Server) and Windows. Operated web servers (Apache), database systems (MySQL), and scripting environments (PHP, Perl). Integrated content management systems and continuously expanded and optimized the infrastructure over time.

Comprehensive documentation of this work can be found in the Projects section.

Hardware, System Integration, and Configurationn

Selected, procured, and configured IT hardware, building stable system environments. Set up LAN and WAN networks, integrated system components, and implemented remote access solutions. Optimized the interaction between hardware and software.

Comprehensive documentation of this work can be found in the Projects section.

Communication, Programming, and Web Development

Set up and operated communication platforms, including an IRC server, complemented by forums and web applications. Developed and customized scripts and automation solutions (including Python and Tcl), and designed and maintained web interfaces, extending functionality through plugins.

Comprehensive documentation of this work can be found in the Projects section.