Projects

PROFESSIONAL PROJECTS

This section showcases a selection of NDA-compliant mechanical systems, industrial automation, and controls solutions delivered for industrial clients and R&D operations.

Cavitation Test Bed

Application: Modelled, assembled, and commissioned a room-sized test plant to induce and analyze pump and control valve cavitation for advanced asset monitoring.

Engineering & Design: Utilized SolidWorks CAD for full mechanical fabrication modeling and MATLAB to mathematically simulate fluid dynamics (pressures, flows, and cavitation behavior across varying pump specs, pipe configurations, and thermal/vacuum conditions). Designed and built the electrical control panel hardware from scratch, and programmed the ABB AC800M DCS alongside a custom ABB Compact HMI SCADA interface for complete PC-based control and multi-variable data acquisition (pressure, flow, level, and temperature) with OPC-DA/UA interface. Integrated a VFD-driven centrifugal pump, custom tank, process piping, 3HP vacuum pump, vacuum regulator, position-controlled ball valve, steam extraction system, and process heater. Streamed real-time multi-variable transmitter data via OPC into a Canary Historian to capture high-fidelity datasets for machine learning model training.

Results: Successfully delivered a fully functional test bed generating high-fidelity operational data utilized to train machine learning models for automated cavitation detection.

R&D Ball Bearing Testbed (V2)

Application: Designed, built, and commissioned an automated ball bearing fatigue test rig capable of applying a controllable 2,000 lbf mechanical load, engineered for unattended, 24/7 autonomous operation over multi-month testing cycles.

Engineering & Design: Leveraged MATLAB to perform preliminary shaft/bearing load and fatigue calculations, bearing life estimations, and thermal cooling calculations, and utilized SolidWorks (CAD and Simulation FEA) for 3D modeling, structural FEA, and DFM—delivering production-ready blueprints for CNC machining, welding, and sheet metal fabrication with post-process heat treatments. Created professional electrical wiring diagrams using Siemens Electra, designed and built the control panel hardware, and programmed the Siemens S7-1200 PLC and HMI to manage a WEG VFD over Modbus RTU, a linear actuator, and feedback loops from load cells, accelerometers, and thermocouples. Integrated complete hardware safety systems using a Keyence GC-1000 safety controller (guard locks, E-Stops, and Safe Torque Off). Streamed real-time sensor data via Kepware into a Canary Historian.

Results: Delivered a fully validated, highly reliable turnkey test bed capable of unattended, multi-month continuous operation under heavy dynamic loads.

Fluid System Trade Show Demo

Application: Designed, assembled, and commissioned a portable fluid process system built for live trade-show demonstrations and rigorous algorithm testing, specifically engineered to simulate pump leakage, valve sticking, and valve clogging.

Engineering & Design: Utilized MATLAB to model and simulate all flow parameters during the design phase, and SolidWorks CAD for physical layout and component routing of pumps, multiple control valves, pressure sensors, and flowmeters. Created professional electrical wiring diagrams using Siemens Electra. Implemented the complete control architecture using a Siemens S7-410E PLC programmed with PCS7, paired with Siemens WinCC for SCADA/HMI operation.

Results: Delivered a robust, transportable industrial test bed capable of live demonstration and failure-mode generation for diagnostic algorithm validation.

R&D Motor Dynamometers

Application: Designed, assembled, and commissioned two induction and PMSM motor dynamometer test beds featuring infinitely adjustable mechanical torque loading to simulate and evaluate various rotor, stator, structural, and electrical faults.

Engineering & Design: Engineered the mechanical layouts and component integration for both test stands: configuring the first test bed with a single induction motor and a Permanent Magnet Synchronous Motor (PMSM) utilizing a common DC bus architecture for shared energy conservation, and the second test bed with dual induction motors paired with a Mitsubishi regenerative converter to absorb power, return it to the grid, and prevent VFD faulting. Created professional electrical wiring diagrams using Siemens Electra. Designed and built the electrical control panel hardware, and programmed Allen-Bradley Micro850 PLCs and PanelView HMI panels to command the ABB VFDs.

Results: Delivered two robust, high-performance motor test platforms capable of dynamic mechanical loading and advanced electrical/structural fault experimentation.

High-Pressure Sensor and Valve Test Station

Application: Designed, assembled, and commissioned a 2,000 psig pneumatic testing station utilizing high-pressure gas cylinders to validate oil/gas field-deployed sensors and compressor needle valves.

Engineering & Design: Designed the testing station framework and layout in SolidWorks CAD. Performed gas dynamics analysis to correctly size solenoid valves for high-pressure service. Created professional electrical wiring diagrams using Siemens Electra, and engineered and built the electrical controls using integrated timer relays, contactors, and a pushbutton interface to manage adjustable duty-cycle testing. Implemented a dedicated safety relay system for emergency bleed-down protection.

Results: Delivered a reliable, high-pressure testing platform capable of rigorous cyclic endurance testing and safe emergency venting for critical oil and gas field equipment.

Ball Bearing Testbed Controls Integration

Application: Commissioned an advanced bearing test platform designed to evaluate bearing fatigue performance under severe mechanical loads and dynamic rotational speeds.

Engineering & Design: Integrated Kyntronics electro-hydraulic actuators to deliver 10,000+ lbf of precise mechanical loading alongside a Siemens G120 VFD for dynamic speed control. Created professional electrical wiring diagrams using Siemens Electra. Engineered custom mechanical load cell integration and designed physical machine guarding. Engineered and built the electrical controls, deploying an Allen-Bradley ControlLogix PLC with a FactoryTalk SE HMI interface, backed by an Allen-Bradley Guardmaster 440C safety controller for comprehensive machine protection and interlocking. Integrated Kepware and a custom-interface software package to acquire and log high-frequency data from accelerometers, ultrasonic, and acoustic emissions sensors.

Results: Delivered a robust, high-load testing platform combining high-force electro-hydraulic actuation, advanced automation, safety architecture, and high-speed multi-sensor diagnostics.

Industrial Robot Cell Control Panel

Application: Designed, assembled, and commissioned a dual-cell industrial robot control system dedicated to pick-and-place performance testing.

Engineering & Design: Designed the custom enclosure with an integrated cooling fan in SolidWorks CAD, generated the comprehensive BOM, and created professional electrical wiring diagrams using Siemens Electra. Assembled and wired the main control cabinet, housing dual ABB IRC5 compact robot controllers at the top and a specialized I/O panel at the bottom. Integrated Wago analog input modules communicating via DeviceNet to monitor end-effector suction pressure per cup and dynamically control vacuum levels based on real-time feedback. Engineered a robust safety architecture featuring Schmersal guard locks on the cell doors interlocked with Allen-Bradley Guardmaster safety relays to initiate protective stops upon unlocking, alongside a hardwired network of emergency stop buttons routed directly to the enclosure.

Results: Delivered a fully integrated, dual-robot testing enclosure combining space-optimized panel layout, active thermal management, closed-loop vacuum regulation, and rigorous safety compliance.