In this project, I migrated an Excel-based parameterization tool to a .NET application based on .NET 8 and WPF. The new solution uses MS SQL Server as the primary database and adds a generic SQLite access layer to make the application more portable and field-independent.
A special challenge was reengineering complex macros and database-like structures used in Excel sheets for input dialogs and validations. These had to be integrated and optimized in the new .NET solution to ensure a seamless and user-friendly experience.
System environment:
Refactoring a .NET-based DDU visualization software in the Train Control & Management System (TCMS), developed from 2020 to 2023 with my participation. The goal was to make the visualization more flexible with interchangeable communication layers. The original implementation supporting the CIP protocol was modularized to prepare it for the MVB bus. I restructured the data handling and relevant components into modules and made them interchangeable via interfaces.
In parallel, I developed an equivalent communication solution for the MVB protocol.
The end goal was to port the visualization originally intended for battery-powered vehicles to hydrogen-powered vehicles.
Additional task: Migrated an Excel-based parameterization tool (including macros) with an MS Access database to a .NET application. The new solution uses SQLite as primary storage, with a generic data access layer supporting MS SQL Server and PostgreSQL.
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Developed a concept for a digital data solution supporting series production of complex medical devices.
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Developed a database-driven tool for parameterizing so-called DataPlugs for PLCs in rail vehicles.
An existing Microsoft Access–based tool was reengineered and ported to SQLite3. The user interface was rebuilt entirely in C# and VB.NET.
For this project, I created an application framework that enables easier porting of other VB6/MS Access applications to .NET.
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Enhanced and commissioned the display visualization of the Train Control & Management System (TCMS) for a new battery-powered rail vehicle.
The DDU display software was ported from VB6 to VB.NET. The application was reengineered, modularized, and many parts were reimplemented in C# and VB.NET.
I developed a new communication channel in C# using the CIP protocol for data exchange between the DDU and the control unit (MPU), including dynamic signal management.
Development followed the industry-standard V-Model, including associated documentation within the cycle.
In another subproject, I further developed the display software in the TCMS for a new hydrogen-powered rail vehicle.
A special challenge was collaborating as a team with remote systems under COVID-19 conditions.
In October 2022, I extended the DDU’s CIP communication layer with an ANSI-C dummy library to feed test data via TCP/IP for automated test cases, allowing pre-testing and simulating data exchange between MPU and DDU.
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Documented the switch from an ERP system to SAP during live "just in sequence" production from the MES system’s perspective.
Expanded an in-house MES system.
Switched from a satellite warehouse for storing complete wheels to connecting a new high-bay warehouse:
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Planning in Germany, on-site commissioning and upgrade in China delayed due to COVID-19
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Upgraded an existing SCADA system to SIMATIC WinCC 7.5.
The SCADA system was rebuilt in a virtualized environment under VMware ESXi.
Challenge: The existing system was a redundant client/server setup with logic in C-scripts on the clients. During the upgrade, both separate WinCC projects (client and server) had to be merged into one, and the C-scripts functionality had to be preserved.
Location: planning in Germany, remote commissioning due to the pandemic
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Built a SCADA system in a virtualized environment with TIA Portal V15 for a new production plant. The SCADA runs as client/server with WinCC WebNavigator and visualizes S7-1500 CPUs.
A key feature was complex material routing that required matching scanner points with a higher-level system via OPC UA.
Location: planning in Germany, commissioning and acceptance in China
System environment:
Switched from an ERP system to SAP during live "just in sequence" production from the MES perspective.
Expanded the in-house MES system.
Switched from a portal warehouse for complete wheels to a new high-bay warehouse:
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Enhanced visualization systems for conveyor systems, commissioning and transitioning plants to production. A group-wide SCADA standard was implemented.
Locations:
China
USA
Brazil
Romania
Germany
On-site training
Created parts of the documentation
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System environment:
Enhanced visualization systems for conveyor systems, commissioning and production rollout in:
China
Romania
Germany
On-site training
Created parts of the documentation
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Enhanced visualization systems for conveyor systems, commissioning and production rollout.
Location: planning in Germany, commissioning in India
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Enhanced visualization systems for conveyor systems, commissioning and production rollout.
Location: planning in Germany, commissioning in USA
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Location: planning in Germany, commissioning in USA
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Remote support for commissioning plant sections at tire plants in Europe, China, and Brazil, including on-site work
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I continue to maintain and expand this project regularly, updating development tool versions as needed.
Contract type: works contract
Ported ActiveX components for recipe selection to WinCC 7.0
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Visualization of a core winder for tire manufacturing using WinCC Flexible 2008 SP2
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Enhanced an application for parameterizing various drive controllers (L-force Engineer) with a team of 10–15 developers.
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Visualized a tire winding machine in VB6 (communication to TwinCAT via ADS)
Recipe management in VB / MS Access
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I continue to maintain and expand this project regularly, updating development tools as needed.
Contract type: works contract
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I continue to maintain and expand this project regularly, updating development tools as needed. The database was migrated to MSSQL 2008 in 05/2010.
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Implemented a recipe processing system for the gearbox filling line in the production process.
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Data exchange and logging of transponder systems on milk collection trucks at the receiving station
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Enhanced recipe processing and production data collection in the blending area
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Created a feasibility study for integrating various data island solutions.
Created requirements specifications for reimplementing the blending process.
Reimplemented recipe processing and production data collection in blending on Microsoft SQL Server 7 with iFix visualization.
Communication to Simatic S7-400
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Reimplemented recipe processing and production data collection in blending on Microsoft SQL Server 7 with WinCC 4 visualization.
Communication to Simatic S5
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Various data technology subprojects in the field of liquid processing.
My focus is on designing and implementing tailored IT solutions in application development for automation technology.
I specialize in two main areas:
At the core is process and workflow analysis, especially considering horizontal data flows between units and vertical integration with higher-level systems. I emphasize effective communication and data exchange between automation devices and controllers as well as higher-level systems like recipe management, measurement and production data collection, and ERP systems (e.g., SAP). I build solutions with both custom software and established SCADA and MES systems, with a special focus on SIMATIC solutions for Industry 4.0.
A key aspect of my work is developing with OPC UA as a standardized transport layer to ensure seamless interoperability.
Additionally, I have experience in designing and developing software components in .NET and support porting VB6- and Excel-based applications into the .NET world. For individual customer requirements, I deliver complete software packages in C# and VB.NET, while handling database solutions with Microsoft SQL Server, PostgreSQL, and SQLite. For low-level hardware communication, I use C under Windows.
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