Explore a selection of real industrial automation projects demonstrating expertise in Beckhoff TwinCAT 3, robotics, motion control, machine vision, safety systems and industrial communication.
Freelance TwinCAT 3 Engineer & Beckhoff PLC Consultant
Advanced PLC programming, motion control, and EtherCAT engineering for industrial automation systems
TwinCAT & Beckhoff Engineering Support for OEMs, System Integrators and End Users
Expert Engineering Services: PLC, Motion Control & IT/OT Integration
Selected TwinCAT Projects
TwinCAT 3 Software Framework for Machine Builders
Automated Assembly and Testing Line for Blood Plasma Storage Bottles
Medical Testing System for Neurosurgical Drill Devices
Description
Development of a comprehensive TwinCAT 3 software framework created to standardize PLC software across multiple machine platforms. The object-oriented architecture included reusable libraries for motion control, robotics, industrial communication, vision systems and automatic HMI generation.
Highlights
- Object-oriented software architecture (OOP)
- Reusable libraries for drives, robotics and industrial communication
- Automatic HMI component generation
- Standardized alarm management using TwinCAT EventLogger
- Significantly reduced engineering and commissioning time
Technologies
TwinCAT 3, OOP, Motion Control, OPC UA, ADS, EventLogger, Software Architecture
Description
Fully automated production line performing assembly, leak testing, labeling, traceability and final product sorting for medical blood plasma storage bottles. The project integrated multiple robotic workstations, industrial vision systems and comprehensive product tracking throughout the manufacturing process.
Highlights
- Fanuc and SCARA robots integrated with the Bosch Rexroth TS2 transfer system
- Automated leak testing using ATEQ leak testers
- Dual labeling stations with print quality and QR code verification
- Complete product traceability using IFM smart cameras
- Object-oriented TwinCAT 3 software architecture
Technologies
TwinCAT 3, Fanuc, SCARA, TwinSAFE, Machine Vision, Leak Testing, Traceability
Description
Development of an advanced testing system for neurosurgical drill devices capable of simulating real operating conditions. The solution provided precise force and torque measurements, automated waveform analysis and complete test reporting in accordance with medical industry requirements.
Highlights
- Closed-loop force control using Festo proportional pressure regulators
- High-speed data acquisition with EtherCAT Oversampling
- Automatic waveform analysis and test reporting
- TwinCAT HMI with recipes, alarms and user management
- Developed in accordance with GAMP 5 and 21 CFR Part 11 principles
Technologies
TwinCAT 3, EtherCAT, TwinCAT HMI, Festo, Medical Automation, GAMP 5
Automated End-of-Line Testing System for Hearing Aid Speakers
Flexible R&D Assembly Platform Based on Beckhoff XTS
Description
Development of a high-speed end-of-line testing system for miniature hearing aid speakers measuring just 3 × 2 mm. The machine combined Beckhoff TwinCAT 3, two Mitsubishi SCARA robots, Cognex vision and electroacoustic measurement equipment, achieving a throughput of one tested part every two seconds.
Highlights
- Coordinated control of two Mitsubishi SCARA robots
- Fully automated electroacoustic testing and part handling
- Intelligent robot synchronization and tray management
- Automatic product classification into one OK and ten NOK categories
- OPC UA integration with the Manufacturing Execution System (MES)
Technologies
TwinCAT 3, Beckhoff CX5140, Mitsubishi SCARA, Cognex Vision, TwinSAFE, OPC UA, Motion Control
Description
Development of a modular research and development platform designed for rapid validation of new assembly processes. Beckhoff XTS and configurable workstation logic enabled complete production flow changes directly from the HMI without modifying PLC software.
Highlights
- Configurable production sequences directly from the HMI
- Intelligent Beckhoff XTS transport system
- Integration of an Asyril flexible feeding system
- Interchangeable tooling and modular process stations
- Designed for Proof-of-Concept and R&D applications
Technologies
TwinCAT 3, Beckhoff XTS, TwinSAFE, Cognex , Asyril, Web HMI
Frequently Asked Questions
TwinCAT Engineer is a specialized Beckhoff brand of AB Automation Systems. As an independent freelance automation engineer and PLC consultant, I deliver expert control system design, advanced programming within the TwinCAT 3 ecosystem, IT/OT integration, and commissioning services for OEMs, system integrators, and smart factories across Europe.
Yes, my goal is to ensure the long-term stability of your system. I provide comprehensive post-commissioning support, hands-on assistance during initial production runs, and tailored training sessions for your maintenance teams so your staff can confidently handle day-to-day diagnostics and operations.
Based in Poland, I provide engineering support to clients throughout Europe. To keep projects cost-effective and agile, conceptual design, network architecture planning, and core PLC programming are handled via remote engineering. For critical phases like factory/site acceptance testing (FAT/SAT), physical commissioning, and production monitoring, I work directly on-site at your facility.
Let’s talk about your automation challenge
Tell me about your system requirements, technical challenges, or engineering support needs — I usually respond within 24 hours
Contact inforamtion
I usually respond to emails within one business day.
Project discussions can be arranged via Microsoft Teams, Google Meet or on-site meetings.
Based in Szczecin, Poland, I provide engineering support for machine builders, system integrators and manufacturers across Europe. My location enables rapid on-site support throughout Central Europe, while remote engineering and on-site commissioning allow projects to be delivered anywhere in Europe.