Joe Berg

Concept and development of a safety control system for a pilot production machine with seven simultaneously operating robots at seven stations for processing and application of freshly extruded material. Analysis, definition, and technical implementation of safety-relevant requirements for a highly dynamic, multi-axis production system, considering hazards from robotics, movement sequences, material processing, and operator interventions. Implementation of safety-related control logic in TIA Portal in combination with KUKA controllers, as well as design of safe operating modes, release concepts, emergency stop structures, door monitoring, and inter-station interlocks. Structuring of the safety architecture for coordinated collaboration of multiple robot cells with a focus on functional safety, diagnostic capability, expandability, and commissioning suitability.

Concept and development of a solution for the automated creation and maintenance of technical documentation for automation projects. Analysis and structured preparation of project data from TIA Portal, KUKA controllers, and TwinCAT systems for generating consistent, versionable documentation. Implementation of scripts and tools for extracting relevant control, robot, and I/O data, as well as integration into existing development and deployment processes.

Implementation of an additional process station on a TwinCAT-based production machine, including expansion of the control architecture, integration of new drive, sensor, and pneumatic systems, as well as adaptation of safety functions and commissioning in the production environment. The location was Mexico.