Automation & Controls Engineer (5+ Years)

RAMAPRASAD PALLAPOTHU

Automation & Controls Engineer 5+ Years of Experience

USA +1-610-***-**** ***********************@*****.*** PROFESSIONAL SUMMARY

Automation & Controls Engineer with 5+ years of experience in designing, developing, and commissioning industrial automation and control systems across manufacturing and process industries. Proficient in Allen-Bradley ControlLogix/CompactLogix PLC programming using Studio 5000, FactoryTalk View ME/SE HMI development, PowerFlex VFD configuration, and EtherNet/IP communication. Experienced in the complete project lifecycle, including control system design, electrical drawing review, PLC/HMI development, I/O verification, FAT/SAT, commissioning, startup support, troubleshooting, and customer handover. Hands-on experience with industrial networking, remote I/O, machine safety, IIoT-based monitoring, and real-time production dashboards using Ignition and OPC-UA. Holds a Master's degree in Engineering Management (USA) and a Bachelor's degree in Electrical ElectronicsEngineering . Recognized for collaborating effectively with cross-functional teams, optimizing machine performance, improving system reliability, and delivering high-quality automation solutions from concept through successful customer acceptance. SKILLS

• PLC Platforms: Allen-Bradley ControlLogix, CompactLogix, GuardLogix (Safety PLC / SIL-rated systems); Siemens S7- 1200/S7-1500

• Programming: Studio 5000, Siemens TIA Portal, Ladder Logic, IEC 61131-3 fundamentals

• HMI/SCADA: FactoryTalk View ME/SE, FactoryTalk Linx (RSLinx), Ignition SCADA, WinCC OA, Wonderware, AVEVA

• Robotics: Fanuc robot integration and programming support

• Drives & Motion: Allen-Bradley PowerFlex VFD configuration, motor control, servo/motion control systems

• Networking & Protocols: EtherNet/IP, Modbus TCP, Profinet, OPC-UA, DeviceNet, MQTT/Sparkplug B

• Electrical & Design Tools: AutoCAD Electrical, EPLAN (panel documentation), I/O list review

• Testing & Commissioning: FAT/SAT execution, I/O verification, sensor testing, alarm validation, startup support

• Continuous Improvement: Root Cause Analysis (RCA/5-Why), Lean Manufacturing, OEE Improvement

• Other Tools: Microsoft Office, Excel, Visio, Jira

• Soft Skills: Cross-functional Collaboration, Technical Documentation, Troubleshooting, Customer Training & Support PROFESSIONAL EXPERIENCE

Calvary Robotics Jan 2025 – Till Date

Automation Controls Engineer Dallas, TX

• Developed and modified PLC programs using Allen-Bradley ControlLogix/CompactLogix platforms in Studio 5000 to support industrial automation systems.

• Created and updated FactoryTalk View HMI screens to improve operator visibility and control system usability.

• Reviewed electrical drawings and I/O lists to verify system design accuracy prior to installation and testing.

• Troubleshot electrical and control system issues, working closely with mechanical engineers, electricians, and project managers to resolve field issues efficiently.

• Participated in FAT and SAT testing, documenting program changes and supporting technical startup activities during customer acceptance.

• Designed and implemented PLC logic modifications to support new product introductions and process changes on the plant floor.

• Configured and tuned PowerFlex VFDs and servo drives to optimize motor performance and reduce downtime on production lines.

• Established and maintained EtherNet/IP and Profinet network communications between PLCs, HMIs, and field devices to ensure reliable data exchange.

• Performed root cause analysis on recurring equipment faults and implemented corrective actions to improve overall equipment effectiveness (OEE).

• Maintained and updated control system documentation, including electrical schematics, I/O lists, and program change logs, to ensure compliance with plant standards.

• Provided on-site technical support and training to plant operators and maintenance staff on new or upgraded automation systems.

Lone Horse Ventures Feb 2024 – Dec 2024

Controls Engineer Pasadena, CA

• Programmed and maintained Allen-Bradley ControlLogix/CompactLogix PLCs using Studio 5000 for automation system upgrades.

• Configured PowerFlex VFDs for motor control applications and validated performance during commissioning.

• Worked with EtherNet/IP, Modbus TCP, and Profinet communication protocols to integrate PLCs, HMIs, and field devices.

• Used AutoCAD Electrical and EPLAN to review and support panel documentation for control system installations.

• Tracked project tasks and documentation using Microsoft Office, Excel, Visio, and Jira. NewEra Technologies Aug 2019 – Jul 2022

Junior Automation Engineer / Software Developer Bangalore, India

• Assisted in developing PLC logic and supported testing activities under senior engineer guidance for automation projects.

• Supported I/O verification, sensor testing, and motor direction checks during commissioning of control systems.

• Contributed to technical documentation of PLC programs and system changes for project records.

• Coordinated with project teams to troubleshoot control system issues and report findings during system startup. KEY PROJECTS

Material Handling Automation & Control System

Technologies: Allen-Bradley ControlLogix, Studio 5000, FactoryTalk View SE/ME, PowerFlex VFDs, EtherNet/IP, Remote I/O, PLC, HMI

Responsibilities:

• Developed PLC control logic using Studio 5000 and designed FactoryTalk View HMI screens for an automated conveyor and palletizing system.

• Configured remote I/O modules and integrated PowerFlex VFDs, validating EtherNet/IP communication to ensure reliable system performance.

• Executed I/O verification, sensor calibration, motor rotation checks, and alarm validation during factory acceptance testing

(FAT), site acceptance testing (SAT), and commissioning.

• Optimized conveyor sequencing, enhanced fault diagnostics, and reduced system downtime through effective troubleshooting and control logic improvements.

• Collaborated with commissioning teams to support system startup, operator training, and successful customer handover. Industrial IoT-Based Power Monitoring and Drive Control System Technologies: Allen-Bradley ControlLogix, Studio 5000, PowerFlex 755 VFDs, FactoryTalk Historian, FactoryTalk View, EtherNet/IP, AOIs, Industrial IoT (IIoT)

• Deployed and commissioned PowerFlex 755 Variable Frequency Drives (VFDs) across 14 pump stations, configuring au-tune parameters to optimize motor performance and reduce peak-demand electricity costs by $42K annually.

• Developed custom Add-On Instructions (AOIs) in Studio 5000 to monitor real-time power consumption and drive performance for each VFD.

• Integrated power and operational data with FactoryTalk Historian to enable historical trending, energy analytics, and monthly management reporting.

• Configured EtherNet/IP communication between PLCs, VFDs, and Historian to ensure reliable real-time data acquisition and monitoring.

• Collaborated with operations and maintenance teams to validate system performance, optimize energy efficiency, and improve predictive maintenance through data-driven insights. Industrial Machine Safety & PLC Modernization

Technologies: Allen-Bradley GuardLogix/ControlLogix, Studio 5000, FactoryTalk View SE, Safety I/O, EtherNet/IP, Safety Relays, E-Stop, Light Curtains

• Developed and enhanced safety PLC logic in Studio 5000, implementing machine safety interlocks, emergency stop (E-Stop) circuits, and safety zone control for stamping press operations.

• Redesigned safety-zone logic and improved FactoryTalk View SE HMI fault messaging, reducing safety-related unplanned line stops by 55% within the first three months after commissioning.

• Performed safety I/O validation, device testing, and commissioning of safety components, including light curtains, safety relays, and emergency stop circuits.

• Troubleshot safety control issues, optimized machine recovery sequences, and collaborated with production and maintenance teams to ensure compliance with industrial safety standards and successful project handover. Real-Time Production Monitoring Using Ignition and OPC-UA (In Progress – 2025) Technologies: Ignition v8.1, Ignition MES, OPC-UA, Allen-Bradley PLCs, Studio 5000, SQL Server, Python Scripting, SCADA, Industrial IoT (IIoT)

• Developing Ignition v8.1 MES applications with OPC-UA connectivity to acquire real-time production data from five Allen- Bradley PLCs.

• Designing and implementing real-time shift performance dashboards to monitor production KPIs, equipment status, downtime, and throughput across three manufacturing lines at Eaton.

• Integrating PLC data with SQL Server and Ignition Historian for real-time visualization, historical trending, and production reporting.

• Configuring OPC-UA tags, alarms, and event monitoring to ensure reliable data acquisition and seamless communication between PLCs and the MES platform.

• Collaborating with production and operations teams to validate dashboard functionality, optimize manufacturing visibility, and support the ongoing MES rollout.

EDUCATION

Master of Science (M.S.) in Engineering Management Indiana tech, USA 2023 Bachelor of Technology (B.Tech.) in Electrical ElectronicsEngineering Andhra University India 2019 CERTIFICATIONS & TRAINING

Rockwell Automation – Studio 5000 / ControlLogix Programming

Siemens – TIA Portal Fundamentals

Inductive Automation – Ignition Core Certification

Inductive Automation – Ignition Gold Certification / Architect

ISA – Certified Control Systems Technician (CCST) Level I

IEC 62443 - Industrial Cybersecurity Foundations

OSHA 10-Hour General Industry Safety

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