I help plan Beckhoff control architecture before programming starts. I develop PLC and HMI software in TwinCAT 3 from scratch, take over unfinished projects and support machine commissioning.
Independent PLC Engineer | Beckhoff TwinCAT 3
I design and develop control systems for machines and production lines — from control concepts and new PLC applications to commissioning, upgrades and modernization of existing equipment.
Engineering support for machine builders, integrators and manufacturers
New machine or unfinished project?
Problems with an existing machine?
I review existing TwinCAT applications, troubleshoot faults, optimize cycle times and add new functions. For older equipment, I can help replace outdated controls with a modern Beckhoff-based system.
Need production data from your machines?
I use available PLC signals or retrofit machines with sensors and I/O modules. I help capture process values, cycle times and downtime, and make the data available to monitoring or MES systems — including from machines with other controller platforms.
Engineering Services
Selected Projects
These projects show how TwinCAT 3 has been used to standardize machine software, integrate production lines, deliver precise automated testing and shorten machine cycles. Each case highlights a practical engineering challenge and the solution behind it.
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
To reduce duplicated PLC code and simplify future machine projects, a reusable TwinCAT 3 framework was developed. Its object-oriented libraries covered motion control, robot integration, industrial communication, vision systems and automatic HMI component 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
- Reusable modules reducing work on subsequent projects
Technologies
TwinCAT 3, OOP, Motion Control, OPC UA, ADS, EventLogger, Software Architecture
Description
A production line for assembling, leak-testing, labeling and sorting medical blood plasma bottles required coordination across multiple stations. The TwinCAT 3 control system integrated the Bosch Rexroth TS2 transport system, industrial robots, machine vision and QR-code-based traceability.
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
A test system for neurosurgical drill devices had to reproduce operating conditions and evaluate results automatically. The solution combined precise force and torque measurement with waveform analysis and reporting according to the project’s 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 with GAMP 5 guidance and relevant 21 CFR Part 11 requirements in mind
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
Testing miniature hearing-aid speakers measuring only 3 × 2 mm required precise part handling and short machine cycles. The TwinCAT 3 system combined two Mitsubishi SCARA robots, Cognex vision and measurement equipment, achieving 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
A modular R&D platform was built to validate new assembly processes without repeatedly rewriting PLC logic. With Beckhoff XTS and configurable station control, production sequences could be adjusted from the HMI without changing the PLC application.
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 the Beckhoff-focused brand of my business, Adrian Bogdzia Automation Systems. I work as an independent engineer designing and developing TwinCAT 3 control software, taking over existing projects and supporting machine commissioning and modernization.
Yes. I can review existing PLC software, troubleshoot problems, add functions or optimize machine cycles. Where appropriate, I can also help retrofit older machines with a Beckhoff control system. The scope depends on the current equipment and documentation.
Yes. I can support production ramp-up, diagnose issues that appear after commissioning, and train operators and maintenance teams. Ongoing technical support can also be arranged based on the needs of the project.
Based in Szczecin, Poland, I support machine builders, system integrators and manufacturers across Europe. Control design and PLC development can be handled remotely, while FAT/SAT, commissioning, optimization and production support are performed on-site when needed.
Let’s Discuss Your Project
Building a new machine, dealing with an existing control system or looking to collect production data? Tell me about the equipment and challenge — I usually reply within one business day.
Contact information
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.