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$10 USD / hour
Flag of UNITED STATES
$10 USD / hour
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Joined June 22, 2022
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James A.

@jamesraulgur

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$10 USD / hour
Flag of UNITED STATES
$10 USD / hour
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Middleware software designer and machine builder

Specializing in motion process controls I have been working as a contractor since 1987 with PLCs and code with C C# VB embedded systems with motor controls, hydraulics, pneumatics, servo and stepper systems, proficient in Fusion 360 for solid modeling and CAM work electrical designs in AutoCad, Industrial Controls systems built from concept to commissioning. Middleware provided for warehouses including barcode collection, weighted scales and shipping and systems. Integration of all aspects of warehouses and manufacturing floors. Entire controls systems built from the ground up. Multi Door plc systems for large systems and small single door wall mounted units for smaller systems.
Freelancer Visual Basic Developers United States

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Portfolio Items

I started manufacturing rotators for paint booths some time ago for a local customer.  The problem was he would just need one but never had any drawings for me to work off of.  Typical customer he didn't see the need for any drawings when he could sketch out what he needed on a bar napkin and say hey build this for me will ya...  I didn't make many of them before I started to make drawings for myself to build these things.  He would want them in all different lengths so I decided to make them modular.  And since I did it in Fusion 360 the parts I could port over to my CNC machines to get the parts made.  He never did pay anything extra for me to do that but in the long run it saved me money and time by making my own drawings. Sometimes you just have to grin and bear it with customers that don't get it.  Now there is no one that can touch him when it comes to his prices so it works out well for both of us.  I won't give him the actual mechanical drawings he gets he gets exploded views.
Mechanical design build. Paint' booth rotators.
I started manufacturing rotators for paint booths some time ago for a local customer.  The problem was he would just need one but never had any drawings for me to work off of.  Typical customer he didn't see the need for any drawings when he could sketch out what he needed on a bar napkin and say hey build this for me will ya...  I didn't make many of them before I started to make drawings for myself to build these things.  He would want them in all different lengths so I decided to make them modular.  And since I did it in Fusion 360 the parts I could port over to my CNC machines to get the parts made.  He never did pay anything extra for me to do that but in the long run it saved me money and time by making my own drawings. Sometimes you just have to grin and bear it with customers that don't get it.  Now there is no one that can touch him when it comes to his prices so it works out well for both of us.  I won't give him the actual mechanical drawings he gets he gets exploded views.
Mechanical design build. Paint' booth rotators.
A few years ago a customer that had an inverted power and free system ended up having a problem with clearance on his turner system.  This was on a carbon fiber turbine blade line and this was the rotator that spun the blades in the curing oven.  The issues were that the machine had to be foldable to get it into the oven and that the inverted power and free carriers were very close to the rotator.  So I designed a system with a center drive on a rotator and found a way to eliminate the engagement problem for the sprockets on the inverted power and free rotator.  This eliminated a problem with space at either end of the turner.  I cantilevered the rotator and brought in the end users carriers in solid models to make sure everything would work.  Once we had it in solids they could see everything would work fine.  And I ended up building it for them.  This was done in Fusion 360 (similar to solid works and inventor but it has CAM abilities.  Concept to finish product. It works great.
Machine Design offering a suggestion brings new work.
A few years ago a customer that had an inverted power and free system ended up having a problem with clearance on his turner system.  This was on a carbon fiber turbine blade line and this was the rotator that spun the blades in the curing oven.  The issues were that the machine had to be foldable to get it into the oven and that the inverted power and free carriers were very close to the rotator.  So I designed a system with a center drive on a rotator and found a way to eliminate the engagement problem for the sprockets on the inverted power and free rotator.  This eliminated a problem with space at either end of the turner.  I cantilevered the rotator and brought in the end users carriers in solid models to make sure everything would work.  Once we had it in solids they could see everything would work fine.  And I ended up building it for them.  This was done in Fusion 360 (similar to solid works and inventor but it has CAM abilities.  Concept to finish product. It works great.
Machine Design offering a suggestion brings new work.
A few years ago a customer that had an inverted power and free system ended up having a problem with clearance on his turner system.  This was on a carbon fiber turbine blade line and this was the rotator that spun the blades in the curing oven.  The issues were that the machine had to be foldable to get it into the oven and that the inverted power and free carriers were very close to the rotator.  So I designed a system with a center drive on a rotator and found a way to eliminate the engagement problem for the sprockets on the inverted power and free rotator.  This eliminated a problem with space at either end of the turner.  I cantilevered the rotator and brought in the end users carriers in solid models to make sure everything would work.  Once we had it in solids they could see everything would work fine.  And I ended up building it for them.  This was done in Fusion 360 (similar to solid works and inventor but it has CAM abilities.  Concept to finish product. It works great.
Machine Design offering a suggestion brings new work.
A few years ago a customer that had an inverted power and free system ended up having a problem with clearance on his turner system.  This was on a carbon fiber turbine blade line and this was the rotator that spun the blades in the curing oven.  The issues were that the machine had to be foldable to get it into the oven and that the inverted power and free carriers were very close to the rotator.  So I designed a system with a center drive on a rotator and found a way to eliminate the engagement problem for the sprockets on the inverted power and free rotator.  This eliminated a problem with space at either end of the turner.  I cantilevered the rotator and brought in the end users carriers in solid models to make sure everything would work.  Once we had it in solids they could see everything would work fine.  And I ended up building it for them.  This was done in Fusion 360 (similar to solid works and inventor but it has CAM abilities.  Concept to finish product. It works great.
Machine Design offering a suggestion brings new work.
A few years ago a customer that had an inverted power and free system ended up having a problem with clearance on his turner system.  This was on a carbon fiber turbine blade line and this was the rotator that spun the blades in the curing oven.  The issues were that the machine had to be foldable to get it into the oven and that the inverted power and free carriers were very close to the rotator.  So I designed a system with a center drive on a rotator and found a way to eliminate the engagement problem for the sprockets on the inverted power and free rotator.  This eliminated a problem with space at either end of the turner.  I cantilevered the rotator and brought in the end users carriers in solid models to make sure everything would work.  Once we had it in solids they could see everything would work fine.  And I ended up building it for them.  This was done in Fusion 360 (similar to solid works and inventor but it has CAM abilities.  Concept to finish product. It works great.
Machine Design offering a suggestion brings new work.
This is middleware.  Years ago I had a customer with a 40 plus lane Buschman shoe sorter.  The problem was that the controls package on the sorter was not flexible enough to do what the customer wanted.  So I intercepted the packets from the sorter via sockets and made modified custom calls against the PKMS warehouse management system, (An AS400 at the time).  I was able to modify the data to ship it properly and correct lane assignments based on the additional data.  A server side middleware package that intercepted data from the sorter, collected data from two barcode scanner weighing scales with a line printers for package printing, the barcode rework loop and it even provided user messages about why the package was rejected via a color message board.  Included here is also a snapshot of the servo controlled PC based weighting scales and SKU collection software, two of these units were also supplied data from my middleware package.  A truly hard core TCP sockets app written in C#.
Seems like yesterday - I have been doing this a long time.
This is middleware.  Years ago I had a customer with a 40 plus lane Buschman shoe sorter.  The problem was that the controls package on the sorter was not flexible enough to do what the customer wanted.  So I intercepted the packets from the sorter via sockets and made modified custom calls against the PKMS warehouse management system, (An AS400 at the time).  I was able to modify the data to ship it properly and correct lane assignments based on the additional data.  A server side middleware package that intercepted data from the sorter, collected data from two barcode scanner weighing scales with a line printers for package printing, the barcode rework loop and it even provided user messages about why the package was rejected via a color message board.  Included here is also a snapshot of the servo controlled PC based weighting scales and SKU collection software, two of these units were also supplied data from my middleware package.  A truly hard core TCP sockets app written in C#.
Seems like yesterday - I have been doing this a long time.
This is middleware.  Years ago I had a customer with a 40 plus lane Buschman shoe sorter.  The problem was that the controls package on the sorter was not flexible enough to do what the customer wanted.  So I intercepted the packets from the sorter via sockets and made modified custom calls against the PKMS warehouse management system, (An AS400 at the time).  I was able to modify the data to ship it properly and correct lane assignments based on the additional data.  A server side middleware package that intercepted data from the sorter, collected data from two barcode scanner weighing scales with a line printers for package printing, the barcode rework loop and it even provided user messages about why the package was rejected via a color message board.  Included here is also a snapshot of the servo controlled PC based weighting scales and SKU collection software, two of these units were also supplied data from my middleware package.  A truly hard core TCP sockets app written in C#.
Seems like yesterday - I have been doing this a long time.
This was a design for a conveyor system that controls an intersections for routing packages throughout the warehouse via a 24 volt low voltage conveyor system.  I designed and built 38 of these units, each contained a SBC (single board computer) with an ethernet connection and a barcode reader.  Each of these units was commissioned via a C# master program written by me that talked to the warehouse management system via TCP sockets.  Depending on the location of the device within the warehouse it would operate in one of three modes.  Stand alone, Near Real Time or Real Time.  In stand alone these units would be loaded with a flat file containing route info for the packages, in near real time it would send a data packet back to my master with the SKU and if requested it would supersede local data and rerouted as required.  In real time, every SKU was routed to the master controller and a call was made to the warehouse management system.  Creating a very robust and flexible system.
Imbedded Systems and SBCs
This was a design for a conveyor system that controls an intersections for routing packages throughout the warehouse via a 24 volt low voltage conveyor system.  I designed and built 38 of these units, each contained a SBC (single board computer) with an ethernet connection and a barcode reader.  Each of these units was commissioned via a C# master program written by me that talked to the warehouse management system via TCP sockets.  Depending on the location of the device within the warehouse it would operate in one of three modes.  Stand alone, Near Real Time or Real Time.  In stand alone these units would be loaded with a flat file containing route info for the packages, in near real time it would send a data packet back to my master with the SKU and if requested it would supersede local data and rerouted as required.  In real time, every SKU was routed to the master controller and a call was made to the warehouse management system.  Creating a very robust and flexible system.
Imbedded Systems and SBCs
This was a design for a conveyor system that controls an intersections for routing packages throughout the warehouse via a 24 volt low voltage conveyor system.  I designed and built 38 of these units, each contained a SBC (single board computer) with an ethernet connection and a barcode reader.  Each of these units was commissioned via a C# master program written by me that talked to the warehouse management system via TCP sockets.  Depending on the location of the device within the warehouse it would operate in one of three modes.  Stand alone, Near Real Time or Real Time.  In stand alone these units would be loaded with a flat file containing route info for the packages, in near real time it would send a data packet back to my master with the SKU and if requested it would supersede local data and rerouted as required.  In real time, every SKU was routed to the master controller and a call was made to the warehouse management system.  Creating a very robust and flexible system.
Imbedded Systems and SBCs
This was a design for a conveyor system that controls an intersections for routing packages throughout the warehouse via a 24 volt low voltage conveyor system.  I designed and built 38 of these units, each contained a SBC (single board computer) with an ethernet connection and a barcode reader.  Each of these units was commissioned via a C# master program written by me that talked to the warehouse management system via TCP sockets.  Depending on the location of the device within the warehouse it would operate in one of three modes.  Stand alone, Near Real Time or Real Time.  In stand alone these units would be loaded with a flat file containing route info for the packages, in near real time it would send a data packet back to my master with the SKU and if requested it would supersede local data and rerouted as required.  In real time, every SKU was routed to the master controller and a call was made to the warehouse management system.  Creating a very robust and flexible system.
Imbedded Systems and SBCs
This was a design for a conveyor system that controls an intersections for routing packages throughout the warehouse via a 24 volt low voltage conveyor system.  I designed and built 38 of these units, each contained a SBC (single board computer) with an ethernet connection and a barcode reader.  Each of these units was commissioned via a C# master program written by me that talked to the warehouse management system via TCP sockets.  Depending on the location of the device within the warehouse it would operate in one of three modes.  Stand alone, Near Real Time or Real Time.  In stand alone these units would be loaded with a flat file containing route info for the packages, in near real time it would send a data packet back to my master with the SKU and if requested it would supersede local data and rerouted as required.  In real time, every SKU was routed to the master controller and a call was made to the warehouse management system.  Creating a very robust and flexible system.
Imbedded Systems and SBCs
Designed from the ground up to the customers specifications with appropriate I/O including HMIs and all the drawings including bills of materials.  I design and build the controls systems to meet my customers needs or use my customers design and build their panels as designed.  I do a power on test and checks, program them and once installed I do testing and debug.  I wrap up the projects with a complete document package including as builts and documented code.  I either spec equipment to be used or use customer requested hardware as requested by my customers.  I enjoy doing this work and on occasion will bring in other builders on an as needed basis to meet my customers deadlines.
Panels being fabricated in my shop
Designed from the ground up to the customers specifications with appropriate I/O including HMIs and all the drawings including bills of materials.  I design and build the controls systems to meet my customers needs or use my customers design and build their panels as designed.  I do a power on test and checks, program them and once installed I do testing and debug.  I wrap up the projects with a complete document package including as builts and documented code.  I either spec equipment to be used or use customer requested hardware as requested by my customers.  I enjoy doing this work and on occasion will bring in other builders on an as needed basis to meet my customers deadlines.
Panels being fabricated in my shop
Designed from the ground up to the customers specifications with appropriate I/O including HMIs and all the drawings including bills of materials.  I design and build the controls systems to meet my customers needs or use my customers design and build their panels as designed.  I do a power on test and checks, program them and once installed I do testing and debug.  I wrap up the projects with a complete document package including as builts and documented code.  I either spec equipment to be used or use customer requested hardware as requested by my customers.  I enjoy doing this work and on occasion will bring in other builders on an as needed basis to meet my customers deadlines.
Panels being fabricated in my shop

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Experience

Industrial Controls business owner and operator

ISICo Industrial Systems Integrators Co,
Nov 1987 - Present
I design and build controls systems (control panels) , mostly electrical but also hydraulic and pneumatic. I build design and build machines from the ground up from concept to completion. My typical customers are usually resellers or distributors for equipment or conveyors. On occasion I work with the end user. This is becoming more important recently due to my life long and repeat customers I have had over the years are getting older, retiring or dying on me. I love what I do...

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Visual Basic Engineering Electronics CAD/CAM C# Programming

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