SHIV KUMAR
Mechanical & Automation
Engineering Portfolio
Shiv Kumar – Engineering Portfolio - kumarshiv_sk@outlook.com
Designed and developed a hydraulic controlled robotic arm with
3 DOF, consisting of following components
• Aluminum Bars – Base Frame
• Plexi Glass
• Servo Motor - Base
• Designed Power Supply to interface with wall adapter
Designed and programmed Servo Motor
Controller to control servo motor (12V) with
Atmega328P and potentiometer through
external (110 V) power supply
ROBOTIC ARM
APPLIED MANUFACTURING PROJECT
Shiv Kumar – Engineering Portfolio
Powered by Arduino microcontroller, Lithium-Ion battery and equipped with
ultrasonic sensors (HC-SR04), infrared sensors, dc motors, L298N driver, Li-Ion battery
etc. designed to navigate through its environment while evading obstacles in its path.
Shiv Kumar – Engineering Portfolio
Speed control circuit
and components
ROBOTIC CAR
ARDUINO – AVR MCU
User Interface for accessing a simple
password protected system.
Reading analog signals from
potentiometer and displaying the
pulse width modulation (PWM) on
oscilloscope
NEMA 17 Stepper Motor controlled with
TB6600 driver and external power supply.
Shiv Kumar – Engineering Portfolio
ARDUINO
MICROCONTROLLERS
// Receiving Side- RX
#define F_CPU 1000000
#include <avr/io.h>
#include <util/delay.h>
int main(void)
{
DDRB |= (1 << PINB2);
PORTB &= ~(1 << PINB2);
// communication
int UBRR_value = 25;
UBRR0H = (unsigned char) (UBRR_value >> 8);
UBRR0L = (unsigned char) UBRR_value;
UCSR0B |= (1 << RXEN0);
UCSR0C |= (1 << USBS0) | (1 << UCSZ00) | (1
<< UCSZ01);
unsigned char receiveData;
while (1)
{
while (!(UCSR0A & (1 << RXC0)));
receiveData = UDR0;
if (receiveData == 0b11110000)
{
PORTB ^= 1 << PINB2;
}
}
}
// Transmitting Side- TX
#define F_CPU 1000000
#include <avr/io.h>
#include <util/delay.h>
int main(void)
{
DDRB |= (1 << PINB1);
PORTB &= ~(1 << PINB1);
DDRB &= ~(1 << PINB0);
PORTB |= (1 << PINB0);
int Pressed = 0;
int Pressed_Confidence_Level = 0;
int Released_Confidence_Level = 0;
// communication
int UBRR_value = 25;
UBRR0H = (unsigned char) (UBRR_value >> 8);
UBRR0L = (unsigned char) UBRR_value;
UCSR0B |= (1 << TXEN0);
UCSR0C |= (1 << USBS0) | (1 << UCSZ00) | (1 <<
UCSZ01);
while (1)
{
if((PINB & (1<<PINB0)) == 1)
{
Pressed_Confidence_Level ++;
Released_Confidence_Level = 0;
if(Pressed_Confidence_Level > 100)
{
if (Pressed == 0)
{
Pressed = 1;
PORTB ^= (1 << PINB1);
while (!(UCSR0A & (1 <<
UDRE0)));
UDR0 = 0b11110000;
}
Pressed_Confidence_Level = 0;
}
}
else
{
Released_Confidence_Level ++;
Pressed_Confidence_Level = 0;
if(Released_Confidence_Level > 100)
{
Pressed = 0;
Released_Confidence_Level = 0;
}
}
}
}
RECEIVER
TRANSMITTER
USART - COMM
2 X ATMEGA
USART REGISTERS – Control and status, Data, Baud Rate
Shiv Kumar – Engineering Portfolio
USART - COMM
2 X ATMEGA
For this project on Washing Machine Controls, we used a MicroLogix 1100 PLC and used RSLogix 500 to design the control system.
We developed flow charts and interfaced I/O modules like motors and limit switches. The system utilized timers, counters, and
comparative instructions, organized with address charts, and implemented using Ladder Logic Diagrams for seamless operation control.
Allen Bradley’s PLC
ALLEN BRADLEY PLC
WASHING MACHINE CONTROLS
Shiv Kumar – Engineering Portfolio
Designed control logic and developed PLC
program to move the elevator between
multiple floors. Essential functionalities include
precise control of
• door cycles,
• registering passenger requests that prompt
elevator movement,
• floor recognition,
• hoist logic,
• determining travel direction and
• updating status indicators.
Simulated the program for expected behavior.
ELEVATOR CONTROLS DESIGN
PROJECT
Shiv Kumar – Engineering Portfolio
Created Recipes and displays in FactoryTalk
View with various ingredients. Linked data
variables with Studio 5000 PLC program.
Features Include:
• On display recipe creation and
modification
• Alarms and Messages
• Security/ User Access
HUMAN MACHINE INTERFACE DESIGN
RECIPES
Shiv Kumar – Engineering Portfolio
Developed control systems and HMI application
for an industrial mixer, enabling precise
monitoring and control of mixing parameters. The
system included real-time data acquisition, alarms,
and automated adjustments, resulting in a 25%
increase in process efficiency and enhanced
operational safety.
Implemented controller communications to load
user values for ingredients from a remote
controller.
Monitored flow, level, temperature properties and
implemented high temperature and overload trip
alarms and management, interlocks, modes of
operation (maintenance, operator, program).
SCADA & CONTROLS DESIGN
Shiv Kumar – Engineering Portfolio
INDUSTRIAL MIXER
HMI Display
Created HMI displays and PLC program to control and
analyze process.
Linked MS SQL Server Management Studio (SSMS) to
various applications and wrote SQL Queries to analyze
data from Factory Talk View SE and Studio 5000.
INDUSTRIAL MIXER
Shiv Kumar – Engineering Portfolio
SCADA & CONTROLS DESIGN
Left: Automatic PID Tuning of temperature (Process Variable),
through PIDE instruction while considering lag and dead time to find
P, I and D values for fast, medium and slow responses.
Right: Manual tuning and response observed with trends.
Implemented proportional, integral and derivative controls
independently and in combinations.
PLC CONTROLS DESIGN
Shiv Kumar – Engineering Portfolio
PID TUNING
Equipment Phase control
Created program to model machinery around the S-88 Industry
Standard for State Machine Control. Added Phase managed system
for batch control of a process to stop, hold, abort, reset etc.
HUMAN MACHINE INTERFACE
PROCESS CONTROL
Shiv Kumar – Engineering Portfolio
WASTE WATER TREATMENT
Shiv Kumar – Engineering Portfolio
Installed Water/ Wastewater Accelerator Toolkit (WWWAT), a
feature rich application from Rockwell for industrial plants and
supervised operation of pumps responsible for movement and
processing of waste.
Switched between various pumps with interlock and permissive
controls for duration, level, temperature, overloads etc.
Overridden faults and acknowledged alarms in different process
modes - Operator, Program, Maintenance.
PROCESS CONTROL
Control Panel Hardware installation
• Installed PLC, Switches, NO-NC contacts,
indicators, Circuit Breaker, contactors,
overload relay, AC and DC power supply
• Wired components, tested and verified for
expected functionality with multimeters
and other electrical test equipment.
• Complied with electric code and safety
regulations
ELECTRICAL INSTALLATION
HARDWARE
Shiv Kumar – Engineering Portfolio
PLC CONTROLS DESIGN
AB MicroLogix PLC Interfacing with analog
devices including potentiometer, lamp and
thermocouple.
• Established PLC connections with
sensors and measured relative current,
voltage with multimeter and observed
relations for closeness
• Recorded respective PLC produced raw
analog values at multiple intervals.
• Scaled raw data and mapped the analog
input of one module to match the
output tag of other module.
• Implemented control logic in RSLogix
500 to adjust the brightness with
potentiometer
Shiv Kumar – Engineering Portfolio
ALLEN BRADLEY
Thermocouple
Lamp
• Wiring diagram of lamp and thermocouple
devices (left image).
• In next step, a thermocouple installed
right next to the lamp was used to observe
rise in temperature with time (right
image).
PLC CONTROLS DESIGN
Shiv Kumar – Engineering Portfolio
ALLEN BRADLEY
Shiv Kumar – Engineering Portfolio
SIEMENS PLC
Sequential Program
Siemens PLC – S7-200
Leveraged MicroWIN software to program
Siemens PLC involving controls for I/O devices.
• Implemented controls in additive
sequence for execution of program in
steps
• Buttons, switches, Indicators, single and
double acting solenoids for pneumatic
cylinders
PLC PROGRAMMING
UK1A E2-0A Ultrasonic sensor with range of
50 to 400 mm
Challenge: Determining position of piston end
by converting the raw analog value from
ultrasonic sensor. And stopping cylinder when
desired position(s) reached.
ALLEN BRADLEY
CONTROLS DESIGN
Shiv Kumar – Engineering Portfolio
Scaling in FBD (Alternate)
Sensor wiring diagram (3-wire)
Concept
Research &
Benchmarking
Design Failure
Mode & Effect
Analysis (DFMEA)
Research and Development of product
systematically through:
• Concept Search & Benchmarking
• Design Failure Mode & Effect Analysis
(DFMEA)
• Product validation (Testing and
Experiments) – DVP&R and Flowchart
PRODUCT DEVELOPMENT
GYM EQUIPMENT
Shiv Kumar – Engineering Portfolio
Designed a Rotary Union to deliver fluid and
pressurized gas to a continuously rotating
cylindrical body via passages including following
features
• Seals to avoid fluid leakage from the
• Back-up Rings
• Shaft steps to position and install other
components and grooves for fitting seals,
back-up rings and bearings
• Retainer Ring to keep shaft in position on one
end
Operating Conditions:
• Max RPM = 200
• Max Pressure = 400 PSI
Retainer Ring
O - Rings
Backup Rings
Deep groove Ball Bearing
Holes to supply different
ingredients separately (gas &
fluid) via passages
DESIGN & DRAWINGS
HYDRO-PNEUMATIC SWIVEL
Shiv Kumar – Engineering Portfolio
• Shaft and Cylinder Design for a rotary Union
• Drawings
• Fits & Tolerancing
• Machined after welding
• Shaft that fits body- Tolerances applied for
outer body to revolve freely around it
DESIGN & DRAWINGS
HYDRO-PNEUMATIC SWIVEL
Shiv Kumar – Engineering Portfolio
• Performed extensive calculations leading to proper selection of
standard off-shelf mechanical components such as electrical motors,
pulleys, belts, sprockets, chains, bearings, couplings.
• Performed extensive calculations leading to design systems’ unique
components (shafts, keys, transmission housing and supporting
frame) of the required strength (shape, size and material selection).
MACHINE DESIGN
INDUSTRIAL MIXER
Shiv Kumar – Engineering Portfolio
Detailed calculations of:
• Various stresses on
Gear teeth
• Shaft stresses
• Reduction ratios and
speeds at several stages
MACHINE DESIGN
MACHINE THEORY
Gear Calculations
Shiv Kumar – Engineering Portfolio
Shaft Calculations
MACHINE DESIGN
MACHINE THEORY
Shiv Kumar – Engineering Portfolio
• Concept Design & Sketches
• 3D Modeling
• Created Drawings for manufacturing and assembly
• Manufactured components (machining, 3D printing)
• Assembled and tested
• Variable speed control, adjustable hub diameter (linear
actuated)
CAPSTONE PROJECT
CABLE WINDER
Shiv Kumar – Engineering Portfolio
• Concept Design & Sketches
• 3D Modeling
• Created Drawings for manufacturing and assembly
• Manufactured components (machining, 3D printing)
• Assembled and tested
• Variable speed control, adjustable hub diameter (linear
actuated)
CAPSTONE PROJECT
CABLE WINDER
Shiv Kumar – Engineering Portfolio
Parts manufactured
End product – working prototype
CAPSTONE PROJECT
CABLE WINDER
Shiv Kumar – Engineering Portfolio
• User-centered Design
• User Interaction Design
• Sustainable Design
Implemented following skills on project
• Ergonomics
• Mass Customization and Personalization
INDUSTRIAL DESIGN
SMART HELMET
Shiv Kumar – Engineering Portfolio
Copyright © shivkumartech.com
