On-Site PLC/Robot Data Integration Expert

PLC & Robot Data Integration Engineer — Contract Project (4 Months)

Project Type:Fixed Price Contract
Budget: ₹3,00,000 (slightly negotiable)
Duration: 4 months
Location: On-site required (Satara, Maharashtra) — remote-only freelancers will not be considered
Start: Immediate

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Project Overview

We run AI-powered robot health monitoring and machine inspection systems on live automotive OEM shop floors — CNC/VMC/HMC/lathe machines and industrial robots (KUKA, Fanuc). We need a hands-on automation/controls freelancer to pull real-time and historical data directly off PLCs, CNC controllers, and robot controllers at our Satara plant, and get that data flowing reliably into our central server/database.

This is floor-based integration work — connecting to control panels and robot cabinets, configuring communication, and building the pipeline that carries the data back to us. Not a remote-only or purely software role.

Scope of Work

- Establish live data connections to PLCs/CNC controllers at the Satara plant: Fanuc (FOCAS/Macro B), Siemens, Allen Bradley, Mitsubishi, Delta — mix varies by machine.
- Configure robot controller communication (KUKA, Fanuc) to extract telemetry: current, temperature, torque, cycle time, alarms/faults.
- Use appropriate protocols per machine: OPC UA, Modbus TCP/RTU, Ethernet/IP, RS232/RS485 serial links.
- Set up an edge gateway to aggregate data from multiple machines/robots on-site before onward transmission.
- Push collected data to our central server (**PostgreSQL**) in a clean, standardized format.
- Handle inconsistent legacy machines — some controllers have limited or no native connectivity (older Fanuc Oi-series, Allen Bradley Micrologix, HMT SPMs on hardwired relay logic); propose and implement fallback approaches where needed.
- Document every connection: protocol used, port/config, machine ID, and any workarounds — handed over as a complete connectivity map.
- Test end-to-end: data visible and updating correctly at the central server for each connected machine/robot before sign-off.

Deliverables

1. Working data pipeline from PLCs/robots → edge gateway → central PostgreSQL server, live across the covered machines.
2. Connectivity documentation (protocol, config, machine mapping) for each cell.
3. Handover walkthrough with our internal engineering team.

Required Skills & Experience

- Proven hands-on experience connecting to industrial PLCs/CNC controllers (Fanuc, Siemens, Allen Bradley, or Mitsubishi) — please share specific project examples.
- Working experience with OPC UA, Modbus, Ethernet/IP, or RS232/RS485 communication.
- Experience pulling data from industrial robot controllers (KUKA or Fanuc preferred).
- Comfortable scripting data pipelines in Python (or similar) and writing to PostgreSQL/SQL.
- Able to read control panel wiring/documentation and troubleshoot connectivity issues independently on-site.
- Based in or able to work on-site in Satara for the full contract duration.

Nice to Have

- IIoT/edge gateway deployment experience.
- Prior work with automotive OEM manufacturing plants.
- Experience with SCADA/MES data integration.

Budget & Terms

- Fixed price: ₹3,00,000 for the full 4-month scope (open to slight negotiation based on demonstrated relevant experience).
- Payment terms: milestone-based only — milestones and payout split to be discussed and agreed based on project timelines.
- On-site work at our Satara plant required for the full contract duration.

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To apply: share examples of past PLC/robot communication projects, the protocols/brands you've worked with, and your availability for a 4-month on-site engagement.