Perry's Résumé - Applications Engineering & Motion Control

Working with the teams delivering electrical automation, on the OT side of the IT/OT boundary.

• Built a secure DNP3 data diode supplying real-time field data to IT systems while leaving OT field equipment unreachable from the IT side, at a fraction of commercial diode cost without relaxing the unidirectional guarantee.
• Stood up dev, staging and production deployment for Ignition SCADA, with automated regression testing of Ignition Python scripting, so script changes are validated before production.

Integration, telemetry and control systems for energy and industrial clients; remote systems that run unattended for years.

• Design and validate PID control systems end to end: ezpwd::pid in C++, deployed in aerial data collection systems; the same design in Python, and on-chain in Solidity, where a governed retune() re-derives the integrator so live loops don't step on gain or setpoint changes.
• Derive low-backlash gear tooth forms from first principles for high-ratio single-stage reducers (ikona-style, open source), and apply them to servo and damper design: balanced multi-plate layouts, reflected-inertia budgets, and the force, speed, duty-cycle and thermal sizing of an energy-recovering active damper as a replacement for a conventional shock absorber.
• Model closed-loop comfort control for multi-zone hydronic plants (pyhydronic, open source): PMV-based setpoints, slab-lag compensation and forecast-driven preheat, with minute-by-minute thermal duty-cycle simulation fast enough to explore trade-offs; the approach has controlled a real home for over a decade.
• Created cpppo, the Python EtherNet/IP and CIP library used worldwide to integrate PLCs and drives (ControlLogix, CompactLogix, PowerFlex) with analytics, documented with worked customer-integration examples.
• Built datasim, a large-scale PLC simulation environment that records and replays real field data and injects latency, loss and bandwidth limits, so a SCADA vendor's polling behaviour was measured against degraded WAN and satellite routes before production cutover.
• Delivered ruggedized satellite-connected monitoring, communications and video systems across Alberta oilfields; field-serviceable and diagnosable from hundreds of kilometres away.
• Designed, fabbed and bench-tested a prototype 1-Wire sensor board for intrinsically safe grain-bin monitoring; the pilot did not proceed.
• Provide engineering support directly to clients: discovery and scoping, design reviews, test planning, written decision records and application notes; guide client teams through unfamiliar technical domains.

Replaced proprietary radio telemetry with commodity SDR hardware, on flight-approved platforms.

• Built an end-to-end real-time receiver decoding 64 concurrent channels from a 25 Msps I/Q stream on commodity x86 and ARMv8, sustained, with no dropped samples.
• Built a recorded-signal regression harness so algorithm changes were measured against captured field data rather than synthetic benchmarks – the lab reproduction of a field signal.

• Architected and validated HoloFuel's partition-tolerant transaction engine in Rust.

Custom RTUs and communications for hydrocarbon pipeline control; the protocol is still in operation.

• Developed solid-state RTU firmware for continuous 24/7 control in remote locations, sustaining fewer than 1 defect per 10,000 lines of code, measured in the field, not the lab.
• Deployed hundreds of ruggedized units across critical infrastructure sites.
• Architected LiveWIRE, a cryptographically secure, Reed-Solomon encoded, multi-route protocol for real-time SCADA telemetry over marginal and intermittent links.

• Re-engineered the core alarm engine of the RTAP SCADA platform around DFA state machines; still deployed in pipeline SCADA systems continent-wide, 30+ years on.