Robert Brandl

Industrial Communication | Proof of Concept: Controller-to-Controller Communication with OPC UA FX

Proof of concept for an OPC UA FX-based controller-to-controller communication between virtual programmable logic controllers (vPLCs) on an industrial edge platform. This involved building a virtual test environment on Debian Linux in two phases (including VM and vPLC), activating shared memory communication (Realtime Information Bus), integrating the RIB solution into a customized product firmware (including shared memory and ProfiNet support), and deploying it in containerized environments (Docker). Additionally, a virtual Ethernet connection was developed to simulate the network topology. Finally, commissioning, functional tests, development of sample applications, comprehensive documentation, and customer support were completed.

Industrial Communication | Linux-based PROFINET I/O Interface Module with PROFINET TSN

Porting and commissioning of an RT-Linux-based PROFINET I/O interface module (interface head unit) with PROFINET TSN. Yocto environments with 32-bit support and cross-compiler toolchains on Windows and Linux were set up for this purpose. Bootable RT-Linux images were created, and a GDB-based debug environment was configured. The PROFINET software stack (EPS) was ported to the target hardware (TI AM64x) and put into operation. This involved U-Boot modifications and TFTP boot for prototype commissioning. Kernel parameters were optimized for real-time operation. In addition, the build process was automated using Yocto, KAS, and CI/CD, and the build environment, scripts, and documentation were continuously maintained.

Embedded PKI | Dynamic OPC UA GDS Certificate Management via Web API

Design, prototype, and final implementation of a dynamic certificate management system for OPC UA GDS. Developed and integrated a web API into the firmware's built-in web server for asynchronous private key generation and management of trust lists and CSRs. The solution was connected to the dynamic OPC UA GDS certificate management and integrated into the PLC engineering environment. In addition, the web SDK was updated, diagnostic messages and alarms were added, and integration with the engineering software was carried out. Finally, code reviews, tests, test support, and documentation were performed.

Industrial Communication | OPC UA and embedded PKI for industrial controllers: evaluation, design, integration, development, and certification

Developed, integrated, and certified OPC UA server/client functions for programmable logic controllers. Implemented dynamic real-time memory management with minimal fragmentation, user and role management, PKI-based certificate management, and asynchronous private key generation. Implemented binary parsers for OPC UA information models and Alarms & Conditions, evaluated and integrated the OPC UA HPC SDK (vs. ANSI C SDK), and prepared and conducted OPC UA compliance certification (including CTT test automation).

Designed and implemented a GDS integration with embedded PKI (including downgradable locks) in close coordination with the SDK vendor. Additional tasks: evaluated OPC UA PubSub, continuous optimizations, debugging, and quality assurance.

Digital Twin | Simulation of a programmable logic controller

Long-term project to develop simulated PLC firmware on Windows for creating simulation-based digital twins. Implemented a POSIX to Windows wrapper (P2W), emulation of a bare-metal RTOS, and setup of deterministic multi-core scheduling.

Key areas included integrating motion control, snapshot and tracing functions, continuous optimization of simulated real-time behavior, code quality, memory and runtime performance, and product protection. In later phases, replaced the P2W wrapper with an RTOS emulation, ported the PLC firmware including communication, and integrated new components like a virtual network switch with Npcap, scalable timing control, feature configuration, and front panel simulation.

Also: Docker feasibility study, Windows driver certification (WHQL/HLK), OpenSSL integration, VS plugin development, co-simulation improvements, and automated testing in a CI environment.

Freelance software developer for embedded systems with a focus on developing, optimizing and quality-assuring hardware-near software for industrial applications in embedded systems, industrial controls, industrial communication and automotive technology. Locations: Fürth, Nuremberg, Erlangen, Bamberg, Karlsruhe.

Commercial software developer for home computer games

• 1985: Publication of 'Roboservant' in the magazine '64'er' (Markt & Technik) for the Commodore 64 (co-author: T. Schmidt).
• 1986: Publication of 'Robo's Revenge' in the magazine 'Happy-Computer' (Markt & Technik), awarded 'Listing of the Month' (co-author: T. Schmidt).
• 1986: Sale and commercial release of 'Suicide Voyage' by Rainbow Arts (Eurogold Ltd.) for the Commodore 64 (co-author: T. Schmidt).
• 1991: Release of the games 'The Hammer' and 'Panic Ball' for the Amiga (GoodSoft Verlag, Wolf Software & Design). Later re-release of these games and 'LadyJ' in the retro game collection 'Retro Classix' (magnussoft Deutschland GmbH).

I was young, happy about the money – and it was my start in hardware-near software development.