Robotic Sanding Workflow Platform

Operators had no standard interface for selecting sanding zones or managing recipes across robotic cells: configuration was manual and inconsistent.

PLC tags were set directly with no audit trail, no validation, and no way to reproduce a previous recipe reliably.

The platform needed to handle real production-floor constraints: RFID-based identity, shift tracking, inactivity timeouts, and live machine state.

Built a React + Vite frontend and FastAPI backend that renders polygon-based zone overlays on part images and writes zone, recipe, and production metadata directly to OPC UA-connected PLC tags in real time.

Implemented role-based authentication with RFID login support, admin/supervisor/operator access tiers, inactivity session handling, and a full user management system.

Designed a recipe engine with JSON-backed persistent storage, orientation-aware validation, live OPC synchronization, audit logging, and full state persistence across sessions.

Chose OPC UA for PLC communication to get live bidirectional machine state without polling: zone and recipe writes reflect immediately on the cell without a separate sync step.

Built the recipe engine as a standalone module so validation rules, storage format, and OPC sync logic can each evolve independently without touching the UI.

Used polygon-based zone overlays (OpenCV-assisted) rather than simple coordinate selectors to correctly represent multi-section part geometries across different orientations.

Built RFID login as its own auth path, with session handling, access tiers, and inactivity timeouts designed around how operators actually work on the floor.

Deployed a production-floor HMI with secure RFID login, shift start/end logging, and live zone-to-PLC synchronization, replacing fully manual PLC configuration.

Eliminated recipe inconsistency by replacing ad-hoc PLC edits with a validated, auditable recipe workflow that persists and restores across sessions.

Created a complete audit trail for zone selections, recipe changes, and production events, enabling traceability and post-production analysis for the first time.