Open to Opportunities
Automation & Controls Engineer

Dhirendra Sah

M.S. Mechanical Engineering (Mechatronics) · NDSU · GPA 3.83

Highly motivated Mechanical Engineer specialising in Mechatronics, Control Systems, and Automation — with an M.S. from North Dakota State University and a Graduate Certificate in Software Engineering. With 3+ years of hands-on industry experience across automotive, packaging, material handling, and food processing, I bring a genuinely multidisciplinary approach: from advanced dynamic modelling and simulation to PLC programming, industrial robotics, and UGV research. Currently designing and commissioning full automation ecosystems at Friesens Inc. in Detroit Lakes, MN — and actively open to Opportunities , research collaborations, and professional networking in robotics, automation, and advanced manufacturing.

Control Systems PLC & SCADA MATLAB / Simulink ROS2 Python Robotics & UGV SolidWorks LabVIEW
3+
Years in Controls
3.83
M.S. GPA
25%
Defect Detection Gain
20%
Manufacturing Error Cut
Dhirendra Sah — Controls Engineer

Based in

Detroit Lakes, Minnesota
Available
About

Who I Am

Dhirendra Sah

Dhirendra Sah

Automation & Controls Engineer

  • Experience3+ Years
  • IndustriesAuto, Packaging, Food
  • DegreeM.S. Mech. Eng. (Mechatronics)
  • LocationDetroit Lakes, MN, USA
  • LanguagesEnglish, Nepali, Hindi
  • InterestsTravelling, Sports

Automation/Controls Engineer with 3+ years of experience in electrical controls, PLCs, and robotics for a variety of industries and applications — including automotive, packaging, material handling, sorting, and food processing.

I specialize in programming and integrating complete automation systems: PLCs/IPCs, HMIs, servo controllers, safety PLCs, and all associated electrical components. My work spans control panel design using SolidWorks Electrical, PLC and DCS logic optimization, safety interlock implementation, and on-site commissioning and troubleshooting.

I approach every project with a focus on process stability, operator usability, and long-term maintainability — whether that means engineering washdown-rated panels for food-grade environments or developing synchronized sequencing logic for integrated packaging lines.

Technical Skills

PLC & SCADA (Studio 5000, RSLogix, TwinCAT 3, FactoryTalk, Wonderware)85%
Drives & Hardware (VFDs, Servo Drives, Microcontrollers, Edge Devices)80%
Programming (Ladder Logic, Structured Text, Python, C/C++, MATLAB)80%
Design Tools (SolidWorks Electrical/3D, CATIA, AutoCAD)78%
Networking (Ethernet/IP, DeviceNet, ControlNet, TCP/IP)75%
0+
Years in Controls
0
Industry Projects
0%
Defect Detection Gain
0%
Sorting Error Reduction
Connect on LinkedIn GitHub Profile
Expertise

What I Do

⚙️

PLC & SCADA Systems

Programming and integrating automation and control systems involving PLCs/IPCs, HMIs, operator interfaces, servo controllers, safety PLCs, and all required electrical components for machine-tools.

Studio 5000 RSLogix 500 TwinCAT 3 FactoryTalk View Wonderware
🖥️

Electrical Panel Design

Designing and developing control panels and full electrical drawing packages using SolidWorks Electrical CAD. Documenting Bills of Material within ERP systems to keep engineering and procurement aligned.

SolidWorks Electrical AutoCAD UL508A NFPA 70 NEMA 250
🔧

Drives & Motion Hardware

Specifying and integrating VFDs, servo drives, electric drive components, edge devices, and microcontrollers into cohesive machine automation systems across a range of industrial applications.

VFDs Servo Drives AB Motion Control FANUC (LR/SR) Independent Cart
🛡️

Safety & Compliance

Implementing safety interlocks, emergency stops, and control safeguards for multi-machine and continuous-process environments, meeting IEC 61131-3, UL508A, NFPA 70, and EHS requirements.

Safety PLCs IEC 61131-3 FAT / IFAT SOPs EHS
🌐

Industrial Networking

Configuring and troubleshooting industrial communication protocols between PLCs, drives, HMIs, and field devices across a range of Ethernet and fieldbus architectures.

Ethernet/IP DeviceNet ControlNet TCP/IP RSLinx
📐

Simulation & Programming

Developing control algorithms and dynamic system models using MATLAB/Simulink, Python, C/C++, and LabVIEW. Experienced in ladder logic and structured text for PLC programming.

MATLAB / Simulink Python C / C++ LabVIEW Structured Text
Resume

Experience & Education

Work Experience
May 2025 — Present
Controls Engineer
Friesens Inc · Detroit Lakes, MN
  • Responsible for overall machine operation, working with Mechanical Engineers to ensure all required sensors and electro-mechanical structures allow optimal machine control and performance.
  • Program automation and control systems involving PLCs/IPCs, HMIs, operator interfaces, servo controllers, programmable switches, safety PLCs, and all electrical components for machine-tools.
  • Design and develop control panels and electrical drawing packages using SolidWorks Electrical CAD; document Electrical Bills of Material within the ERP system.
  • Develop, modify, and optimize PLC and DCS control logic, improving process stability and reducing downtime.
  • Implement safety interlocks and control safeguards to support multi-machine and continuous-process operations per industrial plant safety requirements.
  • Apply electrical engineering principles to resolve technical issues and troubleshoot complex hardware and software problems.
Aug 2022 — May 2025
Graduate Teaching Assistant
NDSU Engineering Measurement Lab · Fargo, ND
  • Delivered hands-on laboratory instruction covering LabVIEW-based DAQ systems, sensors, and measurement instrumentation — emphasizing signal conditioning, data acquisition, and control fundamentals.
  • Taught MATLAB-based control algorithms, supporting students in understanding dynamic system modeling, feedback control, and automation applications.
  • Designed and validated control algorithms for UGV path control, involving real-time sensor integration, dynamic modeling, and control loop optimization.
  • Maintained structured technical documentation and lab procedures, reinforcing safety compliance and standardized experimental workflows.
Aug 2019 — Aug 2021
Project Engineer
AB Plastomech Pvt. Ltd. · Bangalore, India
  • Collaborated directly with customers to define automation requirements, develop control solutions, and deliver on-site system demonstrations and FAT presentations.
  • Designed and prototyped PLC-based automation systems integrating sensors, actuators, and pneumatics to validate functionality before production rollout.
  • Managed vendor relationships and component sourcing for electrical, pneumatic, and safety hardware, ensuring cost efficiency and design compliance.
  • Supported commissioning and troubleshooting of Special Purpose Machines (SPMs), providing technical training and ensuring seamless customer handover.
Education
Aug 2022 — May 2025
M.S. Mechanical Engineering (Mechatronics)
North Dakota State University · Fargo, ND
GPA: 3.83 / 4.00.
Aug 2024
Graduate Certificate, Software Engineering
North Dakota State University · Fargo, ND
GPA: 4.00 / 4.00.
2015 — 2019
B.S. Mechanical Engineering
Visvesvaraya Technological University · India
GPA: 8.5 / 10.0
Leadership
2023 — 2024
Secretary — ASME Student Chapter
American Society of Mechanical Engineers · NDSU
Organised chapter events, coordinated with faculty advisors, and supported membership engagement initiatives.
2023 — 2024
Treasurer — SPE Student Chapter
Society of Plastics Engineers · NDSU
Managed chapter finances, budgeting, and financial reporting for all student activities.
Download Full CV
Coursework

Academic Coursework

Master of Science
Mechanical Engineering / Mechatronics
North Dakota State University
2022 — 2025 · GPA 3.83
  • Advanced Engineering Analysis
  • Advanced Dynamics
  • Mechatronics
  • Modern Control Systems
  • Advanced Control Systems
  • Engineering Measurements & Instrumentation
Graduate Certificate
Software Engineering
North Dakota State University
2024 · GPA 4.00
  • Software Development Processes
  • Software project Plan/Estimation
  • Software Requirements & Analysis
  • Emperical Methods in Software Engineering
Bachelor of Science
Mechanical Engineering
Visvesvaraya Technological University
2015 — 2019 · First Class Distinction
  • Engineering Mathematics I,II,III & IV
  • Machine Design
  • Control Engineering
  • Mechanics of Materials
  • Kinematics and Dynamics of Machinery
  • Manufacturing Processes
Projects

Industry Projects

📷
01
01 — Industrial Automation
Integrated Conveyor & Packaging Line Automation
Designed and programmed PLC control architecture for an integrated conveyor-based packaging line including checkweighers, labelers, scanners, vision systems, and downstream material handling. Developed coordinated sequencing, machine interlocks, and fault-handling logic for continuous synchronized operation. Built operator-friendly HMI screens displaying real-time process status, alarms, and diagnostics.
Studio 5000 HMI Sequencing Logic Fault Handling
📷
02
02 — Panel Design & Commissioning
Washdown-Rated Machine Control Panel Design
Engineered control panels and electrical schematics for washdown-environment machinery using IP-rated components and hygienic design practices for food-industry equipment. Implemented safety circuits, e-stops, and machine interlocks to EHS standards. Created detailed BOMs, panel layouts, and wiring documentation. Supported FAT/IFAT and on-site commissioning with stable production startup.
SolidWorks Electrical IP-Rated Design FAT / IFAT UL508A
Conveyor Belt Sorting System
03 — Vision & Quality
Defect Detection & Sorting Automation
Built a camera-based inspection and sorting system integrating PLC control, pneumatic actuators, and industrial vision cameras with sensor evaluation of load cycles and reliability. Closed-loop automation improved defect identification by 25% and reduced rework costs by 15%.
Industrial Camera PLC Pneumatics Closed-Loop
Conveyor Belt Sorting System
04 — Controls & Sensing
Conveyor Belt Sorting System
Designed and implemented an automated conveyor system using photo eye sensors and Allen-Bradley PLC logic, achieving a 20% reduction in sorting errors. Implemented automated inspection with virtual verification and algorithm tuning for reliable high-speed part identification.
Allen-Bradley PLC Photo Eye Sensors Algorithm Tuning Ladder Logic
Academic & Personal

Academic & Personal Projects

📷
01
01 — Graduate Research · NDSU
UGV Path Control Algorithm Design
Designed and validated control algorithms for unmanned ground vehicle (UGV) path control as part of graduate research at North Dakota State University. Involved real-time sensor integration, dynamic system modeling, and closed-loop control optimization for accurate and stable autonomous navigation across varying terrain conditions.
MATLAB Simulink Real-Time Sensors Control Loop Dynamic Modelling
📷
02
02 — Academic / Personal
Open-source predictive maintenance platform for manufacturing
An open-source predictive maintenance platform for small and mid-sized manufacturers. Built to democratize industrial AI for the 300,000+ SMB manufacturers in the US who can't afford enterprise solutions like Siemens MindSphere or PTC ThingWorx.
Backend: Python · FastAPI · Scikit-learn · NumPy · Pandas Frontend: React 19 · Recharts · Vite ML: Statistical anomaly detection · RMS analysis · Health scoring Deployment: Docker · Render · GitHub Actions
📷
03
03 — Academic / Personal
Personal Portfolio Website
A responsive and accessible portfolio website to showcase my academic and personal projects, publications, and skills.
HTML — structure and content CSS — all styling, layout, animations Vanilla JavaScript — interactivity and dynamic behavior

All Academic/Personal Work on GitHub

Browse the full collection of simulation models, control algorithms, and research code on my GitHub profile.

View GitHub
Publications

Research Publications

Conference
Published
Advancing Autonomous Backing of Tractor-Trailer Systems: a Dynamic Model Approach
Proceedings of the ASME 2024 International Mechanical Engineering Congress and Exposition (IMECE2024), Portland, Oregon, USA, November 17–21, 2024
Dhirendra K. Sah, Majura F. Selekwa
Recent developments in sensing and information processing technology have seen an increased interest in applications of autonomous vehicles. Many driverless vehicles have been tested in various places and environments across the world. Automated backing of tractor-trailer systems is one of the problems yet to be fully addressed in this endeavor, even experienced drivers find it challenging to perform backup maneuvers of tractor-trailer systems in confined spaces. Achieving a fully automated backup maneuver of a tractor-trailer vehicle requires, among other things, the presence of a high-fidelity mathematical model of the vehicle. Often this problem is approached from a kinematic standpoint where the vehicle and the trailer are modeled using a bicycle structure formulation by concentrating weights at the axle centers only, which limits not only the maneuverability of the vehicle system but also its speed. This paper proposes a dynamic model of a tractor-trailer that treats the system as a finite structure of interconnected multi-bodies subjected to various forces and moments emanating from terramechanics and other non-conservative forces acting on the vehicle. This approach presents are more realistic motion of the vehicle even in confined spaces enabling it to avoid colliding with unintended objects during the maneuver. Simulation results by using such a model show that the vehicle can autonomously perform back up maneuvers in as limited clearances as 5% of the vehicle width at moderate speeds without significant slip.
Master's Thesis
Published
ADVANCING AUTONOMOUS BACKING OF TRUCK-TRAILER SYSTEMS: A DYNAMICAL MODEL APPROACH
Master's Thesis, North Dakota State University, Fargo, ND, USA, May 2025
Dhirendra K. Sah
Technological advancement in sensing and information processing have increased interest in autonomous vehicle applications. Many driverless vehicles have been tested in diverse environments globally. However, automated backing of Truck-trailer systems remains a challenge, even experienced drivers struggle with backup maneuvers. Achieving fully automated backing requires, among other things, a high-fidelity mathematical model of the vehicle. This is often approached kinematically, modeling the vehicle and trailer using a bicycle structure that concentrates weight at axle centers, limiting both maneuverability and speed. This paper proposes a dynamic model treating the Truck-trailer as finite structure of interconnected multi-bodies subjected to forces and moments from terramechanics and other non-conservative effects. This approach provides more realistic representation of vehicle motion, even in tight spaces, avoiding collisions during maneuvers. Simulations using this model show the vehicle can autonomously perform backing maneuvers in clearances as narrow as 5% of vehicle width at moderate speeds without significant slip.
Journal
Under Review
Modelling and Autonomous Control of a Truck-Trailer Vehicle System for Back-Up Maneuvers
Submitted to: Journal of Autonomous Vehicles and Systems (JAVS)
Dhirendra K. Sah, Majura F. Selekwa
Recent developments in robotics technology have seen an increased interest in applications of autonomous vehicles. Automated backing of tractor-trailer systems is one of theproblems yet to be fully addressed in deriverless vehicles; even experienced drivers findit challenging to perform backup maneuvers of tractor-trailer systems. Achieving a fullyautomated backup maneuver of a tractor-trailer vehicle requires, among other things, thepresence of a high-fidelity mathematical model of the vehicle. Often, this problem is approached from a kinematic standpoint where the vehicle and the trailer are modeled usinga bicycle structure formulation by concentrating weights at the axle centers only; whilethis approach is sufficient for single motor vehicles that drive the traction wheels througha differential unit, it is not sufficient when the traction wheels are driven independentlyby two or more motors. This paper proposes a dynamic model of a tractor-trailer thattreats the system as a finite structure of interconnected multi-bodies subjected to variousexternal forces and moments. The resulting model enables a controller to use the specifiedway-points to drive the vehicle along the desired path. Experimental results have shownthat to be able to track the way points, a good GPS reception is required on the vehicle.When the GPS reception is very good, the vehicle can track the path with an accuracy ofup to 20% of the total length of the vehicle.Keywords: Mechatronics, Modeling Of Dynamic Systems, Robotics, Vehicular Dynamics
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