Industrial

Hydrotherapy Treadmill HMI

Senior .NET Developer

This project is relevant for clients who need software connected to physical equipment or local operational environments.

Overview

This project was a browser-based HMI for a hydrotherapy treadmill and water exercise system. Operators used a web interface to control warm-up, cool-down, exercise programs, custom speed steps, pumps, heater, lighting, filling/draining, and status monitoring.

My role was to build the .NET bridge between the browser UI and PLC-controlled hardware.

What The System Needed

The system needed a simple on-prem operator interface:

The main challenge was translating UI actions into reliable PLC register/coil reads and writes while keeping the operator workflow clear and responsive.

  • Browser-based equipment control
  • Warm-up, cool-down, manual, graded, and user-defined programs
  • Speed, duration, and acceleration settings
  • Pump, heater, light, fill, drain, and air-jet controls
  • Status and alert monitoring
  • Persisted operator settings
  • Direct Modbus TCP communication with a PLC
  • Minimal deployment dependencies

My Backend Work

I built an ASP.NET Web Forms backend that exposed AJAX WebMethods to the browser. Each method translated operator intent into Modbus TCP communication with PLC registers and coils.

Key work included:

  • ASP.NET Web Forms implementation
  • C# backend methods for equipment control
  • Modbus TCP integration with PLC registers/coils
  • Polling-based UI status updates
  • Press-and-hold safety behavior for critical controls
  • XML-based configuration persistence
  • Warm-up, cool-down, graded, and custom-step program handling
  • Alert/status bitmask handling
  • Bundled EasyModbus tooling and diagnostics
  • On-prem deployment with minimal external dependencies

Technical Highlights

  • Backend stack: C#, ASP.NET Web Forms, .NET Framework
  • Hardware integration: Modbus TCP, PLC register/coil mapping
  • Persistence: XML settings under App_Data
  • UX/safety: polling, status indicators, press-and-hold controls
  • Deployment: self-contained on-prem web application

Why This Project Is Relevant

This project is relevant for clients who need software connected to physical equipment or local operational environments.

It is useful for clients who need:

It shows experience building software where backend code directly affects real-world equipment behavior, safety, and operator confidence.

  • Industrial/device-control interfaces
  • Modbus or PLC integration
  • Legacy ASP.NET systems
  • Browser-based operational tools
  • On-prem software
  • Hardware control workflows
  • Simple, dependency-light deployment

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