Controls Engineer

Vulcan Elements is manufacturing American rare-earth permanent magnets for a secure, resilient future. With a focus on national security and economic resiliency, we serve critical industries such as defense, aerospace, and automotive powering a high-technology future. Vulcan Elements is building a team of ambitious professionals committed to Mission Focus, Technical Excellence, and Transparency.

As the Controls Engineer you will own controls execution for the magnet equipment portfolio within a massive 1 million square foot manufacturing facility expansion . You will own your equipment packages cradle-to-grave - design review, FAT witness, site commissioning, and sustaining support This is a high-impact, high-ownership leadership role requiring technical expertise in industrial automation. The role includes hands-on implementation and domestic travel to OEM FATs up to ~50% during test campaigns.

This role begins in Durham, NC and is expected to move to Benson, NC upon completion of new facility.

• PLC Programming & Commissioning :
  Execute hands‑on programming, debugging, and commissioning of Siemens and Allen Bradley/Rockwell PLCs and HMIs for new and existing automation equipment.
• Advanced Automation & System Integration :
  Drive the integration and commissioning of robotics, conveyors, and motion control systems - including servos and VFDs - to enable seamless material flow and high reliability production operations.
• SCADA/MES Connectivity :
  Configure and maintain communications between PLCs/HMIs and SCADA/Batch systems. Support tag mapping, alarming, and data acquisition to the site SCADA platform as required.
• Vendor Technical Support & FATs :
  Review vendor electrical schematics, controls architectures, and PLC/HMI logic. Participate in and support Factory Acceptance Tests (FATs) and Site Acceptance Tests (SATs) to ensure full compliance with functional and safety requirements.
• Troubleshooting & Technical Escalation :
  Serve as the first‑line, hands‑on responder for diagnosing complex automation issues involving networks, motion systems, instrumentation, and industrial communication protocols.

• Controls & IT : PLC code architecture, HMI screens, vision inspection programs, tag databases, network lists, and system backups.
• Risk & Safety :
  Controls risk assessments, interlock/guarding logic, and safety rated PFMEA inputs.
• Process Design :
  Controls layouts, network topology layouts, station cycle times, sequence diagrams, and automation simulations.
• Engineering Diagrams :
  Electrical schematics, pneumatic drawings, controls panel layouts, and industrial network architecture.
• Operations & Maintenance :
  Calibration procedures, I/O lists, instrumentation documentation, and controls hardware maintenance manuals.

Responsibilities and tasks outlined are not exhaustive and may change as determined by the needs of the business

• Bachelor's or Masters degree in electrical engineering, Automation Engineering, Mechatronics, or related field with 3+ years of direct industrial automation and controls engineering experience.
• Strong hands on experience programming and commissioning Siemens and Allen Bradley/Rockwell PLCs and HMIs.
• Deep understanding of servos, VFDs, highspeed conveyors, robotic cells, and automated material handling systems.
• Proficiency with Ethernet/IP, Profinet, EtherCAT, OPCUA, and similar industrial communication standards.
• Analog loop fundamentals, gas analyzer integration (O₂, pressure, flow), loop tuning, and the literacy to read and validate safety‑rated circuits and safety PLC
• Must be a U.S. Person due to required access to U.S. export‑controlled information or facilities

• Working experience with multiaxis robotic systems and machine vision platforms such as Cognex or Keyence. AGV experience is a strong plus.
• Experience in heavy industrial, greenfield, chemical, or metallurgical manufacturing environments.
• Experience developing SCADA applications in Ignition, Wonderware, or similar platforms.
• Powder or bulk‑solids handling controls (pneumatic conveying, gravimetric dosing, milling), hazardous‑atmosphere or reactive‑material environments (combustible dust, inert‑gas blanketing, hydrogen service), or furnace/vacuum/thermal process controls.
• Familiarity with Python, C++, or other high level languages for automation or data analytics.
• Experience in regulated industries such as Defense, Aerospace, or Automotive.