Controls Engineer

Senior Controls Engineer

This Senior Controls Engineer role focuses on designing and programming custom control systems for highly automated industrial machines. You will create PLC and HMI programs, commission equipment, and perform runoffs that meet customer requirements. The position involves translating customer specifications into robust electrical designs for machine controls and safety circuits, while collaborating closely with software controls technicians, mechanical engineering, and electrical teams to deliver reliable, high-performance automation solutions.

Responsibilities

• Design and program sophisticated industrial control systems from concept through startup, including front-to-back PLC and HMI development.
• Create, configure, and debug PLC and HMI programs to control highly automated machinery and ensure reliable performance.
• Simulate, test, and debug control systems in-house prior to deployment, ensuring they meet functional and safety requirements.
• Commission equipment and perform runoffs to verify that systems meet customer specifications and performance expectations.
• Design electrical controls, including hardware specification, panel layouts, and wiring diagrams, using tools such as AutoCAD.
• Develop and implement electrical and software interfaces for machine tools, robots, and automated loaders.
• Design and implement machine and automation safety circuits, including emergency stops, safety guarding, and related safety functions.
• Commission and tune frequency and servo drives, including servo and AC motors, to achieve required motion performance.
• Design and implement industrial communication and I/O networks using technologies such as Profibus DP, Profinet, Ethernet/IP, Device Net, and remote I/O.
• Support the software controls technicians, mechanical engineering, and electrical departments throughout the project lifecycle.
• Startup systems at end-user facilities, including on-site testing, troubleshooting, and optimization of control systems.
• Provide ongoing technical support for installed systems via phone or on-site visits, resolving issues and implementing improvements.
• Identify and define the best technical solutions and strategies to meet customer automation and motion control requirements.
• Participate in project proposals and technical discussions with sales engineers and customers, contributing to solution design and scope definition.
• Design and author control software to customer specifications so that hardware systems properly control motion control equipment and related automation.
• Program and support PLC systems using platforms such as Allen-Bradley RSLogix and Siemens S7.
• Program and support HMI systems using platforms such as Factory Talk and Siemens WinCC flexible.
• Apply machine safety requirements and standards, including relevant ISO and industry guidelines, to control system designs.
• Work with machine vision systems, integrating vision solutions into automated equipment where required.
• Maintain clear documentation for control software, electrical designs, safety circuits, and network configurations.
• Use Microsoft Office and other productivity tools to prepare technical documentation, reports, and project communications.

Essential Skills

• Strong proficiency in PLC programming, including full lifecycle development (design, programming, troubleshooting, and debugging) with platforms such as Allen-Bradley RSLogix and Siemens S7.
• Proficiency in HMI programming, including experience with Factory Talk and Siemens WinCC flexible or similar platforms.
• Demonstrated experience designing and programming custom control systems for highly automated machines.
• Hands-on experience with industrial electrical design, including control panels, wiring, and hardware specification.
• Ability to design and debug electrical and software interfaces for machine tools and robot or automated loaders.
• Experience designing and implementing machine and automation safety circuits, including emergency stops and safety guarding.
• Experience commissioning and tuning frequency drives and servo drives, including servo and AC motors.
• Ability to design and implement industrial communication and I/O networks such as Profibus DP,…