Senior Controls Engineer

The Controls Engineer III at Aii plays a pivotal role in leading the design, development, and implementation of advanced industrial control systems for a diverse range of clients. This position ensures efficient, safe, and reliable operation of industrial processes and equipment while working closely with project teams to deliver innovative and robust solutions.

• Design and implement control strategies for automated systems, machinery, and industrial processes, including both hardware and software architecture.
• Develop control systems incorporating electrical, pneumatic, hydraulic, and robotic components.
• Program and configure Programmable Logic Controllers (PLCs), Human-Machine Interfaces (HMIs), and industrial robots.
• Ensure seamless integration with auxiliary equipment.
• Specify, select, and configure sensors, actuators, and other control devices to meet client specifications.
• Integrate safety features into designs and ensure compliance with OSHA, industry standards, and company policies.
• Conduct safety risk assessments, system testing, and document methodologies and validations.
• Stay current with safety standards and update designs accordingly.
• Oversee installation, testing, debugging, and startup activities to ensure functionality and reliability.
• Provide technical support during installation, commissioning, and ongoing operations.
• Occasionally assist with field wiring, panel building, and training to meet project deadlines.
• Work closely with project managers, engineers, designers, and clients to meet requirements and resolve challenges.
• Communicate deviations from client specifications and coordinate component selections.
• Create and review electrical schematics, control panel layouts, and system architecture.
• Prepare technical documentation, including user manuals, setup & calibration procedures, as-built records, and Bills of Materials.
• Maintain accurate project records and adhere to electrical codes and best practices.
• Analyze system performance and implement improvements for efficiency and reliability.
• Stay up to date on emerging technologies and integrate innovative solutions.
• Coordinate with vendors for quotes and purchases.
• Perform other duties as assigned.

• A bachelor's degree in electrical, mechanical, or computer engineering, or a related field is required; a master's degree is a plus.
• A Professional Engineer (PE) license and/or a Certified Controls Engineer (CCE) certificate are a plus.

• A minimum of eight years' experience in controls engineering or a related field is required.
• Ability to travel up to twenty-five percent of the time on an as needed basis is required.
• Must have hands-on experience with robotics and complex automation systems.
• Proficiency in PLC programming and HMI development is required.
• Ability to program and integrate industrial robots is necessary.
• Strong understanding of industrial communication networks and protocols is required.
• Skilled in designing and interpreting electrical schematics, control panel layouts, and system architecture is crucial.
• Familiarity with 3D Computer Aided Design (CAD) modeling and PC-Based programming is a plus.
• Proficiency in AutoCAD Electrical is a must.
• Knowledge of control panel construction, wiring layouts, labeling, and cable management is essential.
• Familiarity with plumbing circuits, valves, and schematics is crucial.
• Experience with virtual machines is necessary.
• Knowledge of industry safety standards, functional safety principles, and relevant electrical codes is required (e.g., OSHA, ANSI B11, ANSI/RIA R15.06, NFPA 79, and NFPA 70 (NEC)).
• Strong mathematical foundation with an understanding of physics, engineering, and statistics is necessary.
• Excellent troubleshooting and analytical skills are required.
• Ability to manage multiple priorities and meet deadlines is crucial.
• Strong communication skills and being capable of working independently or on a team is necessary.
• Proficiency in Microsoft Office and Outlook is required.

• Ability to sit at a desk or stand for extended periods while working on a computer or in the field.
• Frequent use of computers for programming, design, and documentation requires visual focus on screens for long durations.
• Walking within office and shop environments with occasional bending, filling, and reaching for equipment or documents.
• Occasional lifting of equipment or components up to thirty pounds which may involve handling tools or small machinery.
• Ability to travel…