Controls Engineer

Controls Engineer III

Job Summary

The Controls Engineer III is responsible for the design, programming, debugging, and on‑site installation of turnkey custom automation equipment. This role involves leading complex controls projects from concept through commissioning while providing technical guidance to other engineers.

Key Responsibilities

• Independently execute large, high‑complexity projects and/or manage multiple smaller projects simultaneously.
• Provide technical leadership and set design direction for portions of larger or more complex projects.
• Train and mentor junior and less‑experienced engineers as needed.
• Perform peer reviews of other engineers' work to ensure accuracy, quality, and completeness.
• Review customer requirements, proposals, cost estimates, and applicable federal, state, and local regulations.
• Participate in Mechanical Design Reviews to understand machine functionality and recommend controls and safety concepts.
• Translate mechanical device lists into detailed controls hardware designs.
• Develop comprehensive controls hardware documentation usingAutoCAD Electrical, including:
  • AC and DC power schematics
  • Safety, servo/stepper, and industrial network schematics
  • I/O, device, enclosure, and control panel layouts
  • Fluid power supply and control schematics
  • Bills of materials
• Develop and maintain symbols and circuits as required, utilizing established standards where applicable.
• Collaborate with controls build personnel to address design questions and resolve issues.
• Support controls build technicians, software engineers, and fellow controls engineers during electrical and fluid power debugging.
• Create, modify, and maintain PLC and HMI programs using standard libraries or customer‑provided code.
• Develop custom device drivers as needed.
• Program control logic based on mechanical timing charts and system requirements.
• Commission and debug control hardware and software, ensuring proper operation, fault handling, and recovery.
• Participate in Factory Acceptance Tests and Site Acceptance Tests at customer facilities.
• Update designs throughout the project lifecycle to reflect changes and improvements.

Additional Duties

• Maintain a clean, organized, and safe work environment.
• Follow all safety policies and procedures, including the use of required PPE.
• Perform other duties as assigned within the scope of the role and regulatory requirements.

Education & Experience

• Bachelor's degree in Electrical Engineering, Electrical Engineering Technology, Mechatronics, or a related field, or equivalent practical experience.
• 10+ years of relevant experience, including at least four of the following hardware design competencies:
  • AutoCAD Electrical
  • NFPA 79, UL 508A, CE, CSA standards
  • AC/DC power calculations and transformer sizing
  • Enclosure heat and SCCR calculations
  • Fluid power flow calculations
  • SISTEMA safety calculations
• Proficiency in at least three of the following programming areas:
  • PLC programming (Rockwell, Siemens, Omron)
  • HMI programming (Rockwell, Siemens, Omron)
  • Robot programming (Fanuc, ABB, Epson, Staubli, KUKA)
  • Vision systems (Cognex, Keyence, Matrox, Teledyne Dalsa)
  • Industrial communication protocols (EtherNet/IP, Profinet, EtherCAT, IO‑Link)

Knowledge, Skills & Abilities

• Strong verbal and written communication skills.
• Ability to interpret technical drawings, procedures, and documentation.
• Proficiency with decimal, octal, hexadecimal, and binary numbering systems.
• Strong problem‑solving skills with the ability to work in minimally standardized environments.
• Highly organized, detail‑oriented, and capable of managing multiple priorities.
• Ability to work independently, collaborate within a team, and provide direction to others.
• Creative, innovative mindset with strong time‑management skills.

Physical Demands & Work Environment

• Regularly required to sit, use hands, reach, and communicate verbally.
• Occasionally required to stand, walk, lift, push, pull, stoop, kneel, crouch, or crawl.
• Requires close, distance, color, and peripheral vision.
• Work is primarily performed indoors, with occasional exposure to moving mechanical parts and moderate noise levels.
• Use of appropriate safety equipment and PPE is required.