Lead Controls Engineer

Qualified Candidates May be eligible for relocation assistance. 

JOB SUMMARY

Our Controls Engineering Department is Growing and we're looking for leaders of the pack who have experience in custom automation - no two projects are quite alike! The Lead Controls Engineer is responsible for providing controls hardware design, programming, debug, and site-installation of turnkey custom automation equipment.

ESSENTIAL FUNCTIONS

• Work independently on larger or high complexity projects and/or multiple smaller projects.
• Training of new and/or less senior engineers.
• Set technical direction for multiple engineers on portions of larger or more complex projects.
• Peer Review of other engineers’ work for accuracy and thoroughness.
• Development of overall machine Controls Architecture
• Enclosures: Standalone, Remote, Local
• I/O: In-cabinet, on-machine
• Network selection & distribution: Ethernet, IOLink, Hardwired
• Cable/Wiring Routing: Ladder Track, Wireway 
• Development of overall machine Controls Software Architecture
• Elements: Cells, Stations, Devices, Sequences
• Interface
• recipe selection
• recipe editing
• status tracking
• data tracking
• report generation 
• Review customer requirements, PMD proposal, PMD cost estimate, and Federal, State, & Local requirements.
• Attend Mechanical Design Reviews to understand machine functionality, suggest concepts & componentry to meet controls & safety requirements, and subsequently incorporate associated Controls Hardware design elements into the Controls Hardware design. 
• Translate device list provided by Mechanical Engineering into Controls Hardware design elements.
• Utilize AutoCad Electrical for drafting.
• Use provided symbols & circuits.
• Develop new symbols & circuits as necessary.
• Controls Hardware Design 
• AC Power schematics
• DC Power schematics
• Safety schematics
• Servo/Stepper schematics
• Industrial Network schematics
• Device schematics
• Testers, Transducers, Laser Markers, Welders, Robots, etc.
• I/O schematics
• Control Enclosure layouts
• Control Panel layouts
• Fluid Power Supply schematics
• Fluid Power Control schematics
• Bill of Materials
• Interact with Controls Build personnel to answer questions.
• Assist Controls Build Technicians, Controls Software Engineers, and Controls Engineers with electrical and fluid power debug.
• Update design as required throughout the project life cycle.
• Use provided standard code and device drivers, or use end-customer provided code and/or formats to create custom control & HMI programs.
• Create custom device driver code.
• Using control schematics, enter I/O into controller programs.
• Using timing chart provided by Mechanical Engineering, program intended sequences into controller programs.
• Download completed programs.
• Commission control hardware.
• Debug control hardware for out-of-box failures, intended design, and correct wiring/plumbing.
• Debug control software, including all intended sequences, modes of operation, special functions, fault detection, fault recovery, tooling return, and interface.
• Participate in Factory Acceptance Test at PMD.
• Participate in Site Acceptance Test at end-customer’s facility.

OTHER DUTIES 

• Maintain a clean and orderly work area.
• Observe safety procedures.
• Any other task assigned by management within scope of position, federal and state regulations.

EDUCATION

• BS in EE, EET, Mechatronics, related engineering field; or demonstrated equivalent experience.

EXPERIENCE (10+ years):

with 4 or more of the following Hardware Design skills:

• AutoCad Electrical
• NFP79, UL508a, CE, CSA standards
• Power calculations (AC 3phase, AC 1phase, DC 5-90V, Transformers)
• Enclosure Heat calculations
• SCCR calculations
• Fluid Power flow calculations
• SISTEMA safety calculations
• Technical Supervision (5+ years)

and 3 or more of the following Programming skills:

• PLC Programming (Rockwell, Siemens, and/or Omron)
• HMI Programming (Rockwell, Siemens, and/or Omron)
• Robot Programming (Fanuc, ABB, Epson, Staubli, and/or Kuka)
• Vision Systems (Cognex, Keyence, Matrox, and/or Teledyne Dalsa)
• Industrial Protocols (Ethernet/IP, ProfiNet, EtherCat, and/or IOLink)
• Technical Supervision (5+ years)

KNOWLEDGE, SKILLS & ABILITIES

• Effective verbal and written communication.  
• Ability to read, analyze, and interpret general technical procedures.
• Ability to work in decimal, octal hexadecimal, and binary numbering systems.  
• Ability to apply concepts of basic algebra and geometry and to calculate scaling factors, proportions, percentages, rates, and ratios.
• Ability to solve practical problems and deal with a variety of concrete variables in situations where only limited standardization exists.  
• Organized
• Detail oriented
• Ability to work independently, collaborate on a team, or direct others
• Ability to take direction
• Creative/Innovative
• Time management skills

PHYSICAL DEMANDS & WORK ENVIRONMENT

The physical demands described here are representative of those that must be met by an employee to successfully perform the essential functions of this job. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.

• Regularly required to sit; use hands to handle or feel; reach with hands and arms; talk or hear; and smell. 
• Occasionally required to stand, walk, push, pull, lift, stoop, kneel, crouch and crawl.
• Specific vision abilities include close vision, distance vision, color vision, peripheral vision, depth perception, and ability to adjust focus. 
• Work environment is primarily performed indoors; partially around moving mechanical parts at a moderate noise level. 
• Wear safety equipment, including proper PPE.