Controls Engineer
This role designs, programs, and commissions advanced automation and control systems for complex manufacturing, material handling, and process applications. The Controls Engineer develops PLC and HMI/SCADA solutions on the Allen-Bradley Logix platform, integrates motion, safety, and third-party equipment, and supports full project lifecycles from system architecture through startup and documentation. The position offers opportunities to work on diverse automation projects, collaborate with cross-functional teams, and contribute to high-performance industrial systems.
Responsibilities
- Design, develop, and deploy comprehensive PLC programs using the Allen-Bradley Logix platform, including Studio 5000 and RSLogix 5000.
- Develop, configure, and maintain HMI and SCADA applications to support operator interfaces and supervisory control.
- Program and commission high-speed, multi-axis synchronized motion systems using Kinetix servo drives, virtual master axes, electronic gearing, and camming for precision manufacturing operations.
- Design, program, and optimize complex conveyor and material handling systems, including accumulation conveyors, sortation systems, palletizers, and handoffs with automated guided vehicles (AGVs) or autonomous mobile robots.
- Implement tracking, merging, diverting, and barcode or RFID scanning logic to ensure seamless product flow through high-throughput logistics and production lines.
- Design and optimize control strategies for web handling applications, including tension control, winding and unwinding, and registration for continuous weblines.
- Engineer control algorithms for extrusion processes, ensuring precise temperature regulation, pressure control, and line speed synchronization.
- Implement complex batch process sequences in alignment with industry standards such as ISA-88.
- Design, tune, and troubleshoot advanced PID control loops, including cascade loops, ratio control, and feed-forward strategies to minimize disturbances and maximize process stability.
- Integrate third-party equipment, robotics, instrumentation, and vision systems into the primary control network using industrial communication protocols such as EtherNet/IP, ControlNet, and DeviceNet.
- Plan and execute rigorous factory acceptance testing (FAT) and site acceptance testing (SAT), including system debugging, troubleshooting, and on-site commissioning.
- Design and implement hardware and software safety systems using Allen-Bradley GuardLogix controllers and safety-rated components in compliance with relevant safety standards such as ISO and ANSI B11.19.
- Create and maintain detailed engineering documentation, including functional design specifications, control philosophy documents, I/O lists, cause-and-effect matrices, and fully commented as-built code.
- Collaborate with cross-functional teams, vendors, and customers to clarify requirements, resolve issues, and ensure successful project delivery.
- Lead or support projects in high-pressure manufacturing environments, ensuring systems meet performance, reliability, and safety expectations.
Essential Skills
- Bachelor's degree in Electrical Engineering, Mechanical Engineering, Computer Engineering, or a related technical discipline, or equivalent practical experience.
- Minimum of 8–10+ years of hands-on controls engineering experience in a manufacturing, machinery builder (OEM), or heavy industrial process environment.
- Expert-level proficiency with Allen-Bradley hardware and software ecosystems, including ControlLogix, GuardLogix, Studio 5000, PanelView Plus, and FactoryTalk View SE/ME.
- Proven experience in PLC programming for Allen-Bradley platforms, including development, troubleshooting, and optimization.
- Demonstrated mastery of high-speed motion control and multi-axis coordination using Kinetix servo drives and related motion technologies.
- Direct experience with continuous web handling lines, including tension control, winding and unwinding, and registration control.
- Experience in batch processing and continuous process industries, including implementation of ISA-88-based batch sequences.
- Deep theoretical and practical knowledge of PID loop tuning, cascade control, ratio control, and feed-forward compensation.
- Extensive experience with conveyor systems and material handling automation, including architecture, product tracking, and high-throughput logistics applications.
- Familiarity with integration to WMS (Warehouse Management Systems) or MES (Manufacturing Execution Systems) for material handling routing.
- Strong working knowledge of industrial networking architecture, including EtherNet/IP topology, managed switches, VLANs, and device-level ring (DLR) configurations.
- Excellent troubleshooting capabilities for complex control systems in manufacturing or industrial environments.
- Strong cross-functional communication skills and the ability to work independently or lead projects in high-pressure settings.
Job Type & Location
This is a Permanent position based out of South Saint Paul, MN.
Pay and Benefits
The pay range for this position is $ - $ /yr. In addition to competitive compensation, the following benefits are available to eligible employees: Medical, dental, and vision insurance; Health Savings Account with employer contribution; Nice Healthcare; Employer-paid life and AD&D insurance; Voluntary supplemental insurance; 401(k) plan with company match; Paid time off and paid holidays; Minnesota ESST and applicable paid leave benefits; Opportunities for professional growth and technical development; Collaborative, team-oriented culture with exposure to diverse automation projects.
Workplace Type
This is a fully onsite position in South Saint Paul, MN.