Controls Hardware Design Engineer

Title: Controls Hardware Design EngineerLocation: Waukesha, WIPosition OverviewWe are seeking a Controls Hardware Design Engineer to design and deliver control hardware for automated machinery and systems.

The role focuses on developing electrical schematics, control panels, 3D enclosure and mounting layouts, and integrating PLCs, HMIs, vision systems, and robotic components to meet performance, safety, and manufacturability requirements.Key ResponsibilitiesDevelop detailed electrical schematics and wiring diagrams for control systems, including power distribution, safety circuits and I/O wiring.Design control panels and enclosures in 3D CAD (e.g., SolidWorks), produce panel layouts and component placement to meet UL/industry standards.Create Bills of Materials (BOMs), procurement specifications and vendor coordination for hardware components.Collaborate with controls engineers and software developers to ensure proper integration of PLCs, HMIs, drives, sensors, vision systems and robots.Specify and integrate vision systems and sensors, define wiring and mounting requirements, and support calibration and validation activities.Design and document safety circuits, interlocks and E-stops to meet relevant codes and customer requirements.Develop and maintain manufacturing and assembly documentation, installation drawings, and wiring harness layouts.Support FAT/SAT, commissioning and field troubleshooting; provide technical support during installation and start-up.Partner with project managers to estimate effort, schedule hardware deliverables and manage changes through design reviews.Apply design-for-manufacturing and cost optimization practices; mentor junior designers and enforce drawing/documentation standards.QualificationsBachelors degree in Electrical Engineering, Mechatronics, Controls Engineering or equivalent experience.3+ years experience designing control hardware for industrial automation, machinery or robotics systems.Hands-on experience with PLC and HMI hardware selection and integration (examples: Allen-Bradley, Siemens, FactoryTalk, WinCC).Experience integrating machine vision systems (e.g., Cognex, Keyence) and coordinating vision wiring, lighting and I/O.Familiarity with industrial robotics integration (e.g., ABB, Fanuc, KUKA) and robot I/O/fieldbus connections.Proficiency with 3D CAD for electrical enclosure and panel layout (SolidWorks or similar) and electrical schematic tools (EPLAN, AutoCAD Electrical or equivalent).Strong understanding of electrical codes and standards (UL508A, NEC) and experience designing safety circuits and interlocks.Skilled in creating clear manufacturing documentation, BOMs and procurement specifications.Excellent troubleshooting, communication and cross-functional collaboration skills; willingness to travel to customer sites as needed.Preferred: experience with servo/drive systems, Ethernet/IP, Profinet and experience in cost estimating for hardware designs.BenefitsFull benefits including medical, dental, 401k, PTO etc.