Control Engineer AIS Engineering, Inc - 4.3 Fort Wayne, IN Job Details Full-time $95,000 - $125,000 a year 22 hours ago Benefits Health savings account Health insurance Dental insurance 401(k) Paid time off Vision insurance 401(k) matching Life insurance Qualifications Customer communication Teamwork Customer service Driver's License Bachelor's degree Task prioritization Organizational skills Customer support

Full Job Description Purpose:

The Controls Engineer is responsible for the design, development, programming, integration, commissioning, and technical support of industrial automation and control systems. This position works primarily with hydraulic presses, automated press lines, material handling systems, and other industrial machinery. The Controls Engineer serves as the technical lead for the controls portion of assigned projects and works closely with engineering, operations, vendors, and customers to develop and implement reliable, safe, and maintainable control systems from initial project development through final commissioning.

Responsibilities:

Controls System Design & Development - Develop complete control system designs for hydraulic presses, automated production lines, material handling equipment, and industrial machinery. Select and specify PLCs, HMIs, VFDs, servo drives, safety controllers, I/O systems, instrumentation, sensors, and other automation hardware based on project requirements. Develop PLC and HMI software using Allen-Bradley and/or Siemens platforms, including machine sequencing, motion control, hydraulic control, fault monitoring, diagnostics, and operator interface functionality. Design and integrate machine safety in accordance with applicable OSHA, NFPA, ANSI, and ISO standards. Project Execution & Technical Leadership - Serve as the lead Controls Engineer for assigned projects from initial quotation and design through installation, commissioning, and final customer acceptance. Support Project Managers and Sales personnel with technical input, scope development, hardware requirements, labor estimates, and project schedules. Review project requirements, customer specifications, and existing equipment documentation to develop appropriate control system solutions. Coordinate with Mechanical and Electrical Engineering to ensure proper integration of controls, instrumentation, electrical systems, and mechanical equipment. Provide technical direction to electricians, technicians, and subcontractors during panel fabrication, installation, wiring, startup, and commissioning. Coordinate with vendors and equipment suppliers regarding controls hardware, software, instrumentation, and technical requirements. Electrical Design & Documentation - Develop and maintain electrical control schematics using AutoCAD Electrical. Develop I/O lists, control panel layouts, network architecture, wiring documentation, and other controls-related engineering documentation. Specify control panel components and assist with panel layout and electrical hardware integration. Review electrical drawings and wiring to verify proper installation and functionality. Maintain accurate revision control of electrical drawings, PLC programs, HMI programs, and other controls documentation. Commissioning & Field Support - Travel to customer facilities to support equipment installation, startup, troubleshooting, commissioning, and production run-off. Perform PLC, HMI, motion, safety, instrumentation, and network commissioning. Troubleshoot hardware, software, electrical, and system-level issues during installation and startup. Diagnose and resolve equipment failures using electrical schematics, PLC diagnostics, network diagnostics, and other engineering tools. Verify machine functionality against project specifications and customer requirements. Train customer personnel on equipment operation, controls functionality, maintenance, troubleshooting, and basic system diagnostics. Provide post-installation technical support and assist with service-related controls issues. Document commissioning activities, outstanding issues, modifications, and final system changes. Hydraulic & Motion Control - Develop and integrate electrical controls for hydraulic systems, including pumps, valves, proportional valves, pressure controls, position feedback, and hydraulic instrumentation. Interface PLC and motion-control systems with hydraulic and electro-hydraulic equipment. Develop control strategies for hydraulic presses, including ram, bolster, knockout, prefill, accumulator, pump, and auxiliary hydraulic systems as applicable. Integrate position, pressure, temperature, proximity, and other process instrumentation into machine control systems. Assist Mechanical and Hydraulic System Engineers with troubleshooting and optimization of machine control performance. Project Documentation & Reporting - Maintain accurate records of engineering work performed, project changes, issues encountered, and corrective actions implemented. Maintain current PLC, HMI, safety, drive, and network configuration files throughout the project. Document software revisions and maintain appropriate backup copies of project programs. Provide regular project status updates to Project Managers and company leadership. Assist with preparation of operating manuals, maintenance documentation, troubleshooting guides, and customer training materials. Other - Other duties, roles and responsibilities as assigned.

Knowledge & Skills:

Strong knowledge of industrial automation, electrical controls, and machine control systems. Proficiency with Allen-Bradley and/or Siemens PLC platforms. Strong technical knowledge of hydraulic systems and electro-hydraulic control integration. Experience with industrial networks, including EtherNet/IP, PROFINET, PROFIBUS, and Modbus. Ability to read and develop detailed electrical schematics using CAD software. Experience with VFDs, servo systems, motion control, safety systems, and industrial instrumentation. Strong problem-solving and analytical skills with the ability to identify root causes and develop effective technical solutions. Ability to work independently while effectively coordinating with Project Managers, Engineers, technicians, electricians, vendors, and customers. Strong organizational skills with the ability to manage multiple projects, priorities, and deadlines. Proficient with Microsoft Office Products. Excellent communication and interpersonal skills. Ability to follow technical instructions and prioritize tasks.

Physical Requirements:

Ability to sit for extended periods at a desk and use a computer. Ability to lift up to forty (40) pounds and work safely in industrial environments. Ability to travel to customer facilities to support equipment installation and commissioning. Availability to work overtime, weekends, and/or holidays when required.

Qualifications:

Bachelor's degree and/or five (5) or more years of relevant experience designing, programming, and commissioning industrial control systems. Strong experience with Allen-Bradley and/or Siemens-based PLC platforms is required. Experience with industrial networks, including EtherNet/IP, PROFINET, PROFIBUS, and Modbus. Ability to read and develop detailed electrical schematics using CAD software. Strong technical knowledge of hydraulic systems and electro-hydraulic control integration. Willingness to travel up to twenty-five percent (25%) to support equipment installation and commissioning is required. Availability to work overtime, weekends, and/or holidays when required. Valid driver's license is required. Ability to work safely in industrial environments. Strong organizational skills with the ability to manage multiple projects, priorities, and deadlines. Strong problem-solving skills with the ability to identify root causes and implement effective solutions. Ability to work independently while effectively coordinating with Project Managers, Engineers, technicians, vendors, and customers.

Preferred Qualifications:

Experience with hydraulic press equipment, including stamping, molding, forging, and forming presses. Experience programming and commissioning large industrial press lines and automated material handling systems. Experience with hydraulic proportional/servo valve control and closed-loop hydraulic systems. Experience with servo motion systems and multi-axis automation. Experience with AutoCAD Electrical. Experience with HMI development and industrial SCADA systems. Ability to read and interpret mechanical drawings and GD&T specifications. Master's degree in Engineering. Why This Role? The Controls Engineer plays a critical role in the successful execution of industrial automation and controls projects. By developing reliable control systems, supporting project execution, and ensuring proper commissioning and technical support, this position helps deliver safe, functional, and maintainable equipment that meets customer requirements and supports the Company's operational goals. Equal Employment Opportunity Statement We are an Equal Opportunity Employer. All qualified applicants will receive consideration for employment without regard to race, color, religion, gender, national origin, disability, or any other characteristic protected by law. Join us to innovate within the industrial automation space! We're committed to fostering a collaborative environment where your technical skills can thrive while contributing to impactful projects that shape the future of manufacturing technology.

Pay:

$95,000.00 - $125,000.00 per year

Benefits:

401(k) 401(k) matching Dental insurance Health insurance Health savings account Life insurance Paid time off Vision insurance

Work Location:

In person