Controls Systems Engineer

Controls Systems Engineer

The Controls Systems Engineer designs, programs, and optimizes control systems for advanced heavy-duty off-road vehicles, ensuring safe, reliable, and deterministic operation in demanding underground and surface environments. This role combines PLC programming, systems engineering, and CAN-based communication expertise to develop robust control architectures, integrate electric and diesel powertrains, and support the full product lifecycle from concept and design through testing and validation. The engineer collaborates closely with mechanical, electrical, hydraulic, and powertrain teams to deliver high‑quality, safety‑compliant solutions that enhance equipment performance and productivity.

Responsibilities

• Develop, program, and troubleshoot control systems for mobile machinery using low‑variability PLC environments such as CODESYS and Danfoss PLUS+1.
• Create structured, maintainable, and safety‑compliant control logic that ensures deterministic behavior and reliable operation in demanding mobile equipment applications.
• Apply systems engineering methodologies, including requirements definition, functional decomposition, interface control, and verification and validation, to design robust and scalable control architectures.
• Support continuous improvement through code reviews, disciplined version control practices, and standardized development workflows.
• Optimize system performance through closed‑loop control tuning, dynamic modeling, and close collaboration with mechanical, electrical, and hydraulic engineering teams.
• Lead root‑cause analysis for system‑level issues and drive corrective actions across hardware, software, and integration domains.
• Implement and configure CAN‑based communication protocols such as CANopen, SAE J1939, and proprietary messaging frameworks.
• Develop and maintain DBC and EDS files, manage network bandwidth, and ensure reliable communication between ECUs, sensors, actuators, and operator interfaces.
• Use diagnostic tools such as Vector CANalyzer, CANoe, or PCAN to validate network performance and troubleshoot communication faults.
• Design vehicle sensor instrumentation systems, including sensor selection, placement, calibration, and signal conditioning for pressure, temperature, position, speed, and environmental measurements.
• Develop electrical and control system architectures that comply with ISO functional safety requirements, including performance level assessments, risk analysis, and safety circuit design.
• Produce detailed documentation such as wiring diagrams, FMEA reports, safety requirement specifications, and validation test plans.
• Evaluate, select, and integrate components from suppliers such as IFM, Danfoss, and ABB into the overall control system.
• Configure and program a variety of ECUs, including I/O modules, hydraulic controllers, motor controllers, and HMI displays.
• Ensure seamless interoperability between third‑party devices and in‑house control systems through communication mapping, firmware management, and hardware validation.
• Support the development and integration of electric vehicle drivetrain components, including traction inverters, battery management systems, DC/DC converters, and onboard chargers.
• Implement control strategies for torque management, regenerative braking, thermal management, and energy optimization in electric and hybrid drivetrains.
• Maintain expertise in diesel engine control systems, including engine ECU integration, emissions control strategies, and powertrain communication over J1939.
• Create and modify technical drawings using AutoCAD, SolidWorks, or similar CAD tools to support mechanical, electrical, and control system design.
• Develop high‑level control system architecture diagrams, network topology layouts, and system block diagrams using tools such as Microsoft Visio or Draw.io.
• Maintain accurate design documentation throughout the product lifecycle, ensuring alignment with engineering standards and regulatory requirements.
• Apply PLC safety specifications and engine model integration knowledge (Subpack, Module, or SEL level) to ensure safe and reliable system performance.
• Contribute to testing activities by interacting directly with mobile equipment during the test phase to validate control strategies and system behavior.

Essential Skills

• Proficiency in PLC programming, particularly in CODESYS and similar low‑variability PLC environments.
• Strong experience with structured text, ladder logic, and function block programming for control systems.
• Hands‑on experience with CAN‑based communication protocols such as CANopen and SAE J1939.
• Ability to implement PLC safety specifications and design safety‑compliant control logic and architectures.
• Demonstrated capability in systems engineering, including requirements definition, functional decomposition, interface control, and verification and validation.
• Experience in integrating and configuring ECUs, including I/O modules, hydraulic controllers, motor controllers, and HMI displays.
• Solid understanding of sensors and instrumentation, including selection, placement, calibration, and signal conditioning.
• Familiarity with ISO functional safety standards and their application to mobile equipment control systems.
• Competence in root‑cause analysis and troubleshooting of complex hardware, software, and integration issues.
• Ability to develop and maintain DBC and EDS files and manage CAN network bandwidth and performance.
• Experience with diagnostic tools such as Vector CANalyzer, CANoe, or PCAN for CAN network validation and fault diagnosis.
• Skill in creating and interpreting wiring diagrams, system block diagrams, and network topology layouts.
• Working knowledge of diesel engine ECU integration, emissions control strategies, and powertrain communication over J1939.
• Proficiency in using AutoCAD and SolidWorks or similar CAD tools for control‑related mechanical and electrical drawings.
• Ability to use diagramming tools such as Microsoft Visio or Draw.io to create architecture and system diagrams.

Job Type & Location

This is a Contract position based out of Collingwood, ON.

Pay and Benefits

The pay range for this position is $48.00 - $60.00/hr.

Workplace Type

This is a fully onsite position in Collingwood,ON.

Diversity, Equity & Inclusion

At Actalent, diversity and inclusion are a bridge towards the equity and success of our people. DE&I is embedded into our culture through:

• Hiring diverse talent
• Maintaining an inclusive environment through persistent self-reflection
• Building a culture of care, engagement, and recognition with clear outcomes
• Ensuring growth opportunities for our people

Actalent is an equal opportunity employer.

About Actalent

Actalent is a global leader in engineering and sciences services. For more than 40 years, we've helped visionary companies advance their goals. Headquartered in the United States, our teams span 150 offices across North America, EMEA, and APAC—with four delivery centers in India led by 1,000+ extraordinary employees who connect their passion with purpose every day.

Our Bangalore, Hyderabad, Pune, and Chennai delivery centers are hubs of engineering expertise, with core capabilities in mechanical and electrical engineering, systems and software, and manufacturing engineering. Our teams deliver work across multiple industries including transportation, consumer and industrial products, and life sciences. We serve more than 4,500 clients, including many Fortune 500 brands. Learn more about how we can work together at actalentservices.com.