Controls Engineer

Controls Engineer

The Controls Engineer will:

Deliver the technical scope

Perform a variety of controls engineering work

Assist Leads

Focus on developing their technical skills

The typical engineering activities include:

1. Control Strategy Development
2. Sensor Integration & Open (measurement) and closed (control) Loops
3. System Validation & Testing, FAT support
4. Documentation & Compliance
5. On-Site Commissioning Support, SAT support
6. Development/update of electrical and pneumatics schemes
7. Safety & Compliance Studies (Risk assessment)

Details of the Engineering Scope of Work:

1. Control Strategy Development

   • Develop control strategies for automation and system optimization.
   • Implement PID, adaptive, and model-based control algorithms.
   • Optimize control loops for stability, responsiveness, and energy efficiency.

2. Sensor Integration & Feedback Loops

   • Integrate sensor feedback loops for real-time data acquisition and system response.
   • Implement tuning methodologies to enhance control system performance.
   • Ensure accurate signal processing for optimal control actions.

3. System Validation & Testing

   • Validate control performance via simulations and real-time testing.
   • Perform stability and robust analysis of developed control strategies.
   • Ensure compliance with industry safety and performance standards.

4. On-Site Support

   • Travel to customer sites for debugging and machine qualification.
   • Provide technical support and troubleshooting as required.
   • Assist in tuning and commissioning control systems on-site.

5. Development/update of electrical schemes

• Develop electrical schemes
• Update existing schemes
• Standards design

6. Safety & Compliance

• Perform risk assessments
• Performance level calculations
• On-site checklist

7. Develop electrical and pneumatics documentation, including:

• User manuals
• BOM & schemes
• Technical data
8. Create design documentation, manuals etc.

Additionally, the role requires the following experience:

• Participate in concept development to obtain the best quality, cost and deadline.
• Perform offline programming of special machinery for the automotive industry.
• Program PLC and HMI systems using the following platforms: TIA Portal / Step 7 (Siemens), Studio 5000 / Factory Talk (Rockwell), etc.
• Configure and set-up servos
• Test the different machine sequences (automatic, manual, audits and calibrations, etc).
• Equipment installation correctly (check that the different devices are wired and calibrated properly).
• Study machine's capability studies and analysis (CGs, CGKs, etc.).
• Troubleshoot of the complete system including Automation, Controls Software and Communication protocols.
• Stay up to date with technological advances and new products.
• Carry out designs, create exploded drawings and details drawings.
• Review self-work and peer work

Work Experience:

Experience Range – 3+ years

Software Skills:

1. PLC and HMI programming
2. Experience in programming of motion controls systems
3. Knowledge of industrial fieldbus (Ethernet/IP, Profinet etc.)
4. Strong computer skills and proficiency in Excel and PowerPoint
5. Tia Portal, Studio 5000, Eplan

Hardware / Domain Knowledge:

1. Engaged in supporting control strategies for automation and system optimization.
2. Technical documentation (drawings, specifications, etc.)
3. Good knowledge of project management and engineering techniques, processes and tools, including project planning tools
4. Knowledge of Machine Directive and other industrial equipment safety rules