Senior Controls Engineer

Position Purpose:

The Controls Engineer III at Aii plays a pivotal role in leading the design, development, and implementation of advanced industrial control systems for a diverse range of clients. This position ensures efficient, safe, and reliable operation of industrial processes and equipment while working closely with project teams to deliver innovative and robust solutions.

Essential Functions:

· Design and implement control strategies for automated systems, machinery, and industrial processes, including both hardware and software architecture.

· Develop control systems incorporating electrical, pneumatic, hydraulic, and robotic components.

· Program and configure Programmable Logic Controllers (PLCs), Human-Machine Interfaces (HMIs), and industrial robots.

· Ensure seamless integration with auxiliary equipment.

· Specify, select, and configure sensors, actuators, and other control devices to meet client specifications.

· Integrate safety features into designs and ensure compliance with OSHA, industry standards, and company policies.

· Conduct safety risk assessments, system testing, and document methodologies and validations.

· Stay current with safety standards and update designs accordingly.

· Oversee installation, testing, debugging, and startup activities to ensure functionality and reliability.

· Provide technical support during installation, commissioning, and ongoing operations.

· Occasionally assist with field wiring, panel building, and training to meet project deadlines.

· Work closely with project managers, engineers, designers, and clients to meet requirements and resolve challenges.

· Communicate deviations from client specifications and coordinate component selections.

· Create and review electrical schematics, control panel layouts, and system architecture.

· Prepare technical documentation, including user manuals, setup & calibration procedures, as-built records, and Bills of Materials.

· Maintain accurate project records and adhere to electrical codes and best practices.

· Analyze system performance and implement improvements for efficiency and reliability.

· Stay up to date on emerging technologies and integrate innovative solutions.

· Coordinate with vendors for quotes and purchases.

· Perform other duties as assigned.

Education and Training:

· A bachelor’s degree in electrical, mechanical, or computer engineering, or a related field is required; a master’s degree is a plus.

· A Professional Engineer (PE) license and/or a Certified Controls Engineer (CCE) certificate are a plus.

Minimum Qualifications

· A minimum of eight years’ experience in controls engineering or a related field is required.

· Ability to travel up to twenty-five percent of the time on an as needed basis is required.

· Must have hands-on experience with robotics and complex automation systems.

· Proficiency in PLC programming and HMI development is required.

· Ability to program and integrate industrial robots is necessary.

· Strong understanding of industrial communication networks and protocols is required.

· Skilled in designing and interpreting electrical schematics, control panel layouts, and system architecture is crucial.

· Familiarity with 3D Computer Aided Design (CAD) modeling and PC-Based programming is a plus.

· Proficiency in AutoCAD Electrical is a must.

· Knowledge of control panel construction, wiring layouts, labeling, and cable management is essential.

· Familiarity with plumbing circuits, valves, and schematics is crucial.

· Experience with virtual machines is necessary.

· Knowledge of industry safety standards, functional safety principles, and relevant electrical codes is required (e.g., OSHA, ANSI B11, ANSI/RIA R15.06, NFPA 79, and NFPA 70 (NEC)).

· Strong mathematical foundation with an understanding of physics, engineering, and statistics is necessary.

· Excellent troubleshooting and analytical skills are required.

· Ability to manage multiple priorities and meet deadlines is crucial.

· Strong communication skills and being capable of working independently or on a team is necessary.

· Proficiency in Microsoft Office and Outlook is required.

Physical Demands:

· Ability to sit at a desk or stand for extended periods while working on a computer or in the field.

· Frequent use of computers for programming, design, and documentation requires visual focus on screens for long durations.

· Walking within office and shop environments with occasional bending, filling, and reaching for equipment or documents.

· Occasional lifting of equipment or components up to thirty pounds which may involve handling tools or small machinery.

· Ability to travel to job sites for installation, commissioning, and troubleshooting may require climbing ladders or accessing confined spaces depending on project needs.

· Adequate vision, hearing, and speech for communication and equipment inspection.

· Use of hands for wiring, panel assembly, and operating power tools when assisting with installations.

Environmental Conditions:

· Majority of work is done in an office environment with standard lighting, temperature, and noise levels.

· Occasional work in production areas or job sites where conditions may include noise, dust, fumes, odors, temperature variations, and moving mechanical parts.

· May require travel to client facilities or construction sites for installation, commissioning, and troubleshooting which may include outdoor exposure to weather elements, working in confined spaces or elevated areas, and use of personal protective equipment (PPE).

· Compliance with OSHA and company safety protocols at all times.

Hendrickson is an Equal Opportunity Employer. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, disability, or status as a protected veteran.

*This is not a comprehensive list of duties. Duties may change without notice in management’s sole discretion.