Automation Controls Engineer

Insight Global; Durham (NC); On-site; USD 110,000 - 160,000; Full time

Job summary

Insight Global is seeking a Senior Robotics Controls Engineer to design, develop, and support control systems for automation and robotics equipment. The role spans software, electrical, and mechanical domains to deliver high-performance motion control solutions.

You'll work on kinematic analysis, PLC programming, and collaboration with cross-disciplinary teams, with some travel for integration and vendor engagement.

Qualifications

• Bachelor's degree in mechanical or electrical engineering or computer science.
• 5–10 years in robotics, automation, or electromechanical system development.
• Experience programming PLC systems (Beckhoff TwinCAT, Siemens, Allen-Bradley, Rockwell, Omron, CODESYS, etc.).
• Strong background in DC motor control, servo systems, and motion control hardware.
• Hands on experience with programming, debugging, and troubleshooting PLC based automation.
• Working knowledge of regulatory standards for hardware and software development (IEC 60601, ISO 13485, ISO 14971).
• Ability to interpret mechanical drawings, electrical schematics, and system level documentation.

Responsibilities

• Perform kinematic analysis and develop control algorithms for robotic and automated systems.
• Design, implement, and test motion control software for prototypes, proof of concept systems, and production equipment.
• Write and document code that drives multi axis motion, servo systems, and automation hardware.
• Collaborate with mechanical and electrical engineering teams to influence system architecture and improve performance related to controls.
• Select, evaluate, and interface with vendors for motion control components, sensors, and related hardware.
• Review and contribute to intellectual property evaluations for new concepts and technologies.
• Ensure compliance with applicable regulatory and design standards throughout the development lifecycle.
• Support sustaining engineering activities, including troubleshooting, root cause analysis, and system enhancements.
• Travel occasionally for system integration, testing, or vendor engagement (approximately 2–3 trips per year).

Skills

Robotics

System integration

Troubleshooting

Education

Bachelor's degree in mechanical engineering, electrical engineering, computer science, or related field

Master’s degree preferred

Tools

Beckhoff TwinCAT

Siemens S7

Allen-Bradley

CODESYS

CAN bus networking

Job description

Job Description

Role Overview

This role focuses on designing, developing, and supporting control systems for automation and robotic equipment. The engineer will contribute to both new product development and sustaining engineering efforts, working across software, electrical, and mechanical domains to deliver reliable, high performance motion control solutions.

Key Responsibilities

• Perform kinematic analysis and develop control algorithms for robotic and automated systems.
• Design, implement, and test motion control software for prototypes, proof of concept systems, and production equipment.
• Write and document code that drives multi axis motion, servo systems, and automation hardware.
• Collaborate with mechanical and electrical engineering teams to influence system architecture and improve performance related to controls.
• Select, evaluate, and interface with vendors for motion control components, sensors, and related hardware.
• Review and contribute to intellectual property evaluations for new concepts and technologies.
• Ensure compliance with applicable regulatory and design standards throughout the development lifecycle.
• Support sustaining engineering activities, including troubleshooting, root cause analysis, and system enhancements.
• Travel occasionally for system integration, testing, or vendor engagement (approximately 2–3 trips per year).

Work Environment & Physical Requirements

• Primarily office based work with limited exposure to adverse environmental conditions.
• Frequent use of hands for typing, grasping, and other repetitive motions.
• Ability to sit, talk, hear, and view computer screens for extended periods.
• Ability to lift, carry, or push/pull up to 5 pounds frequently and up to 30 pounds occasionally.
• Additional physical tasks may be required depending on project needs.

We are a company committed to creating diverse and inclusive environments where people can bring their full, authentic selves to work every day. We are an equal opportunity/affirmative action employer that believes everyone matters. Qualified candidates will receive consideration for employment regardless of their race, color, ethnicity, religion, sex (including pregnancy), sexual orientation, gender identity and expression, marital status, national origin, ancestry, genetic factors, age, disability, protected veteran status, military or uniformed service member status, or any other status or characteristic protected by applicable laws, regulations, and ordinances. If you need assistance and/or a reasonable accommodation due to a disability during the application or recruiting process, please send a request to [e-mail] learn more about how we collect, keep, and process your private information, please review Insight Global's Workforce Privacy Policy: https://insightglobal.com/workforce-privacy-policy/.

Skills and Requirements

Required Qualifications

• Bachelor’s degree in mechanical engineering, Electrical Engineering, Computer Science, or related field (Master’s preferred).
• Five to ten years of experience in robotics, automation, or electromechanical system development.
• Experience programming and configuring PLC systems (ex: Beckhoff TWINCAT, Siemens, Allen-Bradley, Rockwell, Omron, CODESYS, etc.).
• Experience with 2 or more systems
• Strong background in DC motor control, servo systems, and motion control hardware.
• Hands on experience with programming, debugging, and troubleshooting PLC based automation.
• Working knowledge of regulatory standards for hardware and software development (e.g., IEC 60601, ISO 13485, ISO 14971).
• Ability to interpret mechanical drawings, electrical schematics, and system level documentation.

Preferred Experience

• Object oriented software development using C# or C++.
• Experience with the .NET Framework or .NET Standard.
• Understanding of UML state machines and their practical application.
• Knowledge of robotic control theory, including PID control and servo tuning.
• Cross platform software development experience.
• Familiarity with CAN bus networking and other industrial communication protocols.