Control Systems Specialist

BW Systems, Inc; South Saint Paul (MN); On-site; USD 90,000 - 130,000; Full time

Job summary

BW Systems, Inc. is seeking a senior system automation engineer to design, program, and deploy PLC/HMI/SCADA solutions using Allen-Bradley Logix platforms.

You will lead projects across packaging and manufacturing lines, from concept through FAT/SAT, integrating motion control and vision systems. You will optimize processes with advanced control loops, implement robust safety architectures, and maintain comprehensive design documentation.

Qualifications

• Experience designing PLC and HMI/SCADA programs on Allen-Bradley Logix platforms.
• Strong motion control and multi-axis synchronization knowledge.
• Familiarity with ISA-88 batch process principles.
• Ability to integrate third-party equipment and robotics into control systems.

Responsibilities

• Design, program, and deploy PLC and HMI/SCADA using Studio 5000/RSLogix 5000.
• Program and commission motion systems with Kinetix drives and AMR/AGV handoffs.
• Develop material handling integrations: conveyors, sortation, palletizers.
• Implement tracking, barcode/RFID logic for high-throughput lines.
• Design control strategies for web handling, tension, winding, and registration.
• Develop PID and advanced control loops to maximize stability.
• Integrate equipment via EtherNet/IP, ControlNet, DeviceNet.
• Perform FAT/SAT, debugging, and system startup.
• Ensure safety with GuardLogix and ISO 13849 / ANSI B11.19.

Skills

PLC programming

Industrial automation

System architecture

PID control

Tools

Studio 5000

RSLogix 5000

GuardLogix

EtherNet/IP/ControlNet/DeviceNet

Job description

Key Responsibilities

System Architecture & Programming: Design, develop, and deploy comprehensive PLC and HMI/SCADA programs utilizing the Allen-Bradley Logix platform (Studio 5000 / RSLogix 5000).

Motion Control & Coordination: Program and commission high-speed, multi-axis synchronized motion systems (Kinetix servo drives, virtual master axes, electronic gearing, and camming) for precision manufacturing operations.

• Conveyor & Material Handling Integration:
  • Design, program, and optimize complex material handling systems, including accumulation conveyors, sortation systems, palletizers, and automated guided vehicle (AGV) or autonomous mobile robot (AMR) handoffs.
  • Implement tracking, merging, diverting, and barcode/RFID scanning logic to ensure seamless product flow through high-throughput logistics and production lines.
• Process & Web Handling Control:
  • Design and optimize control strategies for web handling (webline) applications, including tension control, winding/unwinding, and registration.
  • Engineer control algorithms for extrusion processes, ensuring tight temperature regulation, pressure control, and line speed synchronization.
  • Implement complex batch process sequences adhering to industry standards (e.g., ISA-88 principles).

Advanced Control Loops: Design, tune, and troubleshoot complex PID control loops, including cascade loops, ratio control, and advanced feed-forward control strategies to minimize disturbance and maximize process stability.

System Integration: Integrate third-party equipment, robotics, instrumentation, and vision systems into the primary control network using industrial protocols (EtherNet/IP, ControlNet, DeviceNet).

Debugging & Commissioning: Conduct rigorous on-site factory acceptance testing (FAT), site acceptance testing (SAT), troubleshooting, and system startup.

Safety Integration: Design and implement hardware and software safety systems compliant with relevant standards (ISO 13849 / ANSI B11.19) using Allen-Bradley GuardLogix controllers and safety-rated components.

Documentation: Create and maintain robust engineering documentation, including functional design specifications (FDS), control philosophy documents, I/O lists, cause-and-effect matrices, and as-built code comments.