Controls Engineer

The AES Group

Dallas (TX)

On-site

USD 110,000 - 150,000

Full time

8 days ago

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Job summary

The AES Group is seeking an experienced Controls Engineer in Dallas, TX to design, program, commission, and support industrial automation systems using ABB and Rockwell platforms. You will handle PLC/HMI/SCADA development, drive configurations, and network integration for diverse manufacturing environments.

Ideal candidates have 8+ years of controls engineering experience, a B.E. in Electrical Engineering, and strong communication skills to collaborate with multidisciplinary teams.

Qualifications

Bachelor's degree in Electrical Engineering or related field.
8+ years of Controls Engineering experience in industrial manufacturing or automation.
Hands-on experience with ABB Automation Systems and Rockwell Automation (Allen-Bradley).
Experience with Studio 5000 and RS Logix 5000 and with FactoryTalk View.
Knowledge of industrial networking protocols (EtherNet/IP, DeviceNet, PROFINET, Modbus).
Strong troubleshooting, documentation, and project coordination skills.

Responsibilities

Design, program, commission, and support industrial automation and control systems using ABB and Rockwell technologies.
Develop and troubleshoot PLC programs (Allen-Bradley family) and HMI/SCADA applications.
Configure ABB drives, motors, VFDs, and related devices for production lines.
Create and maintain electrical schematics, control narratives, and FAT/SAT documentation.
Coordinate with multi-discipline teams across project stages from concept to commissioning.
Travel up to 20-30% for commissioning and customer support when required.

Skills

ABB Automation

Rockwell Automation

PLC Programming

HMI Development

SCADA Systems

Industrial Networking

VFDs & Servo Drives

Motion Control

Education

Bachelor's degree in Electrical Engineering

Tools

Studio 5000

RS Logix 5000

FactoryTalk View

EtherNet/IP

Modbus TCP/IP

OPC UA

Job description

Role: Controls Engineer
Location: Dallas, TX
Let's create our future together at The AES Group!

About The AES Group

The AES Group is a premier technology and engineering consulting company that has been bringing businesses and talent together for over 20 years to deliver innovative solutions that have the greatest positive impact on society. AES has helped over 40 business enterprises, including Fortune 500 companies, engage their customers, empower their employees, and transform their business operations with the power of cloud, data, AI, engineering, and other emerging technologies.

Position Overview

We are seeking an experienced Controls Engineer to join our engineering team in Dallas, TX. The ideal candidate will have extensive hands‑on experience in designing, programming, commissioning, and supporting industrial automation systems using ABB and Rockwell Automation platforms. This role offers the opportunity to work on complex automation projects across manufacturing and industrial environments while collaborating with multidisciplinary engineering teams.

The successful candidate will possess strong expertise in PLC, HMI, SCADA, and industrial networking, with the ability to independently manage automation projects from concept through commissioning.

Key Responsibilities

Design, develop, program, and commission industrial automation and control systems using ABB and Rockwell Automation technologies.
Develop and troubleshoot PLC programs utilizing Allen‑Bradley ControlLogix, CompactLogix, GuardLogix, MicroLogix, and Studio 5000 / RS Logix 5000.
Configure and support ABB PLCs, drives, motors, VFDs, and industrial automation products.
Develop HMI and SCADA applications using FactoryTalk View SE/ME, ABB automation software, or equivalent visualization platforms.
Perform PLC, HMI, VFD, servo, and motion control integration for new and existing production equipment.
Configure industrial communication networks including:
Ether Net/IP
DeviceNet
ControlNet
Modbus TCP/IP
Profinet
OPC UA
Troubleshoot automation, instrumentation, and electrical control systems to minimize production downtime.
Develop electrical control philosophies, control narratives, functional specifications, and I/O lists.
Participate in FAT (Factory Acceptance Test), SAT (Site Acceptance Test), startup, commissioning, and customer acceptance activities.
Coordinate with electrical, mechanical, manufacturing, and project engineering teams throughout project execution.
Support equipment upgrades, process improvements, and continuous improvement initiatives.
Maintain detailed engineering documentation including:
Control panel drawings
Electrical schematics
PLC/HMI backups
Bill of Materials (BOM)
Functional Design Specifications (FDS)
Ensure all automation systems comply with company standards, OSHA regulations, and applicable electrical safety codes.

Required Qualifications

Bachelor's degree in electrical engineering, Controls Engineering, Mechatronics, Automation Engineering, or a related discipline.
Minimum 8+ years of Controls Engineering experience within industrial manufacturing or automation environments.
Strong hands‑on experience with:
ABB Automation Systems
Rockwell Automation (Allen‑Bradley)
Studio 5000
RS Logix 5000
FactoryTalk View
Experience programming PLCs, HMIs, SCADA, VFDs, servo systems, and motion control applications.
Strong understanding of industrial electrical systems, instrumentation, sensors, actuators, and control panel design.
Ability to interpret electrical schematics, P&IDs, wiring diagrams, and engineering documentation.
Experience with industrial networking and communication protocols.
Excellent troubleshooting and analytical problem‑solving skills.
Strong written and verbal communication skills.

Preferred Qualifications

Experience with ABB Robotics or industrial robotic integration.
Knowledge of IEC 61131‑3 programming standards.
Experience in automotive, food & beverage, packaging, pharmaceuticals, material handling, or process manufacturing industries.
Exposure to MES, IIoT, Industry 4.0, and data acquisition systems.
Familiarity with AutoCAD Electrical or EPLAN.
Experience with vision systems such as Cognex or Keyence is a plus.
Ability to travel up to 20 30% for commissioning and customer support, if required.

Technical Skills