CONTROLS ENGINEER

Align Prod; Decatur (IL); On-site; USD 80,000 - 115,000; Full time

Job summary

Align Prod in Decatur, IL is seeking a Controls Engineer to design, develop, and implement electrical controls for material handling systems. You will write PLC programs, develop AGV logic, and support installation and commissioning across projects, coordinating with mechanical engineers and customers.

The role requires strong experience in Allen-Bradley products, Codesys, and NEC standards, with a focus on delivering robust, cost-effective control solutions and documentation.

Qualifications

• Experience designing and implementing electrical controls systems.
• Ability to develop PLC programs and AGV-related logic.
• Lead projects, coordinate with engineering and customers to meet expectations.

Responsibilities

• Interpret customer requirements and translate into control designs and drawings.
• Commission custom control solutions and assist installation and troubleshooting.
• Lead as Project Manager for electrical and programming functions on projects.
• Organize workload, set milestones, and track progress.
• Support manufacture, build, and validation of systems including pneumatics and robotics.
• Write PLC programs that are well-documented and testable.
• Create operation and maintenance manuals related to controls.

Skills

Project Management

Structured Text

CANbus & Ethernet

Codesys

Allen-Bradley

NEC Knowledge

Microsoft 365

Mechanical Knowledge

Education

Bachelors in Automation/Controls

Tools

Automation hardware

Job description

If you are unable to complete this application due to a disability, contact this employer to ask for an accommodation or an alternative application process.

CONTROLS ENGINEER

FULL TIME Decatur, IL, US

Salary Range: $80,000.00 To $115,000.00 Annually

Who We Are:

The Align philosophy is to work together as a team to effectively implement the best solution, on the best schedule, at the best price. This philosophy drives Align to perform our best through quality employees, quality products, and quality customers, what we call, our “Q3.”

Our process has made Align a proven leader in supplying innovative material handling solutions to a diverse range of industries around the globe such as automotive, aerospace, heavy construction, and heavy electrical.

Position Overview:

The Controls Engineer designs, develops, and implements electrical controls and automation systems to perform to customer’s expectations; collaborates with mechanical design engineers, writes programs and operational procedures for industrial material handling equipment; and is a support system during and after installation as the need arises.

ESSENTIAL DUTIES AND RESPONSIBILITIES (other duties may be assigned)

Interpret customer requirements, identify, and address design parameters and engineering problems and ensure solutions are implemented accurately and within budget through clear customer communication.

Commission custom product solutions and systems Assist installation and troubleshooting control systems.

Lead as the Project Manager representing the electrical and programming functions of the business for all projects.

Organize Controls Engineering workload and set deadlines for milestones.

Support the manufacture, build and validation of systems which include pneumatics, hydraulics, servos, variable frequency drives, relays, communication networks, touchscreens, pushbuttons, robotics, and other such integration.

Writing AGV programs in structured text for varying machine designs and applications.

Creating system logic for AGV fleets.

Working with customers to establish AGV communication with the facilities operational system.

Performing startup and diagnostic tests on newly manufactured AGV’s before completion.

Assist application sales engineers and product engineers in estimating cost of controls.

Develop cost-effective designs through key selection of control components to maximize profitability and in collaboration with purchasing.

Draw and review control schematics, able to interpret shop edits and implement them into final draft.

Write PLC programs that are simple to test, are well-documented and versatile.

Assist in the creation of operation and maintenance manuals related to controls.

Ability to balance multiple projects and prevent scope creeps.

SKILLS & KNOWLEDGE

• Project Management
• Structured Text
• CANbus & Ethernet communications
• Ability to read, edit, and troubleshoot in Codesys
• Must have good mechanical knowledge.
• Experience in Allen-Bradley products and software, writing programs using Ladder Logic, and maintaining schematics/programs for future warranty/repairs.
• Knowledge of NEC rules and best practices
• Microsoft 365

EDUCATION and/or EXPERIENCE

Experience Required (Any of):

• Computer Science, or Electrical Engineering, or Controls Engineering Degree

**Troubleshooting skills are paramount.

LANGUAGE SKILLS

• Ability to read, analyze, and interpret component cutsheets, vendor quotes, and sales proposal.
• Ability to respond to common inquiries or complaints from customers, regulatory agencies, or members of the business community.

REASONING ABILITY

• Ability to apply principles of logical or scientific thinking to a wide range of intellectual and practical problems.
• Ability to deal with nonverbal symbolism (formulas, scientific equations, graphs, etc.,) in its most difficult phases.
• Ability to deal with a variety of abstract and concrete variables.

Job Type: Full-time

Education: Bachelor's in Automation or Electrical Controls Engineering