Controls Engineer New Research Triangle Park, NC

Vulcan Elements Inc.; Durham (NC); On-site; USD 90,000 - 140,000; Full time

Job summary

Vulcan Elements Inc. in Durham, NC, seeks a Controls Engineer to own the controls execution for the magnet equipment portfolio within a major facility expansion.

You’ll cradle-to-grave design reviews, FAT/SAT involvement, and hands-on implementation with domestic travel up to 50% during test campaigns. The role requires deep expertise in Siemens and Allen-Bradley PLCs, HMIs, robotics and motion control, SCADA connectivity, and a strong safety/reliability focus.

Qualifications

• Bachelor’s or Master’s degree in electrical/automation engineering or related field.
• 3+ years of direct industrial automation and controls experience.
• Hands-on programming and commissioning Siemens and Allen-Bradley PLCs/HMIs.
• Knowledge of servos, VFDs, conveyors, robotic cells, and material handling.
• Experience with Ethernet/IP, Profinet, EtherCAT, OPC UA.
• U.S. Person due to export control requirements.

Responsibilities

• Owns controls execution for magnet equipment portfolio from design review to commissioning.
• Leads integration of robotics, conveyors, and motion control systems.
• Configures and maintains PLC/HMI connectivity to SCADA/Becton systems.
• Supports FATs and SATs to ensure safety and functional compliance.
• Provides troubleshooting and technical escalation for automation issues.

Skills

PLC programming

Siemens PLC

Allen-Bradley PLC

HMI programming

Industrial automation

SCADA connectivity

Troubleshooting

FAT/SAT testing

Robotics integration

Education

Bachelor’s or Master’s in Electrical/Automation/Mechatronics

Tools

Ignition SCADA

Wonderware

Cognex Vision

Keyence Vision

Ethernet/IP

Job description

Vulcan Elements is manufacturing American rare-earth permanent magnets for a secure, resilient future. With a focus on national security and economic resiliency, we serve critical industries such as defense, aerospace, and automotive powering a high-technology future. Vulcan Elements is building a team of ambitious professionals committed to Mission Focus, Technical Excellence, and Transparency.

As the Controls Engineer you will own controls execution for the magnet equipment portfolio within a massive 1 million square foot manufacturing facilityexpansion .You will own your equipment packages cradle-to-grave - design review, FAT witness, site commissioning, and sustaining supportThis is a high-impact, high-ownership leadership role requiring technicalexpertisein industrial automation. The role includes hands-onimplementationand domestic travel to OEM FATs up to ~50% during testcampaigns.

This role begins in Durham, NC and is expected to move to Benson, NC upon completion of new facility.

Responsibilities

• PLC Programming & Commissioning: Executehands-on programming, debugging, and commissioning of Siemens andAllenBradley/Rockwell PLCs and HMIs for new and existing automation equipment.
• Advanced Automation & System Integration: Drivethe integration and commissioning of robotics, conveyors, and motion control systems-including servos and VFDs-to enable seamless material flow and highreliability production operations.
• SCADA/MES Connectivity: Configure andmaintaincommunications between PLCs/HMIs andSCADA/Batch systems. Support tag mapping, alarming, and data acquisition to the site SCADA platform asrequired.
• Vendor Technical Support & FATs: Review vendor electrical schematics, controls architectures, and PLC/HMI logic. Participate in and support Factory Acceptance Tests (FATs) and Site Acceptance Tests (SATs) to ensure full compliance with functional and safety requirements.
• Troubleshooting & Technical Escalation: Serve as the first-line, hands-on responder for diagnosing complex automation issues involving networks, motion systems, instrumentation, and industrial communication protocols.

Deliverables You Will Develop, Review, or Support

• Controls & IT: PLC code architecture, HMI screens, vision inspection programs, tag databases,network lists,and system backups.
• Risk & Safety: Controls risk assessments, interlock/guarding logic, andsafety ratedPFMEA inputs.
• Process Design: Controls layouts, network topology layouts, station cycle times, sequence diagrams, and automation simulations.
• Engineering Diagrams: Electrical schematics, pneumatic drawings, controls panel layouts, and industrial network architecture.
• Operations & Maintenance: Calibration procedures, I/O lists, instrumentation documentation, and controls hardware maintenance manuals.

Responsibilities and tasks outlined are not exhaustive and may change asdeterminedby the needs of the business

Qualifications

• Bachelor’s orMastersdegree in electrical engineering, Automation Engineering, Mechatronics, or related field with 3+years of direct industrial automation and controls engineering experience.
• Stronghandsonexperience programming and commissioning SiemensandAllenBradley/Rockwell PLCs and HMIs.
• Deep understanding of servos, VFDs, highspeed conveyors, robotic cells, and automated material handling systems.
• Proficiencywith Ethernet/IP,Profinet,EtherCAT, OPCUA, and similar industrial communication standards.
• Analog loop fundamentals, gas analyzer integration (O₂, pressure, flow), loop tuning, and the literacy to read and validate safety-rated circuits and safety PLC

Must be a U.S. Person due to required access to U.S. export-controlled information or facilities

Preferred Skills

• Working experience withmultiaxisrobotic systems and machine vision platforms such as Cognex or Keyence. AGV experience is a strong plus.
• Experience in heavy industrial, greenfield, chemical, or metallurgical manufacturing environments.
• Experience developing SCADA applications in Ignition, Wonderware, or similar platforms.
• Powder or bulk-solids handling controls (pneumatic conveying, gravimetric dosing, milling), hazardous-atmosphere or reactive-material environments (combustible dust, inert-gas blanketing, hydrogen service), or furnace/vacuum/thermal process controls.
• Familiarity with Python, C++, or otherhighlevellanguages for automation or data analytics.
• Experience in regulated industries such as Defense, Aerospace, or Automotive.

Physical and Environmental Requirements

The position requires regular presence on the production floor and the ability to navigate all areas of the facility. Candidates must be able to climb stairs, stand and walk for extended periods, and work in environments that may be hot, humid, or noisy. The role also requires the use of personal protective equipment, including respirators, and adherence to all applicable safety policies, procedures, and regulatory requirements. Employees must be able to complete required fit testing, wear appropriate PPE for the duration of assigned tasks, and respond safely to changing conditions within the production environment.

Voluntary Self-Identification

For government reporting purposes, we ask candidates to respond to the below self-identification survey.Completion of the form is entirely voluntary. Whatever your decision, it will not be considered in the hiringprocess or thereafter. Any information that you do provide will be recorded and maintained in aconfidential file.

As set forth in Vulcan Elements’s Equal Employment Opportunity policy,we do not discriminate on the basis of any protected group status under any applicable law.

If you believe you belong to any of the categories of protected veterans listed below, please indicate by making the appropriate selection.As a government contractor subject to the Vietnam Era Veterans Readjustment Assistance Act (VEVRAA), we request this information in order to measurethe effectiveness of the outreach and positive recruitment efforts we undertake pursuant to VEVRAA. Classification of protected categoriesis as follows:

A "disabled veteran" is one of the following: a veteran of the U.S. military, ground, naval or air service who is entitled to compensation (or who but for the receipt of military retired pay would be entitled to compensation) under laws administered by the Secretary of Veterans Affairs; or a person who was discharged or released from active duty because of a service-connected disability.

A "recently separated veteran" means any veteran during the three-year period beginning on the date of such veteran's discharge or release from active duty in the U.S. military, ground, naval, or air service.

An "active duty wartime or campaign badge veteran" means a veteran who served on active duty in the U.S. military, ground, naval or air service during a war, or in a campaign or expedition for which a campaign badge has been authorized under the laws administered by the Department of Defense.

An "Armed forces service medal veteran" means a veteran who, while serving on active duty in the U.S. military, ground, naval or air service, participated in a United States military operation for which an Armed Forces service medal was awarded pursuant to Executive Order 12985.

Voluntary Self-Identification of Disability

Form CC-305

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