Controls Engineer

AAE North America; Morrisville (NC); On-site; USD 95,000 - 130,000; Full time

Benefits offered by this job

Competitive Pay

Health Coverage

Short-Term Disability

Life Insurance

401(k) Plan

Paid Time Off (PTO)

Holiday Pay

Job summary

AAE North America is seeking a skilled Controls Engineer in Morrisville, NC to design, program, and optimize control systems for automated machinery. You will develop PLC/HMI software, integrate sensors/actuators, and program robots for collaboration and autonomous tasks.

The role requires a BS/MS in engineering, 4+ years in automation, and strong experience with Allen-Bradley/Omron PLCs, HMI development, and NI integration. This is an in-office position in Morrisville with no remote options.

Qualifications

• BS/MS degree in engineering or related discipline (BSEE degree preferred).
• 4+ years of experience in the automation industry.
• 3+ years PLC development experience (Allen-Bradley preferred, Omron).
• Configuring and designing HMI systems (Allen Bradley, PC-based).
• Configuring and programming Motion Controllers/Actuators.
• Programming robots and autonomous mobile robots (Fanuc, UR, MIR).
• Experience troubleshooting control system issues.
• Experience writing User Manuals and other documentation to meet client needs for IQ/OQ/PQ.
• Experience with training operators and engineers on new and existing equipment.
• Desired: Vision/Laser Systems programming (Cognex/Keyence/LMI).
• Desired: NI SW/HW integration.

Responsibilities

• Develop electrical design, schematics, and drawings in AutoCAD Electrical.
• Interpret mechanical design drawings for electrical requirements (e.g., SolidWorks).
• Research supplier products for electrical and controls components.
• Power up electrical systems and configure hardware per specs.
• Check quality of work and assist during assembly.
• Support Sales Engineers with quotes.
• Create specifications for HMI/communication interfaces, networking.
• Review and modify legacy code and field updates.
• Troubleshoot existing systems.
• Design and develop controls per specs or new concepts.
• Program PLCs/HMI from scratch to work with actuators, sensors, pneumatics.
• Conduct risk assessments for safety systems and robotics.
• Participate in requirement reviews with Mechanical Engineering.
• Program and integrate industrial robots for material handling, assembly, and palletizing.
• Prepare customer documentation: electrical schematics, spares BOM, user manuals.
• Train operators and engineers on new equipment.

Skills

PLC Development

HMI Programming

Robotics Programming

Control Systems

Troubleshooting

Documentation

Operator Training

Vision Systems

NI Integration

Education

BS/MS in Engineering

BSEE preferred

Tools

Allen-Bradley PLC

Omron PLC

Allen-Bradley HMI

PC-based HMI

Fanuc Robots

UR/MIR Robots

Cognex/Keyence Vision

NI hardware/software

Job description

We’re growing, and we’re looking for someone who wants to grow with us.

As a Controls Engineer specializing in industrial automation equipment, you will be responsible for designing, programming, and optimizing control systems to ensure efficient and reliable operation of automated machinery. Key tasks will include developing and implementing PLC and HMI programming, integrating sensors and actuators, programming industrial robots for collaborative and noncollaborative applications, interfacing with vision systems, troubleshooting system issues, and collaborating with mechanical and electrical engineers to ensure seamless system performance. This role requires strong analytical skills, expertise in control systems, and knowledge of industrial automation technologies.

What we’re looking for:

Required:

• BS/MS degree in engineering or related discipline (BSEE degree preferred)
• 4+ years of experience in the automation industry
• 3+ years PLC Development experience (Allen-Bradley preferred, Omron)
• Configuring and designing HMI systems (Allen Bradley, PC-based)
• Configuring and programming Motion Controllers/Actuators
• Programming robots and autonomous mobile robots (Fanuc, UR, MIR)
• Experience and skill in troubleshooting control system issues
• Experience writing User Manuals and other documentation to meet client needs for IQ/OQ/PQ
• Experience with training operators and Engineers on new and existing equipment
• Desired - Programming Vision/Laser Systems (Cognex, Keyence, LMI)
• Desired - Programming/integrating National Instruments SW/HW

What you’ll do:

• Develop electrical design, schematics, and drawings in AutoCAD Electrical
• Interpret mechanical design drawings for electrical requirements (e.g., SolidWorks)
• Research supplier products for electrical and controls assembly components
• Power up electrical systems and configure hardware per application specifications
• Check the quality of assemblers and technicians’ work and assist during assembly
• Work with Sales Engineers to provide input with quote preparation as required
• Understand client requirements for HMI/communication interface, networking and create specifications based on these requirements
• Review, modify, and redesign legacy code (in-house and in the field)
• Troubleshoot issues with existing company installed systems
• Design and develop controls systems based on specifications or new concepts
• Program PLC’s and HMI’s completely from scratch ensuring that they work seamlessly with other components like actuators, servos, sensors, pneumatics etc.
• Conduct risk assessments for safety systems and robotics
• Requirement Reviews – Participate in reviews and work with Mechanical Engineering to ensure proper implementation of features
• Program and integrate industrial robots for collaborative and noncollaborative applications with PLC’s and HMIs for material handling, assembly, packaging and palletizing applications
• Prepare customer documentation including electrical schematics, electrical spares BOM, Complete User Manual etc. to meet client requirements
• Train operators and engineers to use new and existing company installed equipment

This position is fully in-office, located in Morrisville, NC. Remote or hybrid work options are not available, and relocation expenses are not covered.

About AAE North America

AAE North America is a family-owned technology company headquartered in the Netherlands, known globally for innovation, precision, and a people-first culture. Based in Morrisville, NC, just minutes from Research Triangle Park , we design and build advanced automation solutions for medical, semiconductor, and other high-tech industries.

We don’t build standard machines. We develop sophisticated modules, systems, and complete automation solutions capable of producing up to 350 million products per year. Our projects are complex, custom, and constantly evolving, which means you’ll always be challenged and learning.

As we continue to grow, we’re looking for driven engineers who want to grow with us, expand their skills, influence projects, and build a long-term career in a collaborative, family-like environment. At AAE, you’re not just an employee, you’re a valued part of something meaningful.

Employee Benefits at AAE North America

At AAE North America, we believe in supporting our employees’ well‑being, security, and growth. We offer a comprehensive benefits package that includes:

• Competitive Pay – Market‑aligned compensation to recognize your skills and contributions.
• Health Coverage – Company‑sponsored medical, vision, and dental.
• Short‑Term Disability - Company‑paid gap coverage
• Life Insurance – Company‑provided life insurance for additional financial protection.
• 401(k) Plan – With employer contributions to help you build long‑term financial security.
• Paid Time Off (PTO) – Flexible paid time off to recharge and take care of personal needs.
• Holiday Pay – Paid company holidays throughout the year.

Respect for all people:

AAE North America is an equal opportunity employer that is committed to diversity and inclusion in the workplace. We prohibit discrimination and harassment of any kind based on race, color, sex, religion, sexual orientation, national origin, disability, genetic information, pregnancy, or any other protected characteristic as outlined by federal, state, or local laws.

This policy applies to all employment practices within our organization, including hiring, recruiting, promotion, termination, layoff, recall, leave of absence, compensation, benefits, training, and apprenticeship. AAE North America makes hiring decisions based solely on qualifications, merit, and business needs at the time.

Please Note:

To 3rd Party Search Firms/Employment Agencies: Please do not call or email any AAE North America employee about current or future job openings. All resumes submitted by search firms or employment agencies to any employee at AAE North America via email, telephone, social media, or other means will be deemed to be the sole property of AAE North America unless the firm submitting the resume has previously entered into a written agreement with AAE North America regarding recruitment services and has been approved by Human Resources to work on an open position. AAE North America will not pay any fee or remuneration concerning candidates without complying with this requirement.