Controls Engineer New Research Triangle Park, NC

Vulcan Elements Inc.; Northern (KY); Hybrid; USD 95,000 - 135,000; Full time

Job summary

Vulcan Elements is seeking a Controls Engineer to own controls execution for the finishing equipment portfolio as the facility expands. You will manage cradle‑to‑grave packages from design reviews to FAT, SAT, commissioning, and sustaining support.

The role calls for hands‑on automation expertise and travel up to ~50% during test campaigns. The position requires 4+ years in industrial automation, with deep experience in Allen‑Bradley/Rockwell and Siemens PLCs/HMIs, plus robot integration with

Qualifications

• 4+ years in direct industrial automation and controls engineering.
• Hands-on programming and commissioning of Allen‑Bradley/Rockwell, Siemens PLCs and HMIs including safety PLCs such as GuardLogix.
• Experience integrating multi‑axis robots (FANUC, ABB, KUKA) and teaching, program review, PLC handshaking, safety zone configuration.

Responsibilities

• Lead hands-on programming, debugging, and commissioning of control hardware across grinding, wire saw, EDM, tumbling, coating, magnetization, and inline inspection equipment.
• Own integration and commissioning of robot cells (FANUC, ABB, KUKA) with cell layout review, end‑of‑arm tooling, PLC‑to‑robot handshaking, machine vision, and coordinated motion.
• Execute task-based risk assessments to ISO 10218-1/2, ISO/TS 15066, and ANSI/RIA R15.06; specify and validate safety functions and FATs.
• Configure and maintain communications between PLCs, robots, CNCs, and the site SCADA/MES layer, including tag mapping and data acquisition.
• Review vendor electrical schematics, controls architectures, robot programs, and PLC/HMI logic; lead FATs and SATs for compliance.
• Integrate dimensional and defect inspection, profilometry, and analytical test instrumentation into the cell control and plant data layer.

Skills

Industrial automation

Robot integration

PLC/SCADA programming

Education

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

Tools

Ignition

FactoryTalk

Wonderware

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 finishing equipment portfolio within a massive 1 million square foot manufacturing facility expansion. You will own your equipment packages cradle-to-grave: design review, FAT witness, site commissioning, and sustaining support. This is a high-impact, high-ownership role requiring technical expertise in industrial automation and industrial robotics. The role includes hands-on implementation and travel to OEM factory acceptance tests, domestic and international, up to ~50% during test campaigns, and transitions from Durham, NC to the Benson, NC facility as commissioning begins.

Responsibilities

• Lead hands-on programming, debugging, and commissioning of Allen-Bradley/Rockwell, Siemens,andother industrialcontrol hardware.Apply internal standardsacross grinding, wire saw, EDM, tumbling, coating, magnetization, and in-line inspection equipment.
• Own the integration and commissioning of robotcells(Fanuc, ABB, Kuka)-cell layout review, end-of-arm tooling, PLC-to-robot handshaking, machine vision, and coordinated motion with indexing conveyors, rotary tables, and servo feed systems.
• Execute task-based risk assessments to ISO 10218-1/-2, ISO/TS 15066, and ANSI/RIA R15.06; specify and validate safety functions — safe soft limits and zone monitoring, enabling devices, guard interlocks, and safety-rated stops — and demonstrate each one at Factory Acceptance Test rather than discovering it on site.
• Configure andmaintaincommunications between PLCs, robots, CNC-class machine controls, and the site SCADA/MES layer, including tag mapping, alarming, and data acquisition.
• Review vendor electrical schematics, controls architectures, robot programs, and PLC/HMI logic.Lead controlsFactory Acceptance Tests (FATs) and Site Acceptance Tests (SATs) to ensure full compliance with functional and safety requirements.
• Integrate dimensional and defect inspection, profilometry, and analytical test instrumentation into cell control and the plant data layer-measurement-to-reject interlocks, SPC data flow, and the disposition logic.
• Serve as the first-line, hands-on responder for diagnosing complex automation issues involving robots, networks, motion systems, instrumentation, and industrial communication protocols-on both the new facility and the running pilot.

Deliverables You Will Develop, Review, or Support

• PLC code architecture, robot programs and safety zone configurations, HMI screens, vision inspection programs, tag databases, network lists, and system backups.
• Robot cell and machine risk assessments, safety function specifications with required performance levels,interlockand guarding logic, and safety-rated PFMEA inputs.
• Cell layouts, controls and network topology layouts, station cycle times, sequence diagrams, and automation simulations.
• Electrical schematics, pneumatic drawings, controls panel layouts, end-of-arm tooling interface drawings, and industrial network architecture.
• Calibration procedures, I/O lists, instrumentation documentation, robot mastering and maintenance procedures, and controls hardware maintenance manuals.

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

Qualifications

• Bachelor’s or Master’s degree in Electrical Engineering, Automation Engineering, Mechatronics, or a related field with 4+ years of direct industrial automation and controls engineering experience.
• Strong hands-on experience programming and commissioning Allen-Bradley/Rockwell, SIemens PLCs and HMIs, including safety PLCs such as GuardLogix.
• Hands-on experience integrating multi-axis robots–FANUC, ABB,and/or KUKA-including teaching, program review, PLC handshaking, and safety zone configuration.
• Grinding, wire saw, EDM, or lapping equipment; mass finishing and deburring lines; conveyorized coating and cure ovens.
• Servos, VFDs, indexing conveyors, rotary tables, and automated feed systems;proficiencywith Ethernet/IP, OPC UA, and similar industrial communication standards.
• DemonstratedFAT and SAT participation — you have tested machines at vendor shops and commissioned them in the field — with structured troubleshooting, disciplined change control, and honest escalation.

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

Preferred Skills

• Working knowledge of ISO 10218 / ANSI-RIA R15.06, the collaborative operation modes and their common misuse, and ISO 13849 performance levels, with the judgment to require that a safety function bedemonstratedrather than asserted.
• Cognex or Keyence class vision platforms, in-line dimensional gauging, or profilometry and SPC-driven inspection systems.
• Standalone CNC machines (FANUC FOCAS,MTConnect, etc..) and/or OEM data retrofits on equipmentshipped without normal factory integration in mind.
• Plant-level conveyor control and AMR/AGV fleet integration (ANSI/RIA R15.08) — a likely growth area for this role as that scope is defined.
• Combustible dust (NFPA 484 — NdFeB grinding swarf is pyrophoric), reactive metals, or strong-field environments where standard inductive, reed, Hall-effect, and magnetic-encoder sensing cannot be used.
• Experience developing SCADA applications in Ignition, FactoryTalk, Wonderware, or similar platforms.
• Familiarity with Python, SQL, or other high-level languages for automation or data analytics.
• Experience in heavy industrial, greenfield, or metallurgical manufacturing environments, or 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.

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We are a federal contractor or subcontractor. The law requires us to provide equal employment opportunity to qualified people with disabilities. We have a goal of having at least 7% of our workers as people with disabilities. The law says we must measure our progress towards this goal. To do this, we must ask applicants and employees if they have a disability or have ever had one. People can become disabled, so we need to ask this question at least every five years.

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