Controls Engineer – Robotics & Industrial Automation Lead

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 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