Electrical Controls Engineer - Industrial Automation

SAI SYSTEMS; Plymouth (MI); On-site; USD 90,000 - 130,000; Full time

Job summary

SAI SYSTEMS in Michigan is seeking an Electrical Controls Engineer to own the controls hardware design for custom automation systems. You will design electrical and controls architecture, industrial control panels, power distribution, safety systems, and I/O networks, and work with the build team to bring designs to life on the shop floor.

The role requires hands-on experience beyond schematics, including panel fabrication, testing, commissioning, and trouble-shooting in real-world environments.

Qualifications

• Minimum 5+ years in controls hardware design for automation or custom machinery.
• Bachelors in Electrical/Controls/Systems Engineering preferred; hands-on experience may substitute.
• Experience with panel fabrication, wiring, testing, and certification in real-world environments.
• Proven ability to develop electrical drawing packages and BOMs.

Responsibilities

• Own controls hardware design from concept through installation and documentation.
• Develop electrical drawings with AutoCAD Electrical and/or EPLAN.
• Design and size 480VAC control panels and power distribution systems.
• Select PLCs, I/O, drives, safety components, and network hardware.
• Collaborate with panel builders and engineers to resolve build issues.
• Develop BOMs and release hardware for purchasing.
• Review designs with customer engineers to ensure compliance.

Skills

Controls hardware design

AutoCAD Electrical

EPLAN

Rockwell/Siemens hardware

PLC selection & I/O

Industrial networks

Panel design & wiring

Safety hardware & NFPA 79

Education

Bachelor's degree in Electrical/Controls/Systems Engineering

Tools

AutoCAD Electrical

EPLAN

Allen-Bradley ControlLogix/CompactLogix

Allen-Bradley Kinetix

Siemens S120 drives

VFDs and servo drives

Job description

Job Description

Electrical Controls Engineer – Industrial Automation

Design the Hardware Behind Complex Automated Systems

We are looking for an experienced Electrical Controls Engineer who enjoys taking an automation project from concept to a fully built and functioning machine.

This is an opportunity to take real ownership of the controls hardware design for complex custom automation systems. You will design electrical and controls architecture, industrial control panels, power distribution, safety systems, I/O, networks, servo systems, hydraulics, and pneumatics—and then work directly with the build team to see those designs come to life on the shop floor.

We are looking for someone who understands more than what looks right on a schematic. You understand how a panel is actually built, wired, tested, certified, installed, and troubleshot in the real world.

If you have spent your career around custom machinery, automation lines, control panels, machine builders, or systems integrators and enjoy being the hardware expert that engineering and the shop can depend on, this could be an excellent fit.

What You'll Do

• Own the controls hardware design for custom automated equipment from initial concept through build, installation, and final documentation.
• Develop complete electrical drawing packages using AutoCAD Electrical and/or EPLAN, including schematics, panel layouts, wiring diagrams, terminal plans, I/O drawings, and power distribution drawings.
• Design industrial control panels ranging from smaller machine enclosures to large, multi-door 480VAC control panels.
• Develop power distribution architecture and perform calculations for FLA, wire sizing, circuit protection, SCCR, and related electrical requirements.
• Select and specify PLC hardware, remote I/O, communication hardware, servo drives, VFDs, safety components, power supplies, circuit protection, and other control components.
• Work with Allen-Bradley and Siemens platforms, including hardware such as Kinetix servo drives and Siemens S120 drive systems.
• Design industrial networks using technologies such as EtherNet/IP, Profinet, DeviceNet, and Modbus.
• Design machine safety systems, determine required safety ratings, select appropriate safety hardware, and perform calculations such as light curtain safety distances.
• Design and specify hydraulic and pneumatic circuits and components as required by the machine.
• Develop accurate Bills of Material (BOMs) and release hardware for purchasing to keep projects on schedule.
• Work directly with panel builders, electricians, machine builders, controls engineers, and commissioning personnel to resolve issues during machine build and startup.
• Provide practical guidance to shop personnel regarding panel construction, wiring, component placement, wire sizing, bend radius, duct fill, and good panel-building practices.
• Troubleshoot electrical hardware and panel issues during build, debug, installation, and commissioning.
• Work directly with customer engineers to review designs, resolve specification questions, and ensure customer standards are incorporated into the final system.
• Maintain accurate as-built drawings, BOM revisions, engineering changes, and final documentation packages.
• Review and contribute to technical documentation, including machine operation and maintenance manuals for complex multi-station automation systems.
• Support Sales and Applications Engineering with technical feasibility reviews, hardware concepts, cost estimates, and change-order evaluations.
• Help improve engineering standards, drawing templates, component libraries, and documentation processes.

What We're Looking For

• 5+ years of controls hardware or electrical design experience involving industrial automation or custom machinery.
• Experience working for a custom automation integrator, machine builder, or industrial equipment OEM.
• Strong experience with AutoCAD Electrical (Acad-E) and/or EPLAN. Experience with both is a plus.
• Hands-on experience designing industrial electrical control panels and power distribution systems.
• Experience designing 480VAC enclosures and selecting/sizing the components within them.
• Strong understanding of Allen-Bradley and/or Siemens controls hardware.
• Experience specifying PLCs, I/O, industrial networks, VFDs, servo systems, and safety hardware.
• Practical knowledge of panel construction and electrical wiring—not simply schematic design.
• Experience with machine safety systems, safety ratings, and safety-device implementation.
• Working knowledge of NEC, NFPA 79, UL 508A, and other applicable industrial electrical standards.
• Understanding of SCCR, FLA, Arc Flash considerations, NEMA enclosure ratings, IEC vs. NEMA components, and CE requirements.
• Ability to troubleshoot electrical and controls hardware using appropriate test equipment.
• Experience creating and maintaining accurate engineering documentation.
• Strong communication skills and the ability to work effectively with customers, engineers, electricians, panel builders, and machine builders.

A Bachelor's degree in Electrical, Controls, or Systems Engineering is preferred; however, significant hands‑on controls hardware design experience may be considered in place of a four‑year engineering degree.

Experience That Will Make You Stand Out

• AutoCAD Electrical / Acad‑E
• EPLAN
• Allen‑Bradley ControlLogix / CompactLogix
• Allen‑Bradley Kinetix
• Siemens PLC hardware
• Siemens S120 drives
• 480VAC industrial control panels
• Multi‑door enclosure design
• NEC / NFPA 79 / UL 508A
• SCCR calculations
• FLA calculations
• Arc Flash
• CE compliance
• IEC and NEMA components
• NEMA enclosure ratings
• Machine safety ratings
• Light curtain distance calculations
• Safety PLCs
• Panel design and panel build
• Electrical troubleshooting
• Hydraulic and pneumatic systems
• Technical wiring
• Technical writing and operations manuals
• Microsoft Word and Excel
• Electrical test equipment, including multimeters and oscilloscopes

Why This Role Is Different

This isn't a position where you design something and never see it again.

You will have the opportunity to own your hardware designs and see them become operating equipment. You'll work alongside the people building and commissioning the machines, solve real engineering problems, interact directly with customers, and have a meaningful voice in how our controls hardware standards evolve.

We're looking for an engineer who takes pride in creating designs that don't just work on paper—they work on the shop floor and in the plant.