Lead Controls Engineer – PLCs, ABB RAPID & Vision Systems

Impact Solutions; Waukesha (WI); On-site; USD 100,000 - 120,000; Full time

Benefits offered by this job

Performance bonuses

Paid travel expenses

Comprehensive benefits package

Job summary

Impact Solutions seeks a Lead Controls Engineer in the Greater Waukesha area for a direct-hire role. You will lead end-to-end automation projects, program ABB RAPID systems, and integrate Rockwell PLCs, vision, and motion control. Travel up to 30% both domestic and international, with a focus on aerospace, medical, and consumer goods sectors.

You will work in a tech-forward facility combining software and floor testing, delivering custom machinery from simulation to on-floor operation. U.S.

Qualifications

• 5+ years of systems integration depth in automation environments.
• Dual controls & robotics competency: Rockwell PLCs (Studio 5000) + ABB RAPID/RobotStudio.
• Hardware & safety architecture mastery across servo, vision, and networking.
• Bachelor's degree in Electrical/Mechanical/Automation Engineering preferred.
• Willingness to travel up to 30% domestically and internationally.

Responsibilities

• Lead end-to-end automation project lifecycles from concept to SAT sign-off.
• Program, simulate, and refine ABB robotics paths using RobotStudio and RAPID.
• Develop PLC logic and HMI using Rockwell Studio 5000 and FactoryTalk.
• Configure industrial networks and fieldbus communications across systems.
• Implement safety architectures (Category 3/4) and safety interlocks.
• Integrate vision systems (Cognex/Keyence) with motion and EOAT.
• Direct site deployments worldwide up to 30% of the year.

Skills

Systems Integration

ABB RAPID

Rockwell Studio 5000

RobotStudio

Machine Vision

Industrial Networking

Safety Standards

Travel Flexibility

Education

Bachelor's Degree in Electrical/Mechanical/Automation Engineering

Tools

ABB RobotStudio

Studio 5000

FactoryTalk

EtherNet/IP

Job description

Lead Controls Engineer - PLCs, ABB RAPID & Vision Systems
Up to $120,000 Starting Base + Earning Bonuses

• 1st Shift
• Up to 30% Travel
• Direct-Hire
• Pay & Incentives: Up to $120,000 base compensation package (commensurate with custom robotics integration depth) + performance incentive bonuses + paid travel expenses + comprehensive corporate benefits package.
• Work Pattern: 1st Shift schedule | Tech-focused Waukesha facility footprint combining software architecture, virtual simulation, and physical floor debug under one roof.
• Field Deployment: 15% to 30% domestic and international site deployments for high-visibility client installations, system commissionings, and final SAT run-offs.
• Equipment & Software: ABB RobotStudio (RAPID coding mastery), Rockwell Allen-Bradley PLCs (Studio 5000 / FactoryTalk), multi-axis servo drives, machine vision (Cognex/Keyence), and industrial Ethernet networks.
• Business Profile: Certified, premier custom industrial automation systems integrator with a robust project pipeline across the aerospace, medical, and consumer goods sectors.
• Compliance & Residency: U.S. Citizen or Green Card holder; active U.S. Passport or readiness to obtain; established residency within daily driving distance of the Greater Waukesha, WI region.

Job Function

• Greater Waukesha, WI
• 1st Shift
• Up to 30% Travel
• Direct-Hire
• Pay & Incentives: Up to $120,000 base compensation package (commensurate with custom robotics integration depth) + performance incentive bonuses + paid travel expenses + comprehensive corporate benefits package.
• Work Pattern: 1st Shift schedule | Tech-focused Waukesha facility footprint combining software architecture, virtual simulation, and physical floor debug under one roof.
• Field Deployment: 15% to 30% domestic and international site deployments for high-visibility client installations, system commissionings, and final SAT run-offs.
• Equipment & Software: ABB RobotStudio (RAPID coding mastery), Rockwell Allen-Bradley PLCs (Studio 5000 / FactoryTalk), multi-axis servo drives, machine vision (Cognex/Keyence), and industrial Ethernet networks.
• Business Profile: Certified, premier custom industrial automation systems integrator with a robust project pipeline across the aerospace, medical, and consumer goods sectors.
• Compliance & Residency: U.S. Citizen or Green Card holder; active U.S. Passport or readiness to obtain; established residency within daily driving distance of the Greater Waukesha, WI region.

If you are an elite controls and robotics engineer feeling stifled by rigid corporate structures or repetitive plant maintenance, this direct-hire engineering seat is your ticket to true technical autonomy. Operating as a certified, premier custom industrial automation systems integrator in the Waukesha area, this organization maintains a robust backlog of custom contracts spanning aerospace, medical, and consumer goods sectors.

Instead of repetitive production lines, you will own and architect custom, first-of-their-kind machinery tailored to complex application requirements. Operating out of a tech-driven facility where design engineering and physical assembly live under one roof, you will lead projects from blank-screen simulations and PLC logic architecture all the way to watching your physical machinery drive dynamic production on the floor.

What You Will Be Doing (Daily Responsibilities)

• Lead End-to-End Automation Execution: Serve as the lead controls authority, owning full project lifecycles from preliminary concept and simulation through shop floor debug and final client sign-off.
• Develop ABB Robotics Systems: Program, simulate, and refine complex multi-axis robotic paths from scratch utilizing ABB RobotStudio and native RAPID coding structures.
• Engineer Master Control Logic: Write, test, and integrate master PLC logic and HMI applications (primarily Rockwell Allen-Bradley Studio 5000 and FactoryTalk) to govern complete cell operations.
• Architect Industrial Networks: Configure fieldbus network communications (EtherNet/IP, PROFINET) bridging multi-axis robots, central controllers, safety devices, and external peripherals.
• Design Machine Safety Interlocks: Implement Category 3/4 safety architectures, safety PLCs, light curtains, and physical interlocks in strict adherence to RIA/ISO benchmarks.
• Integrate Vision & Motion: Partner cross-functionally with mechanical design teams to integrate vision systems (Cognex, Keyence), servo motion drives, and specialized End-of-Arm Tooling (EOAT).
• Execute Site Deployments: Lead customer site deployments up to 30% of the year worldwide to conduct Site Acceptance Testing (SAT) and complete client operational handoffs.

What We Are Looking For (Requirements & Qualifications)

• 5+ Years Systems Integration Depth: Verifiable track record designing, programming, and deploying custom automated machinery within an automation integrator or custom OEM environment.
• Dual Controls & Robotics Competency: Demonstrated capability writing Rockwell PLC programs (Studio 5000) combined with advanced ABB robot programming (RobotStudio / RAPID).
• Hardware & Safety Architecture Mastery: Deep working knowledge of servo motion systems, machine vision calibration, industrial networking, and RIA/ISO safety regulations.
• Engineering Foundation: Bachelor's Degree in Electrical, Mechanical, or Automation Engineering preferred (equivalent hands-on custom integration depth fully valued).
• Travel Flexibility: Valid U.S. Passport and complete availability to undertake up to 30% domestic and global field travel.
• Location & Work Eligibility: Residence established within daily commuting distance of the Greater Waukesha, WI area, and U.S. Citizenship or Green Card holder status.

Preferred Technical Assets (Bonus Skills)

• Secondary Robot Platform Experience: Supplementary programming capabilities on FANUC (KAREL/TP), KUKA, or Yaskawa Motoman controllers.
• Virtual Commissioning & Simulation: Experience utilizing advanced 3D digital twin or virtual commissioning software to validate cycle times prior to physical build.
• Advanced Motion & Torque Tuning: Direct experience tuning high-speed multi-axis servo systems for precise part placement or high-speed insertion.