PLC Systems Design Engineer (PLC/HMI/Drives)

Aleron; Franksville (WI); On-site; USD 85,000 - 130,000; Full time

Job summary

Acara Solutions seeks a System Engineering Design Engineer to design electrical and controls systems for large industrial machines, including PLC/VFD programming, panel design, and testing.

The role involves leading system engineering activities from quoting through shipment, with some travel to customer sites and on-site/remote commissioning support.

Qualifications

• Bachelors in Engineering required; BSEE preferred or equivalent with 10+ years PLC and drive experience.
• Minimum 3 years in PLCs, HMIs, Drives with exposure to networking and data acquisition.
• 5+ years in motor control system design, understanding of motion control theory and machines.

Responsibilities

• Design and develop motor control systems for Paper Converting and Metal Processing.
• Program PLCs, HMIs and VFDs, specify components for customer applications.
• Lead system design reviews and guide CAD designers through panel design.
• Provide on-site and remote commissioning support and ensure meeting safety standards.

Skills

PLC programming

Motor control systems

Power electronics

Electrical schematics

Networking

Education

Bachelor's Degree in Engineering

Tools

SolidWorks

AutoCAD LT

SolidWorks Electrical

Eplan

Job description

Description

Actual Job Title: System Engineering Design Engineer

Location: Milwaukee, WI - Onsite (initially south of Milwaukee, then moving early next year to West Milwaukee)

Employment Type: Salaried direct with comprehensive benefits

Industry: Machine Controls

Compensation: Open

Schedule: M-F standard

About the Opportunity

Engineers at this organization have cradle-to-grave responsibility - from programming to testing to after install support.

C drive theory, PLC programming, pulling code, sewing it together with existing code.

Existing drives.

Possible PLC service call that maintenance team doesn't cover.

Retrofitting the majority of time.

Light travel to client installs.

You're designing the electrical and controls system that makes large industrial machines run (e.g., printing presses and steel processing)-selecting the electrical components, designing the panels and schematics, programming the PLCs/VFDs, testing the system, and then helping troubleshoot and commission it at the customer's facility.

Systems Engineers are critical members of the order process as they support Sales in the quoting stages, serve as technical lead for orders/projects from when the order is received until when the system is shipped, and they provide expert field support for commissioning and field issues. The individual in this position will design and develop best-in-class motor control systems for a variety of industries and applications including testing of electric vehicle propulsion systems, maximizing oil production with artificial intelligence at the well, optimizing metal forming, dynamic automotive testing and delivering precision control systems for a wide range applications in the converting industry. The ideal candidate has a strong background in Power Electronics, design and development of Motor Control Systems and the use of SolidWorks tools.

What You'll Do

• Engineer custom motor control systems primarily for Paper Converting and Metal Processing systems which includes activities such as creation of Power Distribution Diagrams, Network Distribution Diagrams, bills of materials, and Electrical schematics.
• Investigate and employ new components and technologies for use in systems
• Continuously assess designs and investigate new/alternative components as applied to cost savings, quality improvement and certification requirements
• Assist sales engineers in their effort to provide accurate quotes
• Specify variable frequency drives, PLCs, HMIs, and networking components for customer applications
• Program PLCs, HMIs and VFD's
• Serve as technical lead for PC and MP engineered systems through the development cycle
• Guide system CAD designers through panel design
• Participate in and lead system design reviews
• Work with in-house panel shop to ensure proper panel build and provide guidance as necessary
• Confirm system design and panel build meet certification requirements (UL508A, CE, IEEE, etc.)
• Guide and assist in test floor checkout of PC/MP systems
• Provide expert remote and on-site support for commissioning and field issues
• Ensure compliance with all safety and work rules and regulations.
• Verify conformance of components and systems to customer specifications.
• Complete load, voltage, amperage and heat calculations to ensure proper design.
• Work with Purchasing and Vendors to evaluate alternate components and materials.
• Monitor material costs to ensure lowest cost solutions are implemented.
• Troubleshoot application issues or systems field for customer deployed systems.
• Assist in the capture and documentation of customer requirements and translate those requirements into design and manufacturing specifications.
• Help define design standards for the Systems Engineering team.
• Support Aftermarket/Service team on an as-needed basis and serve as on-call rotation for after-hours phone service support.

About Acara Solutions

Acara is a premier recruiting and workforce solutions provider-we help companies compete for talent. With a legacy of experience in various industries worldwide, we partner with clients, listen to their needs, and customize visionary talent solutions that drive desired business outcomes. We leverage decades of experience to deliver contingent staffing, direct placement, executive search, and workforce services worldwide.

Job Requirements

What You'll Bring

• Bachelor's Degree in Engineering (ideally BSEE, but will consider a non-degree candidate with 10+ years of PLC and drive experience).
• Min 3 years of experience with PLCs (including strong programming), HMIs, & Drives, and a plus to have exposure to networking, embedded controllers and data acquisition systems.
• Min 5 years of similar controls systems engineering experience that includes:
  • Experience with design of motor control and test systems.
  • Experience and understanding of motion control theory and algorithms.
  • Good understanding of electric machines and motor control.
  • Good understanding of electric power distribution components (transformers, filters, circuit breakers, etc.).
  • Knowledge of UL and CE standards as they relate to industrial control panels.
  • Expertise in industrial control panel system design.
  • Ability to read electrical schematics and component specification sheets.
  • Understanding of electric machines, motor control & electric power distribution components (transformers, filters, circuit breakers, etc.).
• Min 1 year of experience with electrical system packaging containing transformers, contactors, circuit breakers, VFD/PLCs, etc.

Preferred

• 10+ years of PLC controls electrical engineering experience
• Rockwell controls used the most with some Siemens PLCs used
• Experience with SolidWorks tools and their application in system design
• Experience with electrical schematic drawing packages AutoCAD LT, Solidworks Electrical, Eplan.
• Strong process orientation/discipline and demonstrated application of problem‑solving tools is a plus (e.g. Paretto, 5-Why Analysis, 8-D's, etc.).

Additional

~10% travel overall since the engineer is responsible for the full lifecycle, including follow up at customer site after the install. Domestic only (service teams exist in Mexico and Canada for those clients).

Aleron companies (Acara Solutions, Aleron Shared Resources, Broadleaf Results, Lume Strategies, TalentRise, Viaduct) are an Equal Opportunity Employer. Race/Color/Gender/Religion/National Origin/Disability/Veteran.

Applicants for this position must be legally authorized to work in the United States. This position does not meet the employment requirements for individuals with F-1 OPT STEM work authorization status.