Robot Engineer

Satyam Venture Engineering Services; Illinois; On-site; USD 100,000 - 160,000; Full time

Job summary

The Robotics Engineer at Satyam Venture Engineering Services will be responsible for programming, integrating, commissioning, and optimizing MIG welding using FANUC and NACHI platforms for BIW bodyshop applications.

The role requires 5+ years of hands-on robotics programming, with at least 2 years on MIG welding, and onsite work at Toledo, OH and Normal, IL, including 60 hours per week with rotating am/pm shifts.

Qualifications

• Bachelor’s degree in Robotics, Mechatronics, Automation, Welding, Electromechanical Engineering, or related field.
• Minimum of 5 years hands-on experience programming and integrating FANUC and NACHI robots, with at least 2 years MIG welding in automotive BIW/bodyshop.
• Professional working proficiency in English to interface with global tooling suppliers and corporate engineering standards.

Responsibilities

• Program and refine MIG welding trajectories on NACHI robots with proper torch angles and stick-out.
• Configure and fine-tune welding parameter schedules to reduce porosity, lack of fusion, and burn-through.
• Implement automatic TCP check routines to ensure weld placement after consumable changes.
• Maintain version history and backups of robot controllers.

Skills

FANUC ArcTool

NACHI Arc/MIG

MIG welding

TCP calibration

Robot safety systems

Power source integration

Education

Bachelor’s degree in Robotics / Mechatronics / Automation / Welding

Tools

FANUC ArcTool software

NACHI FD/AX controllers

EtherNet/IP / DeviceNet

Fronius TPS/i / Lincoln / Miller

Robotics tooling & fixtures

Job description

Location: Toledo, OH and Normal, IL

Job Description:

• Candidates will spend 2-3 months in Toledo, OH and then will transition to Normal, IL. Must be available to work onsite at both these sites.
• Travel: Pre-approved travel expenses will be included on top of the rate.
• Schedule: Consultant will work 60 hours per week. 12 hours a day. Will need to work rotating shifts: am and pm.

Key Skills:

• Robot engineers with experience in NACHI robots and Fanuc
• I need robotics engineers specializing in NACHI robots, with sufficient experience to handle integration from scratch.

Job Objective:

The Robotics Engineer is responsible for the programming, integration, commissioning, and optimization of robotic arc welding (MIG systems utilizing FANUC and NACHI platforms within the automotive Bodyshop. The primary goal is to ensure the structural and geometric integrity of body-in-white (BIW) sub-assemblies, minimizing spatter, thermal distortion, and cycle times while maintaining a highly repeatable, production-ready process, also responsible for following and establishing programming standards based on process requirements and application types, from commissioning through to start-up.

Core Responsibilities:

• Path Generation & Optimization: Program and refine complex MIG welding trajectories on NACHI robots, ensuring optimal torch angles (work and travel angles) and proper electrode stick-out.
• Weld Process Optimization: Configure and fine-tune welding parameter schedules directly on the robots to eliminate common defects such as porosity, lack of fusion, undercut, or excessive burn-through.
• TCP Maintenance & Calibration: Implement automatic Tool Center Point (TCP) check routines to ensure the robot maintains precise weld placement after consumable changes (contact tips, nozzles, or goosenecks).
• Backup & Version Control: Maintain clean, documented version history and periodic image backups of all robot controllers under your scope.

Job Requirements:

• Education: Bachelor’s degree in Robotics, Mechatronics, Automation, Welding, Electromechanical Engineering, or a related field.
• Experience: Minimum of 5 years of hands‑on experience programming and integrating FANUC and NACHI robots, with a heavy focus (at least 2 years) on MIG welding applications in an automotive BIW/Bodyshop
• Languages: Professional working proficiency in English to interface with global tooling suppliers and corporate engineering standards.

Technical Skills (Hard Skills):

• FANUC Programming (ArcTool): Advanced mastery of the FANUC ArcTool software package, configuration of weld schedules, torch control, and tool coordinate system management (TCP/Weld Frame).
• NACHI Programming (MIG/Arc): Specialized configuration in NACHI controllers (FD/AX series) for arc applications, power source interfacing, and synchronization of travel speed with wire feed rate.
• MIG/MAG Welding Technology: Deep knowledge in adjusting and optimizing welding parameters (voltage, amperage, wire feed speed, gas flow) and transfer modes (short‑circuit, globular, spray, pulsed arc).
• Welding Peripherals: Integration and maintenance of torch cleaning stations (reamers), wire cutters, neck aligners, and automated TCP calibration units.
• Power Source Integration: Communication setup and configuration of industrial interfaces (Digital/Analog, DeviceNet, EtherNet/IP) with leading power supplies such as Fronius (TPS/i), Lincoln Electric, or Miller.
• Robot Safety Systems: Advanced implementation of safety software options, specifically Fanuc Dual Check Safety (DCS) and Nachi RMU (Robot Monitoring Unit) for collaborative or restricted zone control.

Interpersonal Skills (Soft Skills):

• High-Pressure Troubleshooting: Rapid root‑cause analysis of critical hardware/software faults during high-volume automotive production runs.

Cross-Functional Collaboration:

Strong teamwork skills to interface seamlessly with PLC programmers, mechanical designers, weld quality inspectors, and maintenance technicians.