Controls & Robotics Engineer – ABB & Allen-Bradley Systems

Keystone Distinction Group; Waukesha (WI); On-site; USD 72,000 - 120,000; Full time

Job summary

Keystone Distinction Group in Wisconsin seeks a Robotics Controls Engineer to design, program, and commission custom automated machinery with ABB robots. You will develop RAPID code, RobotStudio simulations, and PLC integration across master PLCs and plant controls.

Expect up to 30% travel for deployment and client acceptance. The role requires 5+ years ABB programming experience in automation environments, a bachelor’s degree in EE/Robotics or related field, and the ability to commute within 45

Qualifications

• 5+ years of verifiable ABB robotic systems programming experience, including RAPID code and RobotStudio.
• 2+ years PLC programming experience (Allen-Bradley/Studio 5000 or similar).
• Strong foundation in industrial motion control and machine safety systems.
• Bachelor’s Degree in Electrical Engineering, Robotics, Automation, or related field.
• Willingness to travel up to 30% worldwide with a valid U.S. Passport.
• Residence within a daily 45-minute commute of Waukesha County / Greater Milwaukee area.

Responsibilities

• Develop, write, and optimize clean RAPID code and RobotStudio simulations to integrate ABB robots with PLCs and plant controls.
• Drive full-lifecycle custom machinery builds including design, kinematics simulation, testing, and debugging.
• Configure electrical setups, communication protocols, and handshakes for ABB packages and EOAT.
• Troubleshoot robotic pathing, cycle-time bottlenecks, and systems integration on the floor and at client sites.
• Travel up to 30% domestically and internationally to lead onsite deployment and client acceptance testing.
• Author technical documentation and system manuals for all builds.

Skills

ABB robot programming

RobotStudio

RAPID language

PLC programming

Industrial motion control

Safety systems

Education

Bachelor’s Degree in Electrical Engineering / Robotics / Automation

Tools

RobotStudio

Studio 5000 / Allen-Bradley

Job description

Robotics Controls Engineer – Custom Systems Integrator

Up to $120,000 Base Salary + Full Benefits • Waukesha County, WI Area • Onsite / Up to 30% Travel • Direct-Hire

• PROJECT VARIETY: Build unique, custom automated machinery and advanced robotic cells from initial simulation to floor commissioning—no repetitive factory lines
• EXPERIENCE: 5+ years of hands‑on ABB robot programming within custom automation or systems integration environments
• TECHNICAL DEPTH: 2+ years of advanced ABB RobotStudio simulation and RAPID code, plus 2+ years of PLC development (Allen‑Bradley or similar)
• TRAVEL & MOBILITY: Up to 30% domestic and international travel for deployment, site commissioning, and client acceptance (Valid U.S. Passport required)
• REQUIREMENTS: US Citizen or Green Card holder residing within a daily 45‑minute drive of the Waukesha County / Greater Milwaukee, WI area

If you are a senior robotics engineer feeling stuck running repetitive cycles at a slow‑moving corporate plant, this direct‑hire engineering seat is your ticket to true technical autonomy. The employer is a certified, highly respected custom industrial automation systems integrator in Waukesha County with a rock‑solid, diversified global client base.

Instead of repetitive production lines, you will design and build custom, leading‑edge machinery tailored to complex application requirements. The organization fosters a culture centered on engineering creativity, multi‑platform learning, and individual ownership. With design teams and physical assembly floors under one roof, you will get the unique satisfaction of seeing your virtual simulations transform into fully operational systems right down the hall.

What You Will Be Doing (Daily Responsibilities)

• Develop, write, and optimize clean RAPID code and RobotStudio simulations to seamlessly integrate ABB robotic arms with master PLCs and plant‑wide controls.
• Drive full‑lifecycle custom machinery builds, executing system design, advanced kinematics simulation, virtual testing, and physical debugging.
• Configure initial electrical setups, communication protocols, and software handshakes for ABB robotic packages and specialized end‑of‑arm tooling (EOAT).
• Troubleshoot complex robotic pathing, cycle‑time bottlenecks, and systems integration challenges on the assembly floor and at client facilities.
• Travel up to 30% domestically and internationally to lead onsite deployment, execute client acceptance testing, and provide high‑level engineering support.
• Author comprehensive technical documentation, logic schematics, and system manuals for all assigned automation builds.

What We Are Looking For (Requirements & Qualifications)

• 5+ years of verifiable experience programming ABB robotic systems, including a minimum of 2 years deeply focused on RAPID code and RobotStudio simulation software.
• 2+ years of practical PLC programming experience (Allen‑Brondley / Rockwell Studio 5000 or similar major platforms).
• Solid foundation in industrial motion control and machine safety systems (light curtains, safety relays, safe zone configuration).
• Degree & Experience Balance: Bachelor’s Degree in Electrical Engineering, Robotics, Automation, or related field (extensive hands‑on systems integration experience will be strongly considered in lieu of a degree).
• Global Mobility: Willingness and ability to travel up to 30% worldwide, with a valid U.S. Passport (or immediate capability to obtain one).
• Local Proximity: Residing within a comfortable daily 45‑minute commute of the Waukesha County / Greater Milwaukee area.