Senior Controls Engineer

EGN Technical Resources; Norcross (GA); On-site; USD 110,000 - 150,000; Full time

Job summary

Top Echelon Software, LLC in Norcross, GA is seeking a Senior Controls Engineer to lead design and deployment of motion control, machine vision, and robotic systems in an industrial setting. The role focuses on ground-up software development for production-grade controls, with strong emphasis on Beckhoff TwinCAT 3, AI-based vision, and mechatronics integration.

On-site commissioning and cross-disciplinary collaboration are key aspects of the job.

Qualifications

• 8+ years in controls engineering with a strong focus on software development, motion control, and machine vision.
• Expertise in Beckhoff TwinCAT 3 motion and control platforms.
• Experience with AI/ML-based machine vision tools and robot programming (e.g., UR, FANUC).
• Proficient in C++, C#, Python, or structured text.
• Reading electrical schematics and mechanical drawings; familiarity with safety standards.

Responsibilities

• Design and maintain motion control and machine software using Beckhoff TwinCAT 3 (IEC 61131-3).
• Develop and integrate AI-based machine vision software for inspection and quality control (OpenCV, TensorFlow, Cognex VisionPro).
• Program industrial and collaborative robots for pick-and-place and material handling.
• Architect integrated mechatronic systems for reliable automated operations.
• Ensure clean, modular, well-documented code with Git version control.
• Establish automated testing frameworks to validate system behavior before deployment.
• Facilitate PLC-vision-robot communication via EtherCAT and OPC-UA.
• Lead on-site commissioning and system integration testing.
• Troubleshoot complex issues in development and live production.
• Conduct root-cause analysis to improve reliability and performance.
• Mentor junior engineers and promote best software practices.

Skills

Software development

Motion control

Machine vision

C++

C#

Python

Industrial robot programming

Education

Bachelor's degree in a relevant field

Tools

Beckhoff TwinCAT 3

OpenCV

TensorFlow

Cognex VisionPro

Universal Robots

FANUC

EtherCAT

OPC-UA

Git

Job description

Location: Norcross, GA

Employment Type: Full-Time

Reports To: Operations Manager

Compensation: Competitive, Based on Experience

Travel: Approximately 10-15% for on-site commissioning and system integration

Position Summary:

We are on the lookout for an accomplished Senior Controls Engineer to spearhead the design, development, and deployment of cutting-edge motion control, machine vision, and robotic systems. This position is a hands-on engineering role, focusing on crafting production-grade software from the ground up, rather than merely configuring pre-existing solutions.

The ideal candidate will possess a robust proficiency in Beckhoff TwinCAT motion and control programming, coupled with experience in developing AI-based vision applications. A comprehensive understanding of mechatronics, integrating mechanical, electrical, and software disciplines, is essential.

In this role, you will manage the complete software development lifecycle for control and vision applications, collaborating closely with multi-disciplinary engineering teams to transform innovative concepts into fully operational automated systems.

Core Responsibilities:

• Design and maintain motion control and machine software using Beckhoff TwinCAT 3, including structured text and PLC programming (IEC 61131-3).
• Develop and integrate AI-based machine vision software for tasks such as part inspection and quality control using tools like OpenCV, TensorFlow, and Cognex VisionPro.
• Program industrial and collaborative robots for various applications including pick-and-place and material handling.
• Architect integrated mechatronic systems for reliable automated operations.
• Ensure development of clean, modular, and well-documented code, employing Git for version control.
• Establish automated testing frameworks to validate system behavior prior to deployment.
• Facilitate communication between PLCs, vision systems, and robotics using protocols like EtherCAT and OPC-UA.
• Lead on-site commissioning, including software deployment and system integration testing.
• Troubleshoot and resolve complex system issues in development and live production environments.
• Conduct root cause analysis to enhance system reliability and performance.
• Mentor junior engineers and promote best practices in software development and system design.

Required Qualifications:

• 8+ years in controls engineering, with a strong focus on software development, motion control, and machine vision.
• Expertise in Beckhoff TwinCAT 3 motion and control platforms.
• Experience with AI/ML-based machine vision tools and robot programming (e.g., Universal Robots, FANUC).
• Proficient in C++, C#, Python, or structured text.
• Comprehensive understanding of mechatronic system design.
• Experience with industrial communication protocols and version control systems.
• Bachelor's degree in a relevant field or equivalent experience.
• Competency in reading electrical schematics and mechanical drawings.
• Familiarity with industrial safety standards.

Preferred Qualifications:

• Experience with custom deep learning vision models.
• Familiarity with robot simulation tools and CI/CD pipelines.
• Experience with additional PLC platforms and cloud-based data platforms.
• Background in advanced manufacturing or system integration environments.

Work Environment:

This role involves working in both development/lab settings and on the production floor in an industrial manufacturing environment. The position requires adherence to safety protocols, including LOTO procedures, and the usage of personal protective equipment. Approximately 10-20% travel is expected for on-site support. Reasonable accommodations are available to enable qualified individuals to perform essential functions.