Senior Controls Engineer

Generac; Sussex (WI); On-site; USD 90,000 - 130,000; Full time

Job summary

Generac is seeking a Senior Controls Engineer to advance new product development and improve legacy systems. You will design, validate, and integrate control components, develop high-fidelity simulations, and program PLCs to optimize machine operation.

Travel to Generac facilities may be required as part of collaborative product development. The ideal candidate has a BS in Electrical Engineering and 5+ years of related experience, with strong skills in model-based design, testing plans, and

Qualifications

• Bachelor of Science Degree in Electrical Engineering or related discipline.
• 5+ years of relevant work experience.

Responsibilities

• Designs, validates, and brings new products to market.
• Specifies precise functional requirements; designs, tests and integrates components; evaluates design costs, reliability, and safety.
• Develops tests and validation plans; creates BOMs and material specifications.
• Collaborates with internal manufacturing partners to optimize designs for manufacturability.
• Utilizes PLC programming to develop control instructions for machines.
• Supports product development plans (schedule, cost, inputs).
• Mentors junior engineers and travels as needed.
• Other duties as assigned.

Skills

Control systems

PLC programming

Model-based design

System simulations

Validation planning

Documentation & communication

MS Excel

Machine design

SAP / ERP

Power system applications

Education

Bachelor of Science in Electrical Engineering

Tools

SAP

MS Excel

Job description

The Senior Controls Engineer is responsible for providing expertise regarding new product development as well as continuous improvement of legacy systems. Day to day responsibilities include control design and tuning, simulation development, PLC programming, and electrical system integration. Additionally, candidates will facilitate product development through design, validation, and release.

Major Responsibilities

• Designs, validates, and brings new products to market.
• Specifies precise new product functional requirements; designs, tests and integrates a variety of moderately complex components to produce final designs; and evaluates the design's overall effectiveness, cost (including cost/benefit analysis), reliability (risk analysis), and safety.
• Designs, develops, executes and evaluates fitness-for-use testing, product specifications and process validation plans for a variety of moderately complex products and/or components; creates and reviews material part specifications and bills of materials.
• Collaborates with internal manufacturing partners, contract manufacturers, designers and product specialists to optimize moderately complex designs for manufacturability.
• Utilizes PLC programming proficiency to develop programming instructions for optimal machine operation.
• Supporting product development plans (schedule, product cost, meeting design inputs)
• Acts as a resource to mentor and teach less experienced engineers.
• Travel to other Generac facilities as necessary.
• Other duties as assigned.

Minimum Qualifications

• Bachelor of Science Degree in Electrical Engineering or related discipline;
• 5+ years of relevant work experience;

Knowledge / Skills / Abilities

• Ability to perform detail-oriented work with a high degree of accuracy on multiple projects;
• Proficiency in developing control solutions for power system applications, including generators and battery energy storage systems;
• Proficiency in closed loop tuning control tuning, stability analysis, and performance optimization of advanced control algorithms;
• Expertise in model-based design methodologies, including development of high-fidelity system simulations, automated design verification and production-ready auto code generation;
• Experience in test & validation plan and procedure development and execution including multiple methods (HIL/SIL, bench component and/or system testing, fault injection methods, etc.);
• Experience in new product design and development;
• Demonstrated written communication and presentation skills;
• Ability to translate technical information to all audiences;
• Applies engineering knowledge and experience to improve products, services and processes;
• MS Excel, MS Word;
• Experience with machine design;
• Previous experience with SAP or equivalent ERP.