Senior Controls Engineer

generac; Sussex (WI); On-site; USD 110,000 - 150,000; Full time

Job summary

Generac Power Systems, based in Wisconsin, seeks a Senior Controls Engineer to drive new product development and improve legacy systems through advanced control design, PLC programming, simulation, and system integration.

The role requires a BS in Electrical Engineering and 5+ years of experience. You will mentor engineers, develop validation plans, and collaborate with manufacturing and ERP teams across Generac facilities.

Qualifications

• Bachelor of Science Degree in Electrical Engineering or related discipline.
• 5+ years of relevant work experience in controls engineering.
• Experience with power systems, PLCs, modeling and validation.
• Strong communication and teamwork abilities.

Responsibilities

• Designs, validates, and brings new products to market.
• Specifies precise functional requirements; designs, tests and integrates components with cost, reliability and safety in mind.
• Develops test plans and validation for products and components; creates material specs and BOMs.
• Collaborates with manufacturing partners to optimize designs for manufacturability.
• Utilizes PLC programming to optimize machine operation and performance.
• Mentors less experienced engineers and supports product development plans.
• Travels to other Generac facilities as necessary.

Skills

Control design

Control tuning

PLC programming

Simulation development

Electrical integration

Manufacturing collaboration

Mentoring

Detail-oriented

Power systems

Model-based design

HIL/SIL testing

Auto code gen

Documentation skills

Excel

Presentations

Education

Bachelor of Science Degree in Electrical Engineering

Tools

SAP

ERP

MS Word

Job description

We believe power is a promise - a shared commitment to be there for others when it matters most.

For more than 65 years, we've turned big ideas into solutions that help protect homes, strengthen businesses and build a more resilient, efficient, sustainable energy future.

Ready to Power a Smarter World with us?

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.

"We are an equal opportunity employer and all qualified applicants will receive consideration for employment without regard to race, color, religion, sex, sexual orientation, national origin, disability status, protected veteran status, or any other characteristic protected by law."