Senior Controls Engineer - Complex Machines & Cells

Adaptec Solutions LLC; City of Rochester (NY); Hybrid; USD 110,000 - 125,000; Full time

Benefits offered by this job

Health insurance

Paid time off

401(k)

Job summary

Adaptec Solutions seeks a Controls Engineer III to own the design, development, and implementation of control systems for complex machines and multi-station cells. You will lead controls execution from design through commissioning and serve as primary contact during debug and FAT.

You will mentor junior engineers, review work, and contribute reusable modules to the library, traveling to customer sites about 25% of the time.

Qualifications

• Bachelor's degree in a related engineering discipline or equivalent experience.
• 4-7 years owning complex machine or cell controls.
• Experience with recovery, abnormal handling and cross-system integration.
• Leadership in on-site debug, commissioning and acceptance.
• Proficient on more than one PLC/HMI platform.
• Experience evaluating safety schemes and validating safety functions.
• Mentoring less experienced engineers; contributing reusable modules.

Responsibilities

• Own controls design for complex machines and integrated multi-station cells.
• Determine control architecture and review the device list.
• Evaluate the safety scheme; participate in hazard risk assessment and validate safety functions.
• Define PLC program structure and outline; advanced use of UDT and AOI.
• Own HMI concept and outline for a cell.
• Design network topology and addressing; integrate robots and third-party equipment.
• Determine power requirements and panel sizing; approve the electrical BOM.
• Lead sequence validation, manual and auto mode runs, and fault recovery.
• Run commissioning debug and electrical install validation.
• Assign and review Controls Engineer I and II work; review code/drawings.

Skills

Rockwell Studio 5000

FactoryTalk View ME/SE

Siemens TIA Portal

AutoCAD Electrical

Ignition

Autodesk Inventor

C#

Python

Education

Bachelor's degree in related engineering discipline or equivalent experience

Tools

Rockwell Studio 5000

Rockwell FactoryTalk View ME/SE

Siemens TIA Portal

AutoCAD Electrical

Ignition

Autodesk Inventor

Job description

Description

JOB SUMMARY:

The Controls Engineer III owns the design, development and implementation of control systems for complex machines and integrated multi-station cells. This role is assigned outcomes rather than methods, chooses its approach within department standards, and leads controls execution from design through commissioning.

The position resolves conflicting requirements, adapts standard approaches where the application requires it, and evaluates the safety scheme for the machines it owns. It is the primary controls contact during debug, FAT and commissioning, assigns and reviews the work of Controls Engineer I and II within its scope, and contributes reusable modules and documentation back to the department.

JOB DUTIES & RESPONSIBILITIES:

• Own controls design for complex machines and integrated multi-station cells
• Determine control architecture and review the device list
• Evaluate the safety scheme; participate in hazard risk assessment and validate safety functions
• Define PLC program structure and outline; advanced use of UDT and AOI
• Own HMI concept and outline for a cell
• Design network topology and addressing; integrate robots and third-party equipment
• Determine power requirements and panel sizing; approve the electrical BOM
• Lead sequence validation, manual and auto mode runs, and fault recovery
• Run commissioning debug and electrical install validation
• Assign and review Controls Engineer I and II work; serve as named reviewer on code and drawings
• Estimate a machine or cell and participate in project risk assessment
• Contribute reusable modules to the library and own a guide family or annex
• Travel to customer sites to lead debug, commissioning and customer acceptance — approximately 25% of time.

EDUCATION and/or EXPERIENCE:

• Bachelor's degree in a related engineering discipline or equivalent experience, required.
• 4–7 years owning complex machine or cell controls
• Experience with recovery, abnormal handling and cross-system integration
• Leadership in on-site debug, commissioning and acceptance
• Proficient on more than one PLC/HMI platform
• Experience evaluating safety schemes and validating safety functions
• Mentoring less experienced engineers; contributing reusable modules

Requirements

SKILLS AND CHARACTERISTICS:

• Software Applications Required
• Rockwell Studio 5000
• Rockwell FactoryTalk View ME and SE
• A second PLC platform (preferably Siemens TIA Portal)
• AutoCAD Electrical
• Software Applications Desired
• Ignition
• Fanuc Handling Tool, RoboGuide and DCS
• Autodesk Inventor
• Structured languages (C#, Python)
• Codes and Standards — working knowledge appropriate to the level
• NFPA 79
• NFPA 70 (National Electrical Code)
• NFPA 70E
• UL 508A
• ANSI/RIA R15.06 — Industrial Robot Safety
• ISO 13849 — Safety-Related Parts of Control Systems
• Advanced technical depth; decomposes complex work into deliverable scope
• Chooses the approach within department standards without direction on method
• Root cause analysis and continuous improvement leadership
• Explains complex concepts to non-technical stakeholders
• Manages customer expectations on their scope through debug, FAT and commissioning
• Mentors Controls Engineer I and II in methods and standards
• Sound judgment under time and ambiguity constraints

MEASUREMENTS OF SUCCESS:

• Controls scope of assigned machines delivered end to end against plan
• Safety schemes evaluated and validated; hazard assessments completed
• Complex issues diagnosed and resolved independently
• Reviews of Controls Engineer I and II work completed, with findings closed
• Reusable modules contributed back to the library
• Owns a guide family or annex and keeps it current
• Customer expectations managed on their scope through debug, FAT and commissioning

In compliance with pay transparency requirements, the wage range for this role is $110K - $125K. The rate range provided is a general guideline. When extending an offer, Adaptec Solutions considers factors including but not limited to experience and geographic location. Adaptec Solutions also offers a variety of benefits including generous paid time off (PTO), 11 paid company holidays including your birthday, generous health plans, dental and vision insurance, HSA/FSA accounts, generous 401(k) match and immediate vesting, short-term/long term disability coverage and basic life/AD&D insurance and education assistance.

Adaptec Solutions, LLC is an equal opportunity organization. We recruit, employ, train, compensate, and promote without regard to race, religion, color, national origin, age, gender, sexual orientation, gender identity, marital status, disability, protected veteran status, or any other basis protected by applicable federal, state or local law.