Senior Controls Engineer — PLCs, Robotics & Vision

Daniels Health; Dallas (NC); Hybrid; USD 125,000 - 141,000; Full time

Benefits offered by this job

Medical insurance

Dental insurance

Vision insurance

401(k) with company match

Job summary

Daniels Health is seeking an experienced Senior Controls Engineer to join our growing US engineering team and help design, build, and optimize automated medical waste processing systems. This hybrid role involves PLC control, robotics, and machine vision in safety-critical environments, with travel across the USA, Canada, and some overseas locations including Taylor, Michigan for induction training.

You will collaborate across mechanical, electrical, robotics, and software teams, ensuring

Qualifications

• Bachelor’s degree in Electrical Engineering, Mechatronics, Automation Engineering, or a related discipline.
• 8+ years of experience in a controls or automation engineering role.
• Strong PLC and HMI programming experience with platforms such as Allen-Bradley, Siemens, Beckhoff, or Automation.
• Hands-on industrial robotics experience including programming, commissioning, and safety integration (FANUC, ABB, KUKA, Hyundai, or similar).
• Strong machine vision experience using Cognex, Keyence, OpenCV, or comparable systems.
• Solid understanding of industrial communication protocols including EtherNet/IP, Modbus, and OPC UA.
• Experience with motion control, servo systems, and safety-rated automation components.
• Ability to read and create electrical schematics, P&IDs, and mechanical drawings.
• Experience working in regulated or safety-critical environments such as medical, pharmaceutical, or waste processing is highly desirable.
• Strong troubleshooting, analytical, and problem-solving skills.
• Excellent written and verbal communication skills and the ability to collaborate across cross-functional teams.
• Ability to work independently and manage projects with multiple stakeholders and vendors.

Responsibilities

• Design, develop, program, and maintain PLC-based control systems for advanced medical waste processing equipment.
• Integrate, program, and commission industrial robots for material handling, sorting, and automated processing.
• Design, implement, and optimize machine vision systems for detection, classification, inspection, and process verification.
• Train, tune, and validate vision models to ensure accuracy, robustness, and regulatory compliance.
• Collaborate with mechanical, electrical, robotics, and software engineering teams to deliver fully integrated automation solutions.
• Support commissioning, troubleshooting, and root-cause analysis across controls, robotics, and vision systems.
• Prepare and review electrical, hydraulic, and pneumatic control drawings for new equipment and system upgrades.
• Develop system documentation including functional specifications, control narratives, operator manuals, maintenance documentation, and validation protocols.
• Ensure all control system designs comply with applicable US medical waste, environmental, and machine safety regulations.
• Work closely with suppliers, system integrators, and external service providers to deliver projects on time and to specification.
• Drive continuous improvement in automation performance, reliability, safety, and sustainability.

Education

Bachelor’s degree in Electrical Engineering, Mechatronics, Automation Engineering, or related

Tools

Allen-Bradley

Siemens

Beckhoff

FANUC

ABB

KUKA

Cognex

Keyence

OpenCV

EtherNet/IP

Modbus

OPC UA

Job description

Daniels Health is seeking an experienced Senior Controls Engineer to join our growing US engineering team and help design, build, and optimize automated medical waste processing systems. This hybrid role involves PLC control, robotics, and machine vision in safety-critical environments, with travel across the USA, Canada, and some overseas locations including Taylor, Michigan for induction training.

You will collaborate across mechanical, electrical, robotics, and software teams, ensuring