Senior Staff Controls Engineer

DR Power LLP; Sussex (WI); Hybrid; USD 120,000 - 180,000; Full time

Job summary

Generac is seeking a Senior Staff Controls Engineer to lead control design, tuning, simulation development, PLC programming, and electrical system integration for both new products and legacy improvements. The role emphasizes close collaboration with cross-functional teams to move designs from concept through validation and release, ensuring reliability and safety across complex power systems.

The position requires 10+ years of experience in control engineering, expertise in model-based design,

Qualifications

• Bachelor of Science Degree in Electrical Engineering or Mechanical or related discipline.
• 10+ years of relevant work experience; knowledge/skills for detailed, multi-project work.
• Expertise in developing control algorithms for power control and power management.
• Experience with model-based design including simulations and auto code generation.
• Experience with test & validation plans (HIL/SIL, bench testing, fault injection).
• Strong written communication and presentation skills.
• Ability to translate technical information for diverse audiences.
• Experience with SAP or equivalent ERP.

Responsibilities

• Designs, validates, and brings new products to market.
• Specifies precise new product functional requirements; designs, tests and integrates complex components; evaluates design’s cost, reliability, and safety.
• Develops testing plans for various products and components; creates and reviews specs and BOMs.
• Collaborates with manufacturing partners and designers to optimize designs for manufacturability.
• Mentors less experienced engineers and supports product development plans; travel up to 80%.
• Other duties as assigned.

Skills

Control design

PLC programming

Simulation

Model-based design

Cross-functional collaboration

HIL/SIL testing

Excel

Written communication

Power control systems

System optimization

Education

BS in Electrical Engineering or Mechanical Engineering

MS in Electrical or Mechanical Engineering (preferred)

Tools

SAP

MS Excel

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 Staff Controls Engineer role is field-based and 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. The role interfaces with the cross functional teams across the organization to 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 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 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 complex and advanced designs for manufacturability.
• Supporting product development plans (schedule, product cost, meeting design inputs) Acts as a resource to mentor and teach less experienced engineers.
• 80% travel required.
• Other duties as assigned.

Minimum Job Requirements

• Bachelor of Science Degree in Electrical Engineering or Mechanical or related discipline.
• 10+ years of relevant work experience; Knowledge / Skills / Abilities Ability to perform detail-oriented work with a high degree of accuracy on multiple, complex projects, Proven expertise in developing control algorithms across diverse power control and power management applications.
• Expertise in closed loop 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 sitting on a regulatory committee in a technical role.
• Strong 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 using SAP or equivalent ERP.

Preferred Job Requirements

• Master's degree in electrical or mechanical engineering with focus on control engineering.
• Knowledge / Skills / Abilities Works independently, with guidance in only the most complex technical issues Requires specialized in-depth knowledge and/or breadth of expertise.
• Interprets internal or external business issues and recommends solutions / best practices, strong business acumen.
• Solves complex problems.
• Takes a broad perspective to identify solutions.
• Strong decision-making skills.
• May lead small- to medium-sized cross-functional technology development teams to achieve milestones and objectives.
• Ensure success cross-functionally.
• Coaches and mentors less experienced engineers.
• Offer recommendations and implement solutions.
• Take ownership of designs.
• Is recognized as an expert in own area within the organization.
• Writes standards and procedures.
• Leading efforts to improve the financial impact of engineering and related cross-functions on the business.
• Excellent conceptualization, visualization, and creativity.
• Excellent time management, prioritization, and analytical problem solving.

Physical Demands

• While performing the duties of this job, the employee is regularly required to talk and hear; and use hands to manipulate objects or controls.
• The employee is regularly required to stand and walk.
• On occasion, the incumbent may be required to stoop, bend, or reach above the shoulders.
• The employee must occasionally lift up to 25 pounds.
• Specific conditions of this job are typical of frequent and continuous computer-based work requiring periods of sitting, close vision, and the ability to adjust focus.

Up to 80% travel and valid Driver's License required.

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.

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?

As one of the leaders and largest suppliers of power generation equipment and technology, the work we do touches millions of lives. Employees at Generac are encouraged to be innovative and are valued as an integral part of our global team. Our challenging goals develop knowledgeable employees dedicated to helping continue Generac's success. Generac provides individuals the opportunity to work in a fast-paced agile work environment where their work makes a difference in people’s lives and their own.