Simulation Engineer

Automation Controls & Engineering LLC; Howell (MI); On-site; USD 80,000 - 120,000; Full time

Job summary

Automation Controls and Engineering (ACE) seeks a Robotic Simulation Engineer to design, validate, and optimize robot workcells in a virtual environment using Siemens Process Simulate. You will model robots, tooling, fixtures, and PLC-driven automation to ensure reach, cycle time, and collision-free motion before on-site commissioning.

You will develop and validate robot paths, perform virtual commissioning, and create offline programs for FANUC, ABB, KUKA, or Yaskawa platforms.

Qualifications

• Bachelor's degree in Mechatronics, Robotics, Mechanical, Electrical, or Industrial Engineering, or equivalent practical experience.
• Robot programming experience with at least one major industrial robot brand (online and offline).
• Industrial automation systems knowledge (PLCs, sensors, safety systems, industrial networks).
• Siemens Process Simulate familiarity (Tecnomatix Process Simulate) for robotic simulation, path planning, and collision checking.
• Understanding of robot kinematics, coordinate frames, and motion planning.
• Ability to read mechanical, electrical, and pneumatic drawings.
• Strong analytical and problem-solving skills, clear written and verbal communication, and cross-functional teamwork.
• Years of experience: 2-5 years.

Responsibilities

• Build and maintain 3D simulation models of robotic workcells and production lines in Siemens Process Simulate.
• Run reach, collision, clearance, and ergonomic studies and recommend changes.
• Develop and validate robot paths, cycle times, and operation sequences to meet throughput targets.
• Perform virtual commissioning by connecting simulation models to PLC logic and verify safety interlocks and I/O handshakes.
• Create and maintain robot kinematics and tool definitions in simulation libraries.
• Create offline robot programs for technicians to download to real robots (FANUC, ABB, KUKA, Yaskawa).
• Calibrate simulated programs to match real robot performance (TCP, user frame, workobject).
• Collaborate with controls engineers on PLC/HMI/network integration to ensure simulated and real behavior align.
• Review electrical, pneumatic, and safety designs for their impact on robot programs.
• Contribute to risk assessments and verify compliance with ISO 10218 and local safety requirements.
• Prepare simulation reports, cycle-time analyses, and video walkthroughs for design reviews.
• Document standards, templates, and best practices, and coach junior engineers.

Skills

Robot programming

Industrial automation

Robot kinematics

Reading drawings

Cross-functional teamwork

Analytical thinking

Communication skills

Education

Bachelor's degree in Mechatronics/Robotics/Mechanical/Electrical/Industrial Engineering

Tools

Siemens Process Simulate

Tecnomatix Process Simulate

RoboDK/RobotStudio/Visual Components/ROBOGUIDE

Job description

Job Description

Job Description

POSITION SUMMARY:

We are seeking a Robotic Simulation Engineer to design, program, validate, and optimize robotic workcells in a virtual environment before they are built and commissioned. You will use Siemens Process Simulate (or similar) to model robots, tooling, fixtures, and PLC-driven automation, and verify reach, cycle time, collision-free motion, and control logic. You will work with mechanical, controls, and manufacturing teams to cut commissioning time, reduce rework, and make sure the digital model matches the production floor.

KEY RESPONSIBILITIES

Simulation and Virtual Commissioning

• Build and maintain 3D simulation models of robotic workcells and production lines in Siemens Process Simulate, including robots, grippers, fixtures, conveyors, and peripheral equipment.
• Run reach, collision, clearance, and ergonomic studies, and recommend layout and equipment changes based on the results.
• Develop and validate robot paths, cycle times, and operation sequences to meet throughput targets.
• Perform virtual commissioning by connecting simulation models to PLC logic (software-in-the-loop or hardware-in-the-loop). Check interlocks, safety logic, and I/O handshakes before installation.
• Create and maintain resource libraries, including robot kinematics, tool definitions, and device behavior models.

Robot Programming

• Create offline robot programs for robot technicians to download them to physical robots on the platforms used at our facility (for example FANUC, ABB, KUKA, Yaskawa).
• Calibrate and correct simulated programs so they perform accurately on the real robot, including TCP, user frame, and workobject adjustments.

Automation Systems Integration

• Work with controls engineers on PLC, HMI, and network integration (for example PROFINET, EtherNet/IP) so simulated and real behavior match.
• Review electrical, pneumatic, and safety designs for their effect on the robot program and sequence.
• Contribute to risk assessments and verify that cell designs conform to applicable safety standards, such as ISO 10218 and relevant local requirements.

Collaboration and Documentation

• Work with mechanical designers, manufacturing engineers, process planners, and project managers to define simulation scope and deliverables.
• Produce simulation reports, cycle-time analyses, and video walkthroughs for design reviews and sign-off.
• Follow data management practices for simulation files, including versioning and PLM integration.
• Document standards, templates, and best practices, and coach junior engineers.

REQUIRED QUALIFICATIONS

• Bachelor's degree in Mechatronics, Robotics, Mechanical, Electrical, or Industrial Engineering, or a related field (or equivalent practical experience).
• Robot programming experience: hands-on with at least one major industrial robot brand, including online and offline programming.
• Industrial automation systems: working knowledge of PLCs, sensors, safety systems, industrial networks, and typical production-line architecture.
• Siemens Process Simulate: familiarity with Tecnomatix Process Simulate, including robotic simulation, path planning, and collision checking.
• Understanding of robot kinematics, coordinate frames, and motion planning.
• Ability to read mechanical, electrical, and pneumatic drawings.
• Strong analytical and problem-solving skills, clear written and verbal communication, and the ability to work in cross-functional teams.
• Years of experience: 2-5 years

PREFERRED QUALIFICATIONS

• Virtual commissioning experience, such as Siemens PLCSIM Advanced or Simulation Unit, or third-party PLC emulation.
• Siemens TIA Portal and S7 PLC programming.
• Other simulation or offline-programming tools (for example RoboDK, Visual Components, RobotStudio, ROBOGUIDE).
• Exposure to OPC UA, digital twin concepts, or Industry 4.0 initiatives.
• Experience in automotive, aerospace, electronics, packaging, or similar high-volume manufacturing.
• Scripting skills (for example Python, C#) to automate simulation tasks; Siemens or robot manufacturer training credentials.

Company Description

Automation Controls and Engineering (ACE) is a growing, innovative automation manufacturing company specializing in custom turnkey automation solutions and integration. ACE provides tailored Automation Solutions that maximize efficiency and simplicity by leveraging technology and innovation.

Company Description

Automation Controls and Engineering (ACE) is a growing, innovative automation manufacturing company specializing in custom turnkey automation solutions and integration. ACE provides tailored Automation Solutions that maximize efficiency and simplicity by leveraging technology and innovation.