Sr. Automation Controls Engineer

Intellectt INC; Pittsburgh (Allegheny County); On-site; USD 62,000 - 69,000; Full time

Job summary

Intellectt INC in Pittsburgh, PA is seeking a hands-on Senior Automation Controls Engineer to design, program, commission, and troubleshoot automation systems used in advanced battery manufacturing. This role supports equipment from initial development through deployment and sustaining operations.

Responsibilities include designing control systems, writing PLC code, commissioning equipment, and integrating PLCs with robotics, vision, SCADA, HMI, and MES.

Qualifications

• 6+ years of hands-on controls engineering in manufacturing.
• Proficient in Siemens and Rockwell PLCs with VFDs and panels.
• Experience with HMI/SCADA and MES integration is required.
• Ability to read schematics and troubleshoot independently.

Responsibilities

• Design and develop industrial control systems for new equipment.
• Write PLC code and add functionality to existing machines.
• Program, troubleshoot, and commission equipment during install.
• Integrate PLCs with robotics, SCADA, HMI, and MES systems.
• Perform FATs, SATs, and provide on-call support as needed.
• Guide junior engineers and coordinate with vendors and operations.

Skills

Siemens PLC

TIA Portal

Rockwell Studio 5000

PanelView

HMI/SCADA

Ignition Perspective

MES integration

Schematic reading

Electrical troubleshooting

Team collaboration

Education

Bachelor's degree in Electrical Engineering, Controls Engineering, Mechatronics, or equivalent

Tools

FANUC robotics

Beckhoff TwinCAT

Siemens Scalance switches

AutoCAD Electrical

SolidWorks

Job description

Title: Sr. Automation Controls Engineer

Location: Pittsburgh, PA.

Duration: 6-month contract

Rate $45/hr - $50/hr W2.

Role Overview

We are seeking a hands-on Senior Controls Engineer to design, program, commission, and troubleshoot automation systems used in advanced battery manufacturing. This role supports equipment from initial development through deployment and sustaining operations.

Key Responsibilities

• Design and develop industrial control systems for new manufacturing equipment.
• Write PLC code from scratch and add new functionality to existing machines.
• Program, troubleshoot, and commission equipment during installation and startup.
• Support machinery, controls, electrical systems, and process improvements in production.
• Lead controls work on larger-scope automation projects.
• Integrate PLCs with robotics, vision, SCADA, HMI, and MES systems.
• Develop PLC product tracking, handshakes, data transactions, and equipment interfaces.
• Perform FATs, SATs, startup support, and vendor coordination.
• Troubleshoot downtime, throughput, safety, and process issues.
• Read and redline electrical schematics; document testing, troubleshooting, and procedures.
• Provide technical guidance to junior engineers and collaborate across engineering, operations, maintenance, and vendors.
• Participate in rotating off-hours on-call support.

Required Qualifications

• 6+ years of hands-on controls engineering experience in a manufacturing environment.
• Strong Siemens PLC programming and troubleshooting experience using TIA Portal.
• Rockwell Studio 5000 programming and troubleshooting experience, including legacy PanelView systems.
• Experience with HMI/SCADA systems, including Ignition Perspective and Siemens WinCC.
• Experience with PLC data transactions, product tracking, handshakes, and MES integration.
• Ability to troubleshoot electrical and controls issues independently.
• Experience with functional safety, including Siemens ProfiSafe, Rockwell CIP Safety, and hardwired safety.
• Ability to read and interpret schematics, diagrams, and blueprints.
• Strong written and verbal communication skills.
• Team-oriented approach and ability to work effectively on complex, cross-functional projects.
• Bachelor's degree in Electrical Engineering, Controls Engineering, Mechatronics, or equivalent experience.

Preferred Experience

• FANUC robotics and ROBOGUIDE.
• Beckhoff TwinCAT.
• FANUC DCS, Epson, or Kawasaki robotics.
• Keyence or Cognex barcode scanners, inspection systems, and vision integration.
• Ignition data integration, Rockwell FTView ME, IPCs, and Panel PCs.
• Siemens Scalance managed switches and industrial OT networks.
• AutoCAD Electrical, SolidWorks, control panel fabrication, and modification.
• iba and Octoplant.
• Battery manufacturing, energy storage, automotive, or other discrete manufacturing.
• Batching applications and powder systems.
• Powder-to-tape conversion, web handling, textiles, electrode manufacturing, or oven controls.