Staff Controls Engineer

generac; Sussex (WI); On-site; USD 90,000 - 120,000; Full time

Job summary

Generac is seeking an Engineer IV - Controls (Staff Engineer) in Sussex, WI to lead advanced control design, tuning, and PLC programming for next-generation power systems. You will drive simulation work, electrical integration, and validation, while mentoring junior engineers and guiding product development from concept to release.

Applicants should have a BS in Electrical Engineering and 7+ years of relevant experience, with strong skills in control algorithms, modeling, and cross-functional

Qualifications

• Bachelor's degree in Electrical Engineering.
• 7+ years of relevant work experience.
• Strong control systems and power management knowledge.
• Excellent communication and teamwork skills.

Responsibilities

• Designs, validates, and brings new products to market.
• Specifies precise functional requirements; evaluates cost, safety, and reliability.
• Develops fitness-for-use testing, BOMs, and validation plans.
• Collaborates with manufacturing partners, designers and product specialists to optimize designs.
• Utilizes PLC programming to develop instructions for optimal machine operation.
• Supports product development plans (schedule, cost, inputs) and mentors junior engineers.

Skills

Control design

PLC programming

Simulation development

Electrical integration

Mentoring

Education

Bachelor of Science in Electrical Engineering

Tools

SAP ERP

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?

Primary Purpose

The Engineer IV - Controls (Staff Engineer) 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. Additionally, candidates will 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 a variety of increasingly 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 increasingly 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 increasingly complex designs for manufacturability.
• Utilizes PLC programming proficiency to develop programming instructions for optimal machine operation.
• Supporting product development plans (schedule, product cost, meeting design inputs).
• Acts as a resource to mentor and teach less experienced engineers.
• Other duties as assigned.

Minimum Job Requirements

Education

Bachelor of Science Degree in Electrical Engineering or related discipline;

7+ years of relevant work experience

Knowledge / Skills / Abilities

• Designs, validates, and brings new products to market.
• Specifies precise new product functional requirements; designs, tests and integrates a variety of increasingly 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 increasingly 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 increasingly complex designs for manufacturability.
• Utilizes PLC programming proficiency to develop programming instructions for optimal machine operation.
• Supporting product development plans (schedule, product cost, meeting design inputs).
• Acts as a resource to mentor and teach less experienced engineers.
• - Other duties as assigned.

Preferred Job Requirements

• Ability to perform detail-oriented work with a high degree of accuracy on multiple projects of increasing complexity
• Proven expertise in developing control algorithms across diverse power control and power management applications;
• Expertise in closed loop tuning 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 in new product design and development;
• Active participant in technical communities tied to industry standards or regulations;
• 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;
• Able to solve complex engineering problems;
• MS Excel, MS Word;
• Experience with machine design;Previous experience with SAP or equivalent ERP.

Physical Requirements and Working Conditions

PHYSICAL DEMANDS :

Office Environment (Includes field sales): 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 vi