Test Systems & Controls Engineer

DeltaHawk Engines, Inc.; Racine (WI); On-site; USD 85,000 - 120,000; Full time

Job summary

DeltaHawk Engines, Inc. is seeking a hands-on Test Systems & Controls Engineer to design, assemble, program, and maintain data acquisition (DAQ) and automation control systems for our R&D and production test operations.

In this role, you will build and support engine test stands, dynamometers, and component test benches that validate the performance and reliability of advanced aviation combustion engines. You will work across the full development cycle - from selecting sensors, building

Qualifications

• BS in Electrical Engineering or related field with 3+ years' experience in test cell controls.
• Experience building and programming PLC- or PC-based data acquisition and control systems.
• Hands-on PID control and industrial automation experience.
• Sensor integration, signal conditioning, and electrical diagnostic equipment.
• Proficiency in Python, C++, or C# for test automation.

Responsibilities

• Design, build, wire, and commission data acquisition and control systems for engines.
• Select, calibrate, and integrate instrumentation and sensors.
• Configure DAQ modules for reliable interface with test hardware.
• Layout and assemble control panels with enclosures and DIN rails.
• Program PLCs and HMIs to automate test sequences and data logging.
• Set up industrial networking to ensure secure communication.
• Create and maintain electrical schematics, BOMs, and SOPs.
• Troubleshoot issues to minimize downtime.
• Maintain safe test cell operations per standards.

Skills

PLC programming

PID control

Sensor integration

DAQ systems

Electrical panel wiring

Python

C++

Education

BS in Electrical Engineering, Controls & Automation Engineering, Mechatronics

Tools

SolidWorks

Electrical schematic design tools

DMMs

Oscilloscopes

Signal generators

Industrial networking gear

Job description

Job Summary

DeltaHawk is seeking a hands-on Test Systems & Controls Engineer to design, assemble, program, and maintain data acquisition (DAQ) and automation control systems for our R&D and production test operations. In this role, you will build and support engine test stands, dynamometers, and component test benches that validate the performance and reliability of advanced aviation combustion engines. You will work across the full development cycle - from selecting sensors, building electrical control panels, and configuring secure test networks to programming PLCs, HMIs, and automated data collection routines. Other duties as assigned.

• Design, build, wire, and commission data acquisition and control systems for engine dynamometer and component test cells.
• Select, calibrate, and integrate instrumentation and sensors (pressure transducers, thermocouples, RTDs, flow meters, torque cells, and Hall effect sensors) based on measurement range, signal type, and environmental requirements.
• Specify, install, and configure DAQ modules (analog/digital I/O, high-speed sampling) to interface reliably with test hardware and instrumentation.
• Layout and assemble control panels, including electrical enclosures, DIN rails, terminal blocks, relays, power supplies, and circuit protection.
• Program PLCs, PC-based controllers, and develop user-friendly HMI/GUI applications to automate test sequences, interlocks, and real-time data logging.
• Set up and configure industrial networking hardware (managed switches, routers, firewalls) to ensure secure, robust communication across test benches and engineering workstations.
• Develop and maintain clear technical documentation, including electrical schematics, wiring diagrams, bills of materials (BOM), and system operating procedures.
• Troubleshoot test stand electrical, sensor, and software issues alongside technicians and test engineers to minimize downtime.
• Maintain safe test cell operations in compliance with industry electrical standards and best practices.

Job Summary

DeltaHawk is seeking a hands-on Test Systems & Controls Engineer to design, assemble, program, and maintain data acquisition (DAQ) and automation control systems for our R&D and production test operations. In this role, you will build and support engine test stands, dynamometers, and component test benches that validate the performance and reliability of advanced aviation combustion engines. You will work across the full development cycle - from selecting sensors, building electrical control panels, and configuring secure test networks to programming PLCs, HMIs, and automated data collection routines. Other duties as assigned.

Essential Duties & Responsibilities

• Design, build, wire, and commission data acquisition and control systems for engine dynamometer and component test cells.
• Select, calibrate, and integrate instrumentation and sensors (pressure transducers, thermocouples, RTDs, flow meters, torque cells, and Hall effect sensors) based on measurement range, signal type, and environmental requirements.
• Specify, install, and configure DAQ modules (analog/digital I/O, high-speed sampling) to interface reliably with test hardware and instrumentation.
• Layout and assemble control panels, including electrical enclosures, DIN rails, terminal blocks, relays, power supplies, and circuit protection.
• Program PLCs, PC-based controllers, and develop user-friendly HMI/GUI applications to automate test sequences, interlocks, and real-time data logging.
• Set up and configure industrial networking hardware (managed switches, routers, firewalls) to ensure secure, robust communication across test benches and engineering workstations.
• Develop and maintain clear technical documentation, including electrical schematics, wiring diagrams, bills of materials (BOM), and system operating procedures.
• Troubleshoot test stand electrical, sensor, and software issues alongside technicians and test engineers to minimize downtime.
• Maintain safe test cell operations in compliance with industry electrical standards and best practices.

Required Qualifications

• BS in Electrical Engineering, Controls & Automation Engineering, Mechatronics, or a related discipline with 3+ years of relevant experience (or 8+ years of hands-on experience in test cell controls/DAQ integration).
• Proven experience building and programming PLC- or PC-based data acquisition and control systems.
• Hands-on experience with closed-loop PID control and industrial automation protocols.
• Demonstrated experience with sensor integration, signal conditioning, and electrical diagnostic equipment (DMMs, oscilloscopes, signal generators).
• Proficiency in a programming language or scripting environment used for test automation and data handling (e.g., Python, C++, C#, structured text, or similar).
• Practical experience in electrical panel assembly, point-to-point wiring, crimping, and soldering.
• Strong collaborative problem-solving skills with the ability to communicate technical details across engineering and operations teams.

Preferred Qualifications

• Experience with engine dynamometers, fuel systems, or propulsion test stands.
• Familiarity with industrial electrical standards (NFPA 70, NFPA 79, UL 508A, ISO 13849, or IEC 62443).
• Experience using 3D CAD/modeling software (e.g., SolidWorks) or electrical schematic design tools.
• Passion for general aviation and aerospace technology.

Working Conditions

This role combines a professional engineering environment with active, hands-on work in the engine test cell facility, including troubleshooting alongside technicians and supporting initial commissioning of new hardware assemblies.