Test Systems & Controls Engineer

DeltaHawk Engines; Racine (WI); On-site; USD 75,000 - 115,000; Full time

Job summary

DeltaHawk Engines is seeking a hands-on Test Systems & Controls Engineer to design, assemble, program, and maintain data acquisition and automation for R&D and production test operations. You will build and support engine test stands, dynamometers, and component test benches to validate performance of advanced aviation engines.

From sensor selection and wiring to PLC/HMI programming and secure test networks, you will develop clear documentation, work with technicians, and ensure safe, compliant

Qualifications

• BS in Electrical Engineering or related with 3+ years of experience in test cell controls.
• Experience building and programming PLC- or PC-based DAQ systems.
• Hands-on experience with closed-loop PID control and industrial automation protocols.
• Sensor integration and signal conditioning.
• Proficiency in Python, C++, or C#.
• Electrical panel assembly and wiring.
• Ability to communicate across engineering and operations teams.

Responsibilities

• Design, wire, and commission data acquisition and control systems for engine dynamometer and component test cells.
• Select, calibrate, and integrate instrumentation and sensors based on measurement range, signal type, and environmental requirements.
• Specify, install, and configure DAQ modules 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 to ensure secure communication across test benches and engineering workstations.
• Develop and maintain technical documentation, including electrical schematics, wiring diagrams, BOMs, and SOPs.
• Troubleshoot test stand electrical, sensor, and software issues with technicians and test engineers to minimize downtime.
• Maintain safe test cell operations in compliance with industry electrical standards.

Skills

PLC programming

DAQ systems

PID control

Sensor integration

Python

C++/C#/Structured text

Electrical panel wiring

Team collaboration

Education

Bachelor's degree in Electrical/Controls/Automation/Mechatronics

Tools

Oscilloscopes

Signal generators

DMMs

SolidWorks

Job description

Location: Racine, WI

Job Id:231

# of Openings:1

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.

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.