Mechatronics/Automation Engineer

Fermel (Pty) Ltd; Gauteng; On-site; ZAR 600,000 - 800,000; Full time

Job summary

Fermel (Pty) Ltd is seeking a Mechatronics Engineer to oversee the design and development of advanced electro-mechanical systems for underground mining applications. This role requires expertise in machine control, embedded systems, and regulatory compliance.

The ideal candidate will combine practical knowledge with innovative solutions in PLC programming and automation systems while adhering to industry safety standards. This position presents an opportunity to impact high-performance mining equipment systems.

Qualifications

• Minimum 3–5 years of experience in a Mechatronics/Automation or vehicle systems engineering role.
• ECSA registration preferred; Professional registration advantageous.
• Proficiency in PLC programming and experience with PLC platforms.

Responsibilities

• Develop, program, and validate machine control software.
• Design and integrate machine control architectures for various systems.
• Support compliance with mining safety and regulatory standards.

Skills

PLC programming

CAN Bus communication

Embedded control systems

Design of machine control systems

Electro-hydraulic systems integration

Software debugging

Education

BEng / BSc Eng / BTech in Mechatronic Engineering, Electrical Engineering, or related

Tools

Danfoss PLUS+1 GUIDE

Siemens TIA Portal

Allen-Bradley Studio 5000

CODESYS

Job description

Role Overview

The Mechatronics Engineer is responsible for the design, development, integration, validation, and lifecycle support of electro‑mechanical systems utilized in underground mining machinery. The role combines mechanical engineering, electrical systems, embedded controls, software integration, automation, and machine functional safety to develop reliable, compliant, and high‑performance mining equipment systems.

The engineer will support new machine development, machine automation, retrofit projects, diagnostics systems, control architecture development, machine safety systems, and compliance with mining industry regulatory standards.

Minimum Experience

• BEng / BSc Eng / BTech in Mechatronic Engineering, Electrical Engineering, Electronic Engineering, or Electromechanical Engineering
• ECSA registration (Candidate Engineer preferred; Professional registration advantageous)
• Valid driver’s license
• Proficiency in PLC programming and experience with PLC platforms such as Siemens (TIA Portal / Step 7), Rockwell Automation (Allen‑Bradley Studio 5000 / RSLogix), Danfoss (Plus+ 1 Guide) – Preferred, Generic (CODESYS) – Preferred, etc.
• Strong understanding of CAN Bus communication systems and SAE J1939 protocols.
• Minimum 3–5 years of experience in a Mechatronics/Automation or vehicle systems engineering role.
• Proven experience in mobile equipment, automotive, mining machinery, heavy equipment or related environments.
• Demonstrated practical experience in design and implementation of machine control systems.
• Experience with underground Trackless Mobile Machinery (TMM) preferred.
• Experience with battery‑electric vehicle (BEV) systems advantageous.

Technical Responsibilities

• Machine Control Systems Development
  • Develop, program, test, and validate machine control software using Danfoss PLUS+1 GUIDE.
  • Design distributed machine control architectures for propulsion, steering, braking, hydraulic actuation and auxiliary systems.
  • Configure machine controllers, calibration parameters, and software release packages.
  • Develop machine diagnostic logic, fault‑handling strategies, and embedded control software.
  • Conduct electrical load analysis and component selection for harsh underground operating environments.
• PLC Programming & Automation Systems
  • Develop, program, troubleshoot and commission PLC‑based control systems for machine automation and subsystem control.
  • Develop control logic for hydraulic systems, safety interlocks, actuator control systems, machine automation, and process monitoring systems.
  • Integrate PLC systems with HMI displays, sensors, CAN Bus communication networks, remote I/O systems, and industrial communication protocols.
  • Support software debugging, system commissioning, field testing, and controller optimization activities.
• HMI Development & Operator Interface Systems
  • Design, develop, and configure Human Machine Interface (HMI) systems for machine operation, diagnostics, fault monitoring and operator feedback.
  • Develop operator display screens for machine status monitoring, alarm management, fault reporting and subsystem diagnostics.
  • Integrate HMI systems with PLC controllers, machine ECUs, CAN Bus communication networks, and embedded control systems.
  • Develop machine parameter configuration interfaces for service and maintenance activities.
  • Support development of operator warning systems, fault annunciation logic, and machine performance monitoring interfaces.
  • Ensure operator interfaces comply with machine safety and ergonomic design requirements for underground mining applications.
• CAN Bus & Communications Systems
  • Develop and troubleshoot CAN Bus communication networks using SAE J1939 and related industrial communication protocols.
  • Integrate communication architecture between controllers, engine ECU systems, operator displays, telematics systems, and safety devices.
  • Perform signal mapping, network diagnostics, and communication fault analysis.
• Electro‑Hydraulic Systems Integration
  • Design and integrate electro‑hydraulic control systems for steering, braking, implement control, and auxiliary hydraulic functions.
  • Develop closed‑loop hydraulic control systems utilizing proportional valves, sensors, and actuator feedback systems.
  • Support hydraulic system performance optimization and validation testing.
• Testing, Validation & Product Development
  • Develop and execute subsystem and full machine validation test plans.
  • Conduct prototype commissioning, software debugging, machine testing, and field validation activities.
  • Perform root cause analysis on machine failures and implement corrective engineering actions.
  • Support continuous product improvement and machine performance optimization.
• Functional Safety & Compliance
  • Develop machine systems compliant with mining safety and international regulatory standards.
  • Implement fail‑safe architecture, emergency stop logic, interlock systems, and machine shutdown strategies.
  • Support compliance with ISO 21815, SANS 1589, EMC/EMI requirements, and underground mining safety requirements.
• Automation & Emerging Technologies
  • Support development of machine automation systems, remote‑control systems, and semi‑autonomous machine functionality.
  • Integrate battery‑electric vehicle systems including battery management systems, charging systems, thermal management systems, and electric drivetrain control.
  • Support telemetry, machine health monitoring, and predictive maintenance technologies.

Advantageous

• Electrical & Electronic Systems Engineering
  • Design experience in machine electrical architecture including power distribution, circuit protection, harness design, grounding systems, and electrical integration.
  • Experience with high‑voltage electrical systems.
  • Experience with Battery Electric Vehicle (BEV) architecture and system design.
  • Familiarity with Battery management systems (BMS), Inverters, DC‑DC converters, Motor controllers, Charging systems, Functional safety concepts.
  • Knowledge of mining equipment regulatory requirements and standards.