Automation Engineer - ABB Robotics & PLC Systems Integration

Automation Engineer – ABB Robotics & PLC Systems IntegrationUp to $120,000 Base Salary + Benefits • Waukesha County, WI Area • Onsite / Up to 30% Travel • Direct-HirePay & Incentives: Up to $120,000 starting base salary (commensurate with programming depth) + full corporate health/retirement benefits package.Work Pattern/Schedule: Onsite in Waukesha County with up to 30% domestic and international travel for client site commissioning, SAT, and deployment (Valid U.S. Passport required).Environment & Company Profile: Certified, highly respected custom industrial automation systems integrator in Waukesha County; engineering design and physical machine assembly under one roof with zero repetitive line work.Core Functional Scope: Ground-up custom machine builds, RAPID coding, ABB RobotStudio virtual simulation, Allen-Bradley / Rockwell PLC integration, fieldbus communications, and client-site deployments.Strict Requirements & Authorization: Requires 5+ years of ABB programming depth (RAPID & RobotStudio), 2+ years of PLC development, US work authorization, and a 45-minute daily commute to Waukesha County / Greater Milwaukee, WI.If you are a senior robotics engineer feeling stuck running repetitive cycles at a slow-moving corporate plant, this direct-hire engineering seat is your ticket to true technical autonomy. The employer is a certified, highly respected custom industrial automation systems integrator in Waukesha County with a rock-solid, diversified global client base.Instead of repetitive production lines, you will design and build custom, leading-edge machinery tailored to complex application requirements. The organization fosters a culture centered on engineering creativity, multi-platform learning, and individual ownership. With design teams and physical assembly floors under one roof, you will get the unique satisfaction of seeing your virtual simulations transform into fully operational systems right down the hall.What You Will Be Doing (Daily Responsibilities)Write & Simulate ABB Code: Develop, write, and optimize clean RAPID code and RobotStudio simulations to seamlessly integrate ABB robotic arms with master PLCs and plant-wide automation systems.Lead Full-Lifecycle Builds: Drive full-lifecycle custom machine projects—from initial system design and advanced kinematics simulation to floor build and physical debugging.Configure Hardware & Protocols: Establish electrical communication setups, fieldbus protocols (EtherNet/IP, PROFINET), and software handshakes for ABB robotic packages and specialized end-of-arm tooling (EOAT).Troubleshoot Complex Integration: Isolate and resolve pathing errors, cycle-time bottlenecks, mechanical interferences, and control logic issues on the build floor and in the field.Lead Client Onsite Deployments: Travel up to 30% domestically and internationally to lead system installations, site acceptance testing (SAT), and customer engineering sign-offs.Generate Technical Documentation: Author comprehensive system logic documentation, sequence-of-operation manuals, and electrical schematic redlines for custom machinery builds.What We Are Looking For (Requirements & Qualifications)ABB Robotics Expertise: 5+ years of verifiable experience programming ABB robots, including at least 2 years focused on RAPID programming and RobotStudio virtual simulation.PLC Programming Skill: 2+ years of practical PLC development and ladder logic programming using Allen-Bradley / Rockwell Studio 5000 (or equivalent major industrial controllers).Safety & Motion Control Literacy: Solid foundation configuring industrial motion control, vision-guided systems, and safety networks (light curtains, safety relays, SafeMove).Education or Trade Balance: Bachelor’s Degree in Electrical Engineering, Robotics, Mechatronics, or related discipline (extensive hands-on systems integration experience fully considered in lieu of degree).Global Travel Readiness: Willingness and capability to travel up to 30% worldwide, backed by a valid U.S. Passport (or ability to obtain one immediately).Local Commute Radius: Established residency within a comfortable daily 45-minute driving distance of Waukesha County / Greater Milwaukee.Preferred Technical Assets (Bonus Skills)Vision & EOAT Integration: Direct experience integrating 2D/3D machine vision systems (Cognex, Keyence) or complex servo-driven end-effectors.Multi-Robot Platform Exposure: Secondary experience programming FANUC (KAREL/TP), KUKA, or Yaskawa robotic systems.Virtual Commissioning & HMI: Familiarity with digital twin software or building custom HMI screens (FactoryTalk View) for machine operators.