Senior Controls Engineer

Senior Controls Engineer

Location: Norcross, GA

Employment: Full-Time

Reports To: [Operations Manager]

Compensation: Competitive, Based on Experience

Travel: Approximately 10-15%, for on-site commissioning and system integration

Position Overview: We are seeking a Senior Controls Engineer with strong software development skills to design, build, and deploy next-generation motion control, machine vision, and robotic systems. This is a hands-on engineering role centered on writing and architecting production-grade code — not just configuring existing systems. The ideal candidate combines deep expertise in Beckhoff TwinCATmotion and control programming with real software development experience building AI-based vision applications, and brings a mechatronics mindset that spans mechanical, electrical, and software disciplines. This role owns the full development lifecycle for control and vision software: architecture, coding, testing, integration, deployment, and ongoing support — working closely with mechanical, electrical, and robotics engineers to bring automated systems from concept to production.

Key Responsibilities:

• Design, develop, and maintain motion control and machine control software using Beckhoff TwinCAT 3, including structured text, function block, and object-oriented PLC programming (IEC 61131-3).
• Develop and integrate AI-based machine vision software for part inspection, guidance, defect detection, and quality control, using tools such as OpenCV, TensorFlow, PyTorch, Cognex VisionPro, Keyence, or Halcon.
• Build and train vision models (classification, object detection, defect segmentation) and integrate them into real-time production control systems.
• Program and integrate industrial and collaborative robots (e.g., Universal Robots, FANUC, ABB, KUKA) for pick-and-place, assembly, inspection, and material handling applications.
• Architect mechatronic systems that unify motion control, sensing, vision, and robotics into cohesive, reliable automated machines.
• Write clean, modular, well-documented, and version-controlled code (Git) for control and vision applications, following software engineering best practices.
• Develop and maintain automated testing, validation, and simulation frameworks to verify system behavior prior to on-site deployment.
• Design and implement communication architectures between PLCs, vision systems, robots, and higher-level software (EtherCAT, EtherNet/IP, OPC-UA, TCP/IP, REST APIs).
• Collaborate with mechanical and electrical engineers throughout the design process to ensure control, vision, and robotic systems are integrated from the ground up rather than bolted on after the fact.
• Commission new systems on-site, including software deployment, calibration of vision systems, robot path tuning, and full system integration testing.
• Troubleshoot and debug complex control, vision, and robotic system issues in both development and live production environments.
• Conduct root cause analysis on system failures and implement software and hardware improvements to increase reliability, throughput, and accuracy.
• Create and maintain technical documentation including software architecture diagrams, code documentation, vision model performance reports, and commissioning records.
• Mentor junior engineers on coding practices, motion control theory, and vision/robotics system design.
• Stay current with advances in industrial AI, machine vision, and motion control platforms, recommending new tools and approaches to improve system capability.

Required Qualifications:

• 8+ years of experience in controls engineering with a strong software/programming component, ideally including motion control and machine vision or robotics development.
• Hands-on software development experience with Beckhoff TwinCAT 3 motion and control platforms, including structured text and object-oriented programming approaches.
• Demonstrated experience developing or integrating machine vision software, including familiarity with AI/ML-based vision tools (OpenCV, TensorFlow, PyTorch, or commercial vision platforms such as Cognex, Keyence, or Halcon).
• Experience programming industrial or collaborative robots (Universal Robots, FANUC, ABB, KUKA, or similar).
• Strong general-purpose programming skills in one or more of: C++, C#, Python, or structured text at an advanced level.
• Solid understanding of mechatronic system design — the interaction between mechanical design, electrical/electronic systems, sensors, and software control.
• Experience with industrial communication protocols: EtherCAT, EtherNet/IP, OPC-UA, Modbus TCP/RTU.
• Familiarity with version control systems (Git) and standard software development practices (code review, testing, documentation).
• Bachelor's degree in Electrical Engineering, Computer Engineering, Mechatronics, Computer Science, or related field (equivalent hands-on experience will be considered in lieu of a degree).
• Ability to read and interpret electrical schematics and mechanical drawings, with proficiency in SkyCAD, AutoCAD Electrical, or EPLAN P8 a plus.
• Strong understanding of industrial safety standards, including LOTO procedures and safety circuit design (E-stops, interlocks, safety relays, SIL-rated systems).
• Effective communicator able to work across engineering, operations, and manufacturing functions, and to explain complex technical concepts clearly.

Preferred Qualifications:

• Experience training and deploying custom deep learning vision models for industrial inspection or guidance applications.
• Experience with robot simulation and offline programming tools (RoboDK, FANUC ROBOGUIDE, ABB RobotStudio, or similar).
• Experience with CI/CD pipelines, automated testing frameworks, or Agile development practices applied to industrial software.
• Experience with additional PLC platforms (Allen-Bradley, Siemens) in a multi-vendor automation environment.
• Experience with cloud or edge-based data platforms for industrial analytics (Azure IoT, AWS IoT, or similar).
• Prior experience in a machine builder, systems integrator, or advanced manufacturing environment developing first-of-kind automation solutions.

Work Environment:

This position works across both a development/lab environment and the production floor in an industrial manufacturing setting, with exposure to moving machinery, robotics, electrical panels, and standard plant conditions. The employee must be able to safely enter production areas, work around energized and operating equipment following LOTO procedures, and use required personal protective equipment. This role includes approximately 10-20% travel, primarily for on-site commissioning and integration support. Reasonable accommodations may be made to enable qualified individuals to perform the essential functions. This description is not an exhaustive list of duties; compensation range and shift schedule should be confirmed prior to publication.