Controls Engineer

Role: Controls Engineer
Location: Dallas, TX




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About The AES Group

The AES Group is a premier technology and engineering consulting company that has been bringing businesses and talent together for over 20 years to deliver innovative solutions that have the greatest positive impact on society. AES has helped over 40 business enterprises, including Fortune 500 companies, engage their customers, empower their employees, and transform their business operations with the power of cloud, data, AI, engineering, and other emerging technologies.

Position Overview

We are seeking an experienced Controls Engineer to join our engineering team in Dallas, TX. The ideal candidate will have extensive hands-on experience in designing, programming, commissioning, and supporting industrial automation systems using ABB and Rockwell Automation platforms. This role offers the opportunity to work on complex automation projects across manufacturing and industrial environments while collaborating with multidisciplinary engineering teams.

The successful candidate will possess strong expertise in PLC, HMI, SCADA, and industrial networking, with the ability to independently manage automation projects from concept through commissioning.

Key Responsibilities

• Design, develop, program, and commission industrial automation and control systems using ABB and Rockwell Automation technologies.
• Develop and troubleshoot PLC programs utilizing Allen-Bradley ControlLogix, CompactLogix, GuardLogix, MicroLogix, and Studio 5000 / RS Logix 5000.
• Configure and support ABB PLCs, drives, motors, VFDs, and industrial automation products.
• Develop HMI and SCADA applications using FactoryTalk View SE/ME, ABB automation software, or equivalent visualization platforms.
• Perform PLC, HMI, VFD, servo, and motion control integration for new and existing production equipment.
• Configure industrial communication networks including:
• Ether Net/IP
• DeviceNet
• ControlNet
• Modbus TCP/IP
• Profinet
• OPC UA
• Troubleshoot automation, instrumentation, and electrical control systems to minimize production downtime.
• Develop electrical control philosophies, control narratives, functional specifications, and I/O lists.
• Participate in FAT (Factory Acceptance Test), SAT (Site Acceptance Test), startup, commissioning, and customer acceptance activities.
• Coordinate with electrical, mechanical, manufacturing, and project engineering teams throughout project execution.
• Support equipment upgrades, process improvements, and continuous improvement initiatives.
• Maintain detailed engineering documentation including:
• Control panel drawings
• Electrical schematics
• PLC/HMI backups
• Bill of Materials (BOM)
• Functional Design Specifications (FDS)
• Ensure all automation systems comply with company standards, OSHA regulations, and applicable electrical safety codes.

Required Qualifications

• Bachelor s degree in electrical engineering, Controls Engineering, Mechatronics, Automation Engineering, or a related discipline.
• Minimum 8+ years of Controls Engineering experience within industrial manufacturing or automation environments.
• Strong hands-on experience with:
• ABB Automation Systems
• Rockwell Automation (Allen-Bradley)
• Studio 5000
• RS Logix 5000
• FactoryTalk View
• Experience programming PLCs, HMIs, SCADA, VFDs, servo systems, and motion control applications.
• Strong understanding of industrial electrical systems, instrumentation, sensors, actuators, and control panel design.
• Ability to interpret electrical schematics, P&IDs, wiring diagrams, and engineering documentation.
• Experience with industrial networking and communication protocols.
• Excellent troubleshooting and analytical problem-solving skills.
• Strong written and verbal communication skills.

Preferred Qualifications

• Experience with ABB Robotics or industrial robotic integration.
• Knowledge of IEC 61131-3 programming standards.
• Experience in automotive, food & beverage, packaging, pharmaceuticals, material handling, or process manufacturing industries.
• Exposure to MES, IIoT, Industry 4.0, and data acquisition systems.
• Familiarity with AutoCAD Electrical or EPLAN.
• Experience with vision systems such as Cognex or Keyence is a plus.
• Ability to travel up to 20 30% for commissioning and customer support, if required.

Technical Skills

• ABB Automation
• Rockwell Automation
• Allen-Bradley PLCs
• Studio 5000
• RS Logix 5000
• FactoryTalk View SE/ME
• PLC Programming
• HMI Development
• SCADA Systems
• Industrial Networking
• Ether Net/IP
• Device Net
• Modbus TCP/IP
• OPC UA
• VFDs & Servo Drives
• Motion Control
• Control Panel Design
• Electrical Troubleshooting
• FAT / SAT / Commissioning