Senior Automation Controls Engineer

Job Description
Job Objective

The Robotics Engineer is responsible for the programming, integration, commissioning, and optimization of robotic arc welding ( MIG systems utilizing FANUC and NACHI platforms within the automotive Bodyshop . The primary goal is to ensure the structural and geometric integrity of body-in-white (BIW) sub-assemblies, minimizing spatter, thermal distortion, and cycle times while maintaining a highly repeatable, production-ready process,also responsible for following and establishing programming standards based on process requirements and application types, from commissioning through to start-up.

Core Responsibilities

• Path Generation & Optimization: Program and refine complex MIG welding trajectories on NACHI robots, ensuring optimal torch angles (work and travel angles) and proper electrode stick-out.
• Weld Process Optimization: Configure and fine-tune welding parameter schedules directly on the robots to eliminate common defects such as porosity, lack of fusion, undercut, or excessive burn-through.
• TCP Maintenance & Calibration: Implement automatic Tool Center Point (TCP) check routines to ensure the robot maintains precise weld placement after consumable changes (contact tips, nozzles, or goosenecks).
• Backup & Version Control: Maintain clean, documented version history and periodic image backups of all robot controllers under your scope.

Job Requirements

• Education: Bachelor's degree in Robotics, Mechatronics, Automation, Welding, Electromechanical Engineering, or a related field.
• Experience: Minimum of 5 years of hands-on experience programming and integrating FANUC and NACHI robots, with a heavy focus (at least 2 years) on MIG welding applications in an automotive BIW/Bodyshop
• Languages: Professional working proficiency in English to interface with global tooling suppliers and corporate engineering standards.

Requirements

Technical Skills (Hard Skills)

• FANUC Programming (ArcTool): Advanced mastery of the FANUC ArcTool software package, configuration of weld schedules, torch control, and tool coordinate system management (TCP/Weld Frame).
• NACHI Programming (MIG/Arc): Specialized configuration in NACHI controllers (FD/AX series) for arc applications, power source interfacing, and synchronization of travel speed with wire feed rate.
• MIG/MAG Welding Technology: Deep knowledge in adjusting and optimizing welding parameters (voltage, amperage, wire feed speed, gas flow) and transfer modes (short-circuit, globular, spray, pulsed arc).
• Welding Peripherals: Integration and maintenance of torch cleaning stations (reamers), wire cutters, neck aligners, and automated TCP calibration units.
• Power Source Integration: Communication setup and configuration of industrial interfaces (Digital/Analog, DeviceNet, EtherNet/IP) with leading power supplies such as Fronius (TPS/i) , Lincoln Electric , or Miller .
• Robot Safety Systems: Advanced implementation of safety software options, specifically Fanuc Dual Check Safety (DCS) and Nachi RMU (Robot Monitoring Unit) for collaborative or restricted zone control.

Interpersonal Skills (Soft Skills)

• High-Pressure Troubleshooting: Rapid root-cause analysis of critical hardware/software faults during high-volume automotive production runs.
• Cross-Functional Collaboration: Strong teamwork skills to interface seamlessly with PLC programmers, mechanical designers, weld quality inspectors, and maintenance technicians.

Location: Toledo, OH and Normal, IL. - Candidates will spend 2-3 months in Toledo, OH and then will transition to Normal, IL. Must be available to work onsite at both these sites.
Travel: Pre-approved travel expenses will be included on top of the rate.
Schedule: Consultant will work 60 hours per week. 12 hours a day. Will need to work rotating shifts: am and pm