Automation & Controls Engineer - PLC/HMI & Systems Development

Job Description

Job Description

Automation & Controls Engineer – PLC/HMI & Systems Development

Commerce, Michigan

Position Summary

Seeking a hands-on, versatile Automation & Controls Engineer to design, develop, integrate and support industrial automation , instrumentation and engineered equipment across diverse applications. This Automation & Systems Development Engineer role combines PLC programming , HMI development , control-system architecture, electrical and mechanical integration, data acquisition , and software-based measurement, calculation, visualization and reporting.

Applications involve temperature, pressure, flow and other engineering parameters. The engineer will create intuitive operator interfaces, implement mathematical and statistical functions, and apply sound software engineering and cybersecurity practices.

Rapid Cooling is the immediate product priority, with responsibility extending to Fuel Conditioning, FluidBlend and future systems. Success requires curiosity, adaptability and the ability to develop reusable automation solutions across unfamiliar equipment and processes.

Key Responsibilities

• Lead automated equipment projects from requirements and concept through design, prototyping, fabrication, factory acceptance testing (FAT) , installation, site acceptance testing (SAT) and commissioning.
• Design PLC control sequences, PID control loops, temperature ramps, interlocks and alarms for pumps, valves, heat exchangers and other equipment. Develop clear HMI screens, trends, diagnostics and operator workflows.
• Develop modular PLC/HMI software using IEC 61131-3 programming languages and appropriate CODESYS tools. Implement engineering calculations, unit conversions, derived measurements, statistical averages, data validation and reporting functions.
• Develop and maintain P&IDs , electrical schematics , I/O lists, control narratives, industrial communications and network diagrams, CAD drawings, software documentation and system integration records.
• Apply thermal-fluid systems fundamentals to component selection and equipment design, including heat transfer, pump curves, pressure drop, flow measurement, piping, valves and temperature control.
• Select and integrate sensors, transmitters, variable frequency drives (VFDs) , motors, actuators, industrial networks and safety devices. Support UL 508A/UL 698A control panel design as applicable.
• Use CAD, engineering calculations and analysis to improve equipment packaging, performance, serviceability, cost and manufacturability.
• Develop reusable software modules, standard designs, bills of materials (BOMs), test plans and commissioning procedures. Establish practical version control , software testing, cybersecurity and engineering practices to improve quality and repeatability.
• Coordinate multidisciplinary teams, vendors, fabrication, assembly, procurement, internal testing and customer acceptance. Manage multiple project priorities and communicate directly with customers.

Required Qualifications

• Hands-on experience designing, integrating, troubleshooting and commissioning PLC-controlled industrial machines, skids, test equipment or process automation systems.
• Competence in PLC programming, HMI development, instrumentation and controls , PID/process control, industrial communications , engineering-unit scaling, data logging and electrical troubleshooting .
• Working understanding of mechanical systems and thermal/fluid processes, with the ability to collaborate across electrical, controls and mechanical engineering disciplines.
• Ability to interpret and produce practical engineering documentation, including electrical drawings, P&IDs and CAD-based designs.
• Demonstrated adaptability across different projects, applications or industries. Willingness to learn unfamiliar hardware and software, evaluate alternatives objectively and work effectively in a small, hands-on engineering team.
• An engineering degree in electrical, mechanical, mechatronics, controls or a related discipline is preferred; equivalent relevant experience will be considered.
• Ability to translate measured physical quantities into reliable operator displays, engineering calculations, trends and actionable diagnostics. Strong analytical reasoning and clear technical communication skills.

Preferred / Additional Experience

• CODESYS and IEC 61131-3 programming; Beijer iX Developer , WAGO Touch Panel 600 or other integrated PLC/HMI platforms; experience evaluating and migrating industrial control platforms.
• C#/.NET for HMI scripting and applications; Python for engineering analysis and test-data processing; SQL or other databases for data storage and reporting.
• SCADA/HMI integration , industrial networking using EtherCAT , Modbus , EtherNet/IP or OPC UA ; RTU interfaces, data acquisition, industrial cybersecurity , access control, secure communications, update practices and remote diagnostics.
• 3D CAD , electrical CAD and practical computer-aided engineering (CAE) for thermal/fluid analysis; design for manufacturing, standardization and cost reduction.
• Allen-Bradley/Rockwell , Siemens , Wonderware/iFIX or other PLC/SCADA platforms; databases, calibration/metrology, pneumatic actuation, industrial hydraulics or dynamometer/test-cell systems.
• Experience with utility/substation automation, DNP3, IEC 61850 or industrial combustion/burner controls is useful additional breadth but is not a core requirement.

Automation & Controls Engineer, industrial automation, PLC programming, HMI development, data acquisition, factory acceptance testing (FAT), site acceptance testing (SAT), PID control, IEC 61131-3, CODESYS, P&IDs, electrical schematics, thermal-fluid systems, variable frequency drives (VFDs), UL 508A/UL 698A, version control, process automation, instrumentation and controls, industrial communications, data logging, electrical troubleshooting, Beijer iX Developer, WAGO Touch Panel 600, C#/.NET, Python, SQL, SCADA/HMI integration, EtherCAT, Modbus, EtherNet/IP, OPC UA, industrial cybersecurity, 3D CAD, electrical CAD, Allen-Bradley/Rockwell, Siemens, Wonderware/iFIX