Controls Engineer - PLC / Industrial Automation (Vehicle Wash Systems)
BlackStar
Job Title: Controls Engineer – Vehicle Wash Systems (PLC / Industrial Automation)
Location: Cary, IL 60013 (On-site) | ~20% Travel (Overnight monthly)
Position Overview
We are seeking a Controls Engineer with strong PLC programming and hands-on mechanical aptitude to support the design, commissioning, and troubleshooting of automated vehicle wash systems. This role blends controls engineering, industrial automation, and mechanical system problem-solving in both office and field environments.
You will work on electro-mechanical systems involving pumps, conveyors, spray assemblies, and drive mechanisms—supporting projects from design through startup and ongoing service improvements.
Key Responsibilities
- Design, program, modify, and troubleshoot PLC and HMI systems for automated vehicle wash equipment
- Support projects from engineering design through installation, commissioning, and field startup
- Travel to customer sites (~20%) to assist with system commissioning, troubleshooting, and inspections
- Diagnose and resolve equipment issues with a strong focus on both electrical controls and mechanical root cause analysis
- Create and update AutoCAD drawings including mechanical layouts, electrical schematics, and control documentation
- Interpret mechanical prints, wiring diagrams, and equipment layouts to ensure proper system integration
- Collaborate with project managers, service teams, and sales engineering on project execution and technical support
- Support BOM creation, technical quotes, retrofit recommendations, and system upgrades
- Apply continuous improvement practices to enhance system reliability, performance, and serviceability
Required Qualifications
- 3–5+ years of experience in industrial automation, controls engineering, or OEM machine building
- Strong PLC programming and troubleshooting experience (Allen-Bradley, Siemens, or similar)
- Hands-on experience with HMI development and industrial control systems
- Strong mechanical aptitude with ability to troubleshoot systems such as pumps, conveyors, spray systems, and drive assemblies
- Ability to read and interpret mechanical drawings, electrical schematics, and wiring diagrams
- Experience with AutoCAD or similar CAD tools for engineering documentation
- Background in electro-mechanical systems in manufacturing, packaging, material handling, or similar automated environments
- Strong analytical and problem-solving skills in field and production environments
- Excellent communication and collaboration skills across engineering and service teams
Preferred Experience
- Prior exposure to vehicle wash systems or fluid-based automation equipment
- Experience in field commissioning, equipment startups, or customer-facing technical support
- Exposure to lean manufacturing or continuous improvement practices
Work Environment & Travel
- On-site role based in Cary, IL (60013)
- Approximately 20% travel (typically monthly overnight site visits)
- Local candidates within commuting distance are strongly preferred due to on-site requirements
Controls Engineer, PLC Programmer, Automation Engineer, Industrial Controls, HMI Programmer, Electro-Mechanical Engineer, Field Service Engineer, OEM Automation, Vehicle Wash Systems, Manufacturing Automation, AutoCAD Controls Engineer, Mechanical Troubleshooting, Industrial Equipment Commissioning
Vacancy posted 1 day ago
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