Lead Controls Engineer

Lead Controls Engineer

Location: On-site - Victor, NY. Design it. Build it. See it run.

Qualified Candidates May be eligible for relocation assistance.

Salary: $135,000 - $160,000/yr

Job Summary

Our Controls Engineering Department is growing and we're looking for leaders of the pack who have experience in custom automation - no two projects are quite alike! The Lead Controls Engineer is responsible for providing controls hardware design, programming, debug, and site-installation of turnkey custom automation equipment.

At PMD, our engineers don't just design automation systems from a desk. They work alongside the teams building, integrating and commissioning the machines — from concept through completion.

Essential Functions

• Work independently on larger or high complexity projects and/or multiple smaller projects.
• Training of new and/or less senior engineers.
• Set technical direction for multiple engineers on portions of larger or more complex projects.
• Peer review of other engineers' work for accuracy and thoroughness.
• Development of overall machine Controls Architecture
• Enclosures: Standalone, Remote, Local
• I/O: In-cabinet, on-machine
• Network selection & distribution: Ethernet, IOLink, Hardwired
• Cable/Wiring Routing: Ladder Track, Wireway
• Development of overall machine Controls Software Architecture
• Elements: Cells, Stations, Devices, Sequences
• Interface
• Recipe selection
• Recipe editing
• Status tracking
• Data tracking
• Report generation
• Review customer requirements, PMD proposal, PMD cost estimate, and Federal, State, & Local requirements.
• Attend Mechanical Design Reviews to understand machine functionality, suggest concepts & componentry to meet controls & safety requirements, and subsequently incorporate associated Controls Hardware design elements into the Controls Hardware design.
• Translate device list provided by Mechanical Engineering into Controls Hardware design elements.
• Utilize AutoCad Electrical for drafting.
• Use provided symbols & circuits.
• Develop new symbols & circuits as necessary.
• Controls Hardware Design
• AC Power schematics
• DC Power schematics
• Safety schematics
• Servo/Stepper schematics
• Industrial Network schematics
• Device schematics
• Testers, Transducers, Laser Markers, Welders, Robots, etc.
• I/O schematics
• Control Enclosure layouts
• Control Panel layouts
• Fluid Power Supply schematics
• Fluid Power Control schematics
• Bill of Materials
• Interact with Controls Build personnel to answer questions.
• Assist Controls Build Technicians, Controls Software Engineers, and Controls Engineers with electrical and fluid power debug.
• Update design as required throughout the project life cycle.
• Use provided standard code and device drivers, or use end-customer provided code and/or formats to create custom control & HMI programs.
• Create custom device driver code.
• Using control schematics, enter I/O into controller programs.
• Using timing chart provided by Mechanical Engineering, program intended sequences into controller programs.
• Download completed programs.
• Commission control hardware.
• Debug control hardware for out-of-box failures, intended design, and correct wiring/plumbing.
• Debug control software, including all intended sequences, modes of operation, special functions, fault detection, fault recovery, tooling return, and interface.
• Participate in Factory Acceptance Test at PMD.
• Participate in Site Acceptance Test at end-customer's facility.

Other Duties

• Maintain a clean and orderly work area.
• Observe safety procedures.
• Any other task assigned by management within scope of position, federal and state regulations.

Requirements

EDUCATION

• BS in EE, EET, Mechatronics, related engineering field; or demonstrated equivalent experience.

Experience (10+ years):

With 4 or more of the following Hardware Design skills:

• AutoCad Electrical
• NFP79, UL508a, CE, CSA standards
• Power calculations (AC 3phase, AC 1phase, DC 5-90V, Transformers)
• Enclosure Heat calculations
• SCCR calculations
• Fluid Power flow calculations
• SISTEMA safety calculations
• Technical Supervision (5+ years)

And 3 or more of the following Programming skills:

• PLC Programming (Rockwell, Siemens, and/or Omron)
• HMI Programming (Rockwell, Siemens, and/or Omron)
• Robot Programming (Fanuc, ABB, Epson, Staubli, and/or Kuka)
• Vision Systems (Cognex, Keyence, Matrox, and/or Teledyne Dalsa)
• Industrial Protocols (Ethernet/IP, ProfiNet, EtherCat, and/or IOLink)
• Technical Supervision (5+ years)

Knowledge, Skills & Abilities

• Effective verbal and written communication.
• Ability to read, analyze, and interpret general technical procedures.
• Ability to work in decimal, octal hexadecimal, and binary numbering systems.
• Ability to apply concepts of basic algebra and geometry and to calculate scaling factors, proportions, percentages, rates, and ratios.
• Ability to solve practical problems and deal with a variety of concrete variables in situations where only limited standardization exists.
• Organized
• Detail oriented
• Ability to work independently, collaborate on a team, or direct others
• Ability to take direction
• Creative/Innovative
• Time management skills

Physical Demands & Work Environment

• Regularly required to sit; use hands to handle or feel; reach with hands and arms; talk or hear; and smell.
• Occasionally required to stand, walk, push, pull, lift, stoop, kneel, crouch and crawl.
• Specific vision abilities include close vision, distance vision, color vision, peripheral vision, depth perception, and ability to adjust focus.
• Work environment is primarily performed indoors; partially around moving mechanical parts at a moderate noise level.
• Wear safety equipment, including proper PPE.