Lead Controls Engineer / Controls Architect

Key Responsibilities

• Review, analyze, and document the current controls architecture, hardware platform, electrical design, safety systems, sensors, networks, wireless communication, and software integration points.
• Establish a clear baseline of current controls systems and identify gaps, risks, reliability concerns, and opportunities for improvement.
• Develop controls architecture roadmaps covering PLC hardware, I/O, drives, motion control, safety systems, diagnostics, data logging, networking, and serviceability.
• Evaluate the current Allen-Bradley / Rockwell Automation platform while investigating alternative platforms such as Siemens, Beckhoff, B&R, Codesys-based systems, or other relevant automation technologies.
• Implement error handling, alarm management, diagnostic messaging, event logging, and data collection methods.
• Design, validate, and troubleshoot industrial communication networks, including Ethernet/IP, radio systems, and industrial Wi-Fi.
• Develop network testing standards for latency, signal strength, packet loss, roaming, bandwidth, interference, and communication reliability.
• Lead the development of commissioning plans, controls checkout procedures, startup plans, field verification documents, installation standards, and acceptance test support documentation.
• Lead or support on-site commissioning, including wiring checks, I/O checkout, safety validation, device setup, network validation, dry-cycle testing, loaded testing, fault testing, and performance testing.
• Troubleshoot complex controls, electrical, network, software interface, and mechanical integration issues during startup and service escalation.
• Work with mechanical and software teams to ensure controls designs align with shuttle design, drive systems, lift mechanisms, sensors, guarding, communication protocols, and system recovery logic.
• Support customer acceptance testing, rate testing, reliability testing, final turnover documentation, and continuous improvement efforts.

Required Qualifications

• 5+ years of hands-on controls engineering experience in industrial automation, material handling, robotics, ASRS, conveyor systems, mobile equipment, or related automation environments.
• Strong PLC programming experience, preferably with Allen-Bradley / Rockwell Automation platforms.
• Ability to design, troubleshoot, and improve complex controls systems involving motion, safety, sensors, networks, and upper-level software integration.
• Experience developing structured PLC code, reusable logic, fault handling, diagnostics, and machine control standards.
• Strong understanding of electrical schematics, control panels, field wiring, I/O checkout, device configuration, and industrial installation practices.
• Experience commissioning automated systems in the field, including startup planning, checkout documentation, troubleshooting, and customer coordination.
• Strong technical documentation skills, including architecture documents, commissioning plans, checkout sheets, test procedures, standards, and support documentation.
• Willingness to travel for on-site R&D efforts, project commissioning & startup, and occasional service needs.

Preferred Qualifications

• Experience with automated storage and retrieval systems, pallet shuttle systems, AGVs/AMRs, conveyors, lifts, robotics, or warehouse automation.
• Experience with Siemens, Beckhoff, B&R, Codesys, or other PLC/control platforms.
• Experience with industrial motion control, servo systems, VFDs, drive tuning, encoder feedback, positioning systems, and mobile machine controls.
• Experience designing or troubleshooting industrial wireless, radio, or Wi-Fi networks for mobile automation equipment.
• Experience with machine safety design, risk assessments, safety PLCs, guarding, interlocks, safe torque off, and safety validation.