Senior Controls Engineer R&D

About the role

As a Controls Engineer in our Innovation Center, you will be responsible for designing, implementing, commissioning and maintaining automated systems to improve efficiency, reliability, and productivity in industrial processes. You will work closely with cross-functional local and remote teams to analyze requirements, develop automation solutions, integrate hardware and software components, and ensure seamless operation of automated systems.

Responsibilities

• Apply sound engineering principles to design and develop advanced magnet wire production equipment, processes and programs to improve quality, efficiency, and cost.
• Perform hands-on design and implementation of machine and process automation, including electrical design, PLC programming and SCADA development.
• Develop and integrate new automation technologies to enhance performance of existing products and processes.
• Support and improve machine vision–based inspection systems (e.g., Keyence, Cognex).
• Interface with global Innovation Teams to share knowledge, provide technical expertise, and co-develop new equipment solutions.
• Contribute to development of intellectual property through innovative equipment and process design.
• Design and implement industrial networking architectures (Ethernet/IP, EtherCat, Modbus TCP, etc.) to ensure reliable, scalable, and high-performance communication between automation systems.
• Collaborate with IT and OT teams to develop secure, robust network infrastructures that support data acquisition, system integration, OPC, and enterprise connectivity while adhering to cybersecurity best practices.
• Ensure proper network segmentation, device configuration, and secure connectivity for industrial control systems to enable safe and resilient operations.
• Collaborate with mechanical, process and electronics engineering to ensure effective electro-mechanical system design and operation.
• Understand and apply basic mechanical concepts; fabricate or assemble basic components as needed to support controls systems.
• Continuously evaluate, adopt, and implement emerging controls technologies, including advanced automation, data analytics, machine learning, and AI-driven solutions to improve system performance and capability.
• Provide technical support for equipment evaluation, installation, startup, commissioning, and product launch activities.
• Integrate automation systems with existing equipment and infrastructure, ensuring compatibility and seamless communication.
• Connect and configure equipment within SCADA systems (e.g., Ignition) for monitoring, visualization, and data collection, including SQL transactions.
• Conduct system testing, validation, and commissioning to ensure performance, reliability, and compliance with design requirements.
• Evaluate prototype equipment, document performance results, and recommend design improvements.
• Troubleshoot automation systems, diagnose issues, and implement corrective actions to minimize downtime and optimize system performance.
• Aid in project planning, scope definition, project management and execution in coordination with cross-functional teams.
• Utilize project planning software such as Monday.com or MS Project.
• Communicate project milestones, risks, timelines, and critical paths to ensure on-time & on-budget delivery.
• Develop and maintain comprehensive technical documentation, including:
• Functional specifications
• Wiring diagrams
• Configuration files
• Operating procedures
• Maintain accurate records of system changes, revisions, and technical updates.
• Support procurement activities by specifying and selecting automation hardware (sensors, actuators).

Qualifications

• Bachelor’s degree in Electrical Engineering, Mechatronics, Automation Engineering or equivalent.
• 3+ years previous electrical design experience required.
• 3+ years previous controls design & programming experience required.
• Ability to create and modify electrical schematics in AutoCAD Electrical (or similar) and supporting documentation for system quoting, construction, installation, and post commissioning as-built documentation.
• Experience with Ignition SCADA or strong willingness to learn.
• Possess demonstrated ability with analytical skills: methodically investigate problems, organize logical experimental trials, document data, and present results.
• Possess “hands-on” experience with equipment design and evaluation.
• Ability to use hands-on tools such as oscilloscope, digital multi-meter for process measurement, testing, and troubleshooting.
• Knowledgeable on NEC code, NFPA-70E, and Arc Flash requirements.
• Practical experience sufficient to compose and modify basic mechanical solutions, relying on practical mathematics proficiency and engineering comprehension.
• Possess ability to document and create standard work procedures, instructions, BOMs and other documentation.
• Strong PC skills required.
• Willingness to learn and apply new technical skills.
• Positive outlook and team social skills.
• Self-initiative as a senior level role.
• Willingness and ability to work on-site M-F 8am-5pm and travel 5%-10% (occasionally machine commissioning/ startups may require slightly more), mostly day trips to other Essex sites, occasionally overnight.