The Controls Engineer/Designer III role is an experienced engineering position at RND. The ideal candidate will be responsible for designing, developing, and implementing control systems for various industrial processes. This role requires a strong understanding of automation systems, as well as the ability to troubleshoot and optimize PLC programs to ensure efficient and reliable operation. This position will be responsible for applying RND standards in both layout and programming functions to develop PLC, HMI, robot, and vision programs for custom automation machines. This multi-faceted position offers an exciting opportunity to work with cutting-edge technologies and contribute to the success of various projects. Travel is a part of this position to support the team and our customers.

Duties and Responsibilities:

• Programming:

  • Develop control programs using Allen-Bradley PLCs (e.g., ControlLogix, CompactLogix) and associated software (e.g., RSLogix 5000, Studio 5000).

  • Develop HMI screens and links, utilizing RND standard modules and custom programming where needed.

  • Develop safety programs for Banner/GuardLogix safety controllers/safety devices.

  • Develop custom vision applications utilizing Keyence Software and Cognex Spreadsheet for Cognex Cameras.

  • Develop robot applications primarily using Fanuc and Epson

  • Develop applications for miscellaneous devices that will be used on future projects.

• System Design: Design and configure control systems, including I/O configuration, HMI integration, and communication protocols. Will also perform Risk Assessments and help design appropriately safe systems.

• Troubleshooting: Diagnose and resolve issues related to PLC programs, control systems, and field devices. Implement corrective actions to minimize downtime and improve system performance.

• Testing and Validation: Conduct thorough testing and validation of control systems to ensure they meet design specifications and operational requirements.

• Documentation: Create and maintain detailed documentation for control system designs, including pinning charts, code comments, and user manuals.

• Collaboration: Work closely with engineering, project management, and assembly teams to understand system requirements and provide technical support throughout the project lifecycle. Will utilize and maintain RND standards while also suggesting appropriate improvements.

• Continuous Improvement: Identify opportunities for process improvements and implement changes to enhance system efficiency, reliability, and performance.

• Compliance: Ensure all control systems comply with relevant industry standards, safety regulations, and company policies.

Daily Activities:

• Attend project huddles and project design meetings
• Attend sales meetings
• Develop time estimates for sales proposals
• Be an active participant in collaboration with mechanical engineers on machine design
• Develop advanced PLC and HMI programs offline
  • Development will include either software, vision, or hardware RND has not seen before.
  • Perform high risk testing on machine designs
  • Develop benchtop vision tests to ensure correct camera, lighting, and lensing of vision applications
• Commission and debug automation machines
• Troubleshoot issues on machines that are at RND or at customer locations
• Research/train on new technologies used on machines.
• Start-up machines at customer sites.
• Mentor Controls I and II engineers.
• Maintain code standards.
• Perform PLC/HMI reviews on applications of Controls I and II engineers.
• Develop manuals for automation equipment.