Controls Engineer

Job Description: Controls Engineer

Location: Houston, TX

Position Overview: We are seeking a skilled Controls Engineer to join our team. This position will support the Controls Engineering Manager by providing technical expertise in the successful execution of industrial automation projects. The role involves hardware design, parts list development, software development, testing, and commissioning at customers manufacturing facilities. Responsibilities include PLC logic programming and revisions, configuring variable speed drives, designing control panels, and providing remote support to end customers.

Responsibilities:

• Develop and customize PLC programs for discrete manufacturing processes, motion control, and material handling systems following design best practices and company standards.
• Work with minimal supervision in a dynamic work environment.
• Utilize control platforms, primarily Allen Bradley's Logix, and occasionally Siemens Simatic S7.
• Specify and select appropriate control hardware including controllers, I/O modules, communication hardware, and other related components.
• Develop PLC programs using Rockwell Automation s Studio 5000; experience with Siemens TIA Portal is a plus.
• Integrate PLC controllers with AC and DC drives via industrial networks such as Ethernet/IP and Profinet.
• Collaborate with the Data/MES Engineering department to develop HMI and MES programs.
• Generate customer-oriented documentation, including programming diagrams, network diagrams, I/O lists, single-line diagrams, electrical schematics, and user manuals.
• Perform in-house system tests.
• Travel to customer sites for installation, debugging, and commissioning of automation systems (approximately 20% of the year, typically for two weeks or less).
• Diagnose and troubleshoot control system errors remotely and on-site.
• Coordinate with the Project Manager to meet project milestones.
• Communicate with clients to determine requirements, expectations, and project needs.

Minimum Qualifications:

• Bachelor s degree in Electrical Engineering or a related field.
• 10 years of experience in industrial controls.
• Strong knowledge and hands-on experience in PLC programming.
• Proven track record in hardware and software automation project development.
• Demonstrated expertise in automation project commissioning.

Preferred Qualifications: (Ideal but not required)

• 5 years of experience in industrial controls.
• Proficiency in PLC function block programming & troubleshooting (Rockwell/Allen-Bradley and Siemens preferred, with an emphasis on Rockwell).
• Hands-on experience in AC variable speed drive configuration and troubleshooting (Variable frequency drives, DC drives at 480VAC or lower).
• Experience with PLC communication protocols (Ethernet/IP preferred).
• Ability to configure and test communication hardware.
• Hands-on HMI/SCADA programming and deployment experience, including Ignition.
• Willingness to travel more than 20% of the time.
• Field experience in a heavy industry environment.
• Experience working for a controls system integrator handling both master integration and machine-level control systems.
• Experience with AutoCAD Electrical for drawing creation.
• Knowledge of National Electrical Code (NEC) regulations.
• Understanding and implementation of control safety systems and Safety over Ethernet.

Additional Responsibilities:

• Design and optimize process flows.
• Mentor and transfer knowledge to client project team members.
• Act as a primary, co-author, or contributing author on all project deliverables related to assigned areas.
• Participate in data conversion and maintenance.
• Provide best practices and industry-specific solutions.
• Offer out-of-the-box alternative solutions.
• Provide technical leadership and hands-on development when necessary.
• Contribute as a functional team member.
• Perform other duties as assigned.