We are seeking a highly skilled and experienced Senior Controls Engineer with a strong background in industrial automation and a deep expertise in CoDeSys for PLC programming. The successful candidate will play a critical role in the design, development, implementation, and commissioning of complex control systems for our [products/systems/manufacturing processes]. This role requires a hands-on approach, strong problem-solving skills, and the ability to lead technical initiatives while mentoring junior engineers, all with a keen understanding of manufacturing principles and operational efficiency.
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Key Responsibilities:
System Design & Architecture:
- Lead the conceptualization, design, and specification of complex control systems, including hardware selection (PLCs, HMIs, drives, sensors, actuators) and network architecture.
- Develop detailed electrical schematics, I/O lists, and wiring diagrams in collaboration with electrical engineers.
- Define control strategies, safety interlocks, and operational sequences, always considering manufacturing process flow, cycle time optimization, and overall equipment effectiveness (OEE).
CoDeSys Programming & Development (Core Responsibility):
- Expertly program, test, and debug PLC logic using CoDeSys (IEC 61131-3) in various languages (ST, FBD, LD, SFC).
- Develop and implement reusable CoDeSys libraries, function blocks, and structured text routines, ensuring solutions are robust, maintainable, and scalable for production environments.
- Integrate and configure various fieldbus protocols (e.g., EtherCAT, PROFINET, Modbus TCP/IP, CANopen) within the CoDeSys environment.
- Develop and integrate HMI/SCADA applications using CoDeSys visualization or other compatible platforms, prioritizing operator usability, process visibility, and diagnostic capabilities for manufacturing personnel.
Commissioning & Troubleshooting:
- Lead the on-site commissioning, testing, and tuning of control systems, ensuring optimal performance and adherence to specifications, with a focus on achieving production targets and minimizing downtime.
- Perform advanced troubleshooting and diagnostics of complex hardware and software issues, often under pressure in a live manufacturing environment.
- Collaborate with mechanical, electrical, and software engineers to resolve system integration challenges, understanding their impact on the manufacturing line
•Documentation & Standards:
- Create and maintain comprehensive technical documentation, including functional specifications, design documents, test plans, and as-built drawings, which are essential for long-term manufacturing support and maintenance.
- Ensure all control system designs and implementations comply with relevant industry standards (e.g., UL, CE, NFPA, ISO, ANSI) and manufacturing specific regulations.
- Adhere to established coding standards and best practices for CoDeSys development.
Project Leadership & Mentorship:
- Lead technical aspects of projects, including scope definition, scheduling, and resource allocation, considering production timelines and resource availability within a manufacturing context.
- Provide technical guidance and mentorship to junior controls engineers, fostering their development in CoDeSys and control system design with an emphasis on practical manufacturing applications.
- Participate in design reviews and provide constructive feedback.
Continuous Improvement & Manufacturing Optimization:
- Stay abreast of new technologies, industry trends, and best practices in industrial automation and CoDeSys, specifically those applicable to improving manufacturing processes and efficiency.
- Proactively identify opportunities for process improvement, standardization, cost reduction