Development Controls Engineer – System Performance Testing

Job Responsibilities and Requirements

• Own the design, development, documentation, debugging, deployment, and support of PLC, HMI, and controls software used for developmental conveyor equipment, conveyor test loops, prototype equipment, and test systems.
• Work closely with Test Engineers to translate equipment behavior, test objectives, and performance gaps into practical controls strategies and improvement concepts.
• Configure and integrate field devices such as VFDs, photoeyes, encoders, barcode scanners, sensors, actuators, solenoids, safety devices, alarms, I/O, cameras, and related automation hardware.
• Support rapid iteration in a development environment by adapting controls logic and system configurations as equipment concepts, test plans, and performance targets evolve.
• Contribute to control system architecture decisions for test loops and developmental equipment, with emphasis on modularity, repeatability, maintainability, and efficient troubleshooting.
• Partner with Test Engineers to improve test loop capability, standardize setup procedures, refine configuration workflows, and reduce cycle time across test operations.
• Take ownership of complex controls-related problems and drive them toward clear conclusions, corrective actions, or design recommendations.
• Serve as a technical bridge between R&D Controls Engineers, Test Engineers, Mechanical Engineers, and other development stakeholders.
• Create clear documentation for controls logic, equipment setup, troubleshooting procedures, standard operating practices, and test-system configuration.
• Identify opportunities to increase testing efficiency through automation, data capture, diagnostics, visualization, and AI-assisted tools where appropriate.
• Bachelor’s degree in Electrical Engineering, Computer Engineering, Computer Science, Mechatronics, or a related technical field.
• 5+ years of controls, automation, or industrial equipment development experience; significant hands-on industrial automation experience may be considered in lieu of a degree.
• Strong PLC programming experience in an industrial automation environment, including comfort with ladder logic and structured text.
• Experience with Rockwell, Siemens, Beckhoff, or comparable controls platforms, with the ability to learn and adapt across platforms as needed.
• Proficiency configuring and troubleshooting PLCs, HMIs, industrial PCs, networks, VFDs, sensors, cameras, and related automation hardware used on conveyors, sorters, or other industrial equipment.
• Ability to diagnose equipment behavior by combining controls knowledge with an understanding of mechanical systems, product flow, safety systems, and test objectives.
• Demonstrated ability to work in an ambiguous development environment where equipment concepts, controls strategies, and performance targets may evolve over time.
• Ability to collaborate closely with Test Engineers and Mechanical Engineers to influence equipment design, testing strategy, and performance outcomes.
• Experience creating or interpreting electrical schematics, control-panel layouts, and control-circuit documentation; AutoCAD Electrical experience preferred.
• Strong problem-solving skills with the ability to take ownership of complex technical issues and drive them to practical resolution.
• Excellent written and verbal communication skills, including the ability to document controls changes, test-system configurations, and troubleshooting guidance clearly.
• Positive, proactive attitude with strong attention to detail and a willingness to work hands-on with developmental equipment and hand tools.
• Ability to lift 40 lbs.
• Ability and willingness to travel domestically and internationally, support field activities as needed, and work weekends, holidays, or overtime when required.
• Experience in conveyor, industrial automation, product handling, packaging, logistics, warehousing, or material-handling equipment.
• Experience with Beckhoff controls platforms and TwinCAT programming.
• Experience with MATLAB, Python, SQL, or other tools used for data analysis, automation, diagnostics, or test-system support.
• Experience developing controls solutions for prototype equipment, R&D systems, test stands, or developmental machinery.
• Experience designing systems that support data capture, equipment diagnostics, test automation, or repeatable performance measurement.
• Experience applying AI-assisted tools to reduce manual, repetitive work in troubleshooting, documentation, data extraction, video review, or test analysis.