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Controls Engineer (Hardware Design Focus - Material Handling Systems)

Dearborn, MI
Work for as the Controls Engineer for a company that offers challenging work assignments and competitive compensation!

Our client has a culture that emphasizes employee happiness and offers:
  • challenging work assignments
  • an onsite fitness center
  • tuition reimbursement
  • competitive pay/benefits
  • many career development and team-building opportunities
  • philanthropic activities 
Job Summary:
As a Controls Engineer, you will design controls systems including hardware design, software design, network configurations, power distribution, and the selection of field devices for a variety of manufacturing processes, including material handling and parcel handling systems. PLC programming is not involved in this role. 

Primary Responsibilities:
  • Understand the basics of mechanical systems and manufacturing processes for which control systems will be designed.
  • Provide feedback on mechanical designs where necessary for control considerations.
  • Participate in overall engineering of system designs, system flow schematics, general layouts and detailed sequence of operations.
  • Understand and be familiar with client specifications and electrical code/standards.
  • Coordinate with project teams and clients to prepare project specifications and scope of work for controls design and system installation.
  • Specify and design power distribution systems, including substations, bus duct and power distribution panels.
  • Specify and design power distribution to and within production and process equipment. Perform calculations and designs relative to demand and diversity factors, bus loading, voltage drops, circuit protection and coordination, feed sizing, distribution equipment sizing, etc.
  • Specify and design control panels, motor control centers and motor control panels. This includes selection of control panel components including circuit breakers, power supplies, motor starters, VFD’s, relays, etc.
  • Specify field devices for controls systems. This includes the selection of the devices and the interface of them in the overall system design.
  • Design installation drawings including cable tray and conduit layouts, field interconnect diagrams and bill of materials.
  • Specify equipment and interface for stand-alone control systems such as AVI readers, including both bar code readers and RF systems.
  • Participate in engineering of material handling applications including speed matching, position synchronization, product tracking, transfer systems, etc.
  • Specify and design PLC control systems. This includes selection of hardware components including type of PLC’s, I/O modules, communication cards, interface modules, etc.
  • Specify operator interface requirements, HMI components and related programming software.
  • Schematic design of PLC network systems for communication and control. This would also include PLC to PLC and PLC to I/O communications.
  • Schematic design of upper level production support systems.
  • Specify and design lighting systems for industrial production applications.
  • Specify and design control and power distribution system installation work, provide budget estimate input for control systems and related installation work.
  • Provide project scheduling input for control systems implementation. Review project schedules and identify the engineering, design and CAD resources trades to complete the projects.
  • Review and approve of fabrication drawings for controls systems including control panels, MCCs (Motor Control Centers), field devices and production equipment prior to shipment to site.
  • Review and approve fabrication of controls systems including control panels, MCCs, and production equipment prior to shipment to site. This includes visiting fabricators of equipment being provided. This will include traveling to the vendors.
  • Participate in review of the installation of the systems being installed. This review will include the mechanical systems, as well and the electrical installation. This will include traveling to the project job sites.
  • Participate in the system commissioning, including initial system checks, inspection of wiring, powering up of the equipment, start-up, debug, balancing and testing, and finally provide punch-listing of the installation.
  • Review and approve system as-built drawings.
  • Perform field checking of existing equipment, sites, and facilities.

  • Education / Experience:  Bachelor's Degree in an engineering discipline from an accredited university with at least 5 years of related work experience. 
  • Skills/Competencies:
    • Proficient in material handling and conveyor controls, hardware and software design and engineering.
    • Previous Automatic Vehicle Identification (AVI), product routing and tracking, Quality Audit Systems (QAS) and Plant Floor Monitoring Systems (PFMS) experience preferred.
    • Previous experience with PLCs (e.g., Allen Bradley Control Logix family, Siemens S series), HMIs and networks (Profibus, Ethernet, DeviceNet, etc.), and related software packages.
    • Proficient in AutoCAD and MS Office.
    • Good verbal and written communication skills
    • Must be able to travel and accept field assignments (outside of the Detroit area) to promote project success (however the travel is very little!).

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