Senior Controls and Automation Engineer

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POSITION TITLE: Senior Controls and Automation Engineer

DEPARTMENT: Engineering

REPORTS TO: Engineering Manager

LOCATION: Viola

JOB SUMMARY:

A Senior Controls & Automation Engineer to design, build, and support custom automated test equipment, manufacturing systems, and embedded control solutions for powertrain development and production support.This role bridges industrial automation, embedded hardware/firmware, and system integration, supporting everything from robotic test cells and PLC-controlled machinery to ECU-integrated embedded devices and Windows-based engineering tools.

The ideal candidate is a hands-on engineer comfortable working across electrical design, firmware, PLCs, robotics, HMIs, and on-site commissioning of one-off and low-volume systems

ESSENTIAL FUNCTIONS:

Industrial Automation & Controls

• Design, modify, and maintain automated test stands, endurance systems, and manufacturing equipment

• Program and troubleshoot PLCs and HMIs for presses, test fixtures, and special-purpose machinery

• Integrate industrial robots with presses and test systems, including interlocks and safety logic

• Retrofit and modernize legacy equipment where original electronics or controls are obsolete

• Support and repair custom, one-off automation equipment used in engineering and manufacturing

Embedded Hardware & Firmware

• Design custom embedded control hardware for test systems and product prototypes

• Develop firmware in C/C++ for microcontroller-based controllers

• Implement CAN bus communication with ECUs and vehicle subsystems

• Create embedded solutions for sensors, actuators, motor control, and data acquisition

• Support prototype development through testing, iteration, and limited production readiness

Test Systems & Instrumentation

• Develop automated engine and motorcycle test systems for endurance, EPA mileage accumulation, and performance testing

• Build systems for dyno automation, robotic control, and long-duration unattended operation

• Integrate sensors, cameras, and data acquisition hardware for mechanical and powertrain analysis

• Develop data visualization and processing tools for test and lab environments

Software & Interfaces

• Develop Windows-based engineering and test applications (Visual Studio / C#)

• Interface off-the-shelf HMIs and custom hardware for operator control and remote monitoring

• Support configuration and calibration tools for embedded and test systems

ECU & System Integration

• Integrate and interface with automotive ECUs, including CAN messaging and control features

• Support ECU feature development and experimentation for R&D projects

• Work closely with engineering and manufacturing teams to support powertrain development

• Reverse engineer CAN bus data in order to interface various ECUs with custom test equipment

QUALIFICATIONS:

• Bachelor’s degree in Electrical Engineering, Computer Engineering, Mechatronics, or equivalent experience

• 5+ years experience in industrial automation, controls engineering, or custom machinery

• Strong experience with:

  • PLC programming and industrial I/O

  • Embedded firmware development (C/C++)

  • Electrical schematics and hardware design, PCB layout. 

  • Sensors, actuators, motors, VFDs, and safety circuits