Key Responsibilities and Required Skills for Electrical Controls Engineer

🎯 Role Definition

As an Electrical Controls Engineer, you are the architect and troubleshooter of the automated systems that power modern industry. You will be responsible for the entire lifecycle of control systems, from conceptual design and electrical schematic creation to PLC/HMI programming, system commissioning, and ongoing support. This role requires a unique blend of electrical engineering expertise, software development skills, and hands-on problem-solving. You will collaborate closely with cross-functional teams—including mechanical engineering, operations, and maintenance—to drive innovation, improve efficiency, and ensure the reliability and safety of our automated processes. This is a critical, high-impact position for a creative thinker who thrives on tackling complex challenges in a fast-paced environment.

📈 Career Progression

Typical Career Path

Entry Point From:

Junior Controls Engineer / Controls Engineer I
Automation Technician
Electrical Designer
Field Service Engineer

Advancement To:

Senior Electrical Controls Engineer
Controls Engineering Manager
Automation Project Manager
Principal Engineer

Lateral Moves:

Robotics Engineer
Systems Integration Engineer
Instrumentation & Controls (I&C) Engineer
Application Engineer

Core Responsibilities

Primary Functions

Design, develop, and deploy robust electrical control systems for industrial automation machinery and processes from concept to completion.
Create and maintain comprehensive electrical documentation packages, including schematics, panel layouts, and bills of materials (BOMs) using AutoCAD Electrical or similar E-CAD software.
Program, configure, and troubleshoot Programmable Logic Controllers (PLCs), primarily with Allen-Bradley (ControlLogix, CompactLogix) and Siemens (S7, TIA Portal) platforms.
Develop intuitive and functional Human-Machine Interface (HMI) and SCADA applications using software like Rockwell FactoryTalk View, Wonderware, or Ignition.
Integrate, configure, and tune Variable Frequency Drives (VFDs), servo motors, and motion control systems to meet machine performance requirements.
Lead the integration of industrial robots (e.g., Fanuc, KUKA, ABB) into automated cells, including programming, safety configuration, and end-of-arm tooling.
Manage controls-related aspects of capital projects, including developing project scope, estimating costs, creating timelines, and managing vendors.
Provide hands-on support during system installation, commissioning, and startup, ensuring systems are delivered on time and meet all functional requirements.
Troubleshoot and resolve complex electrical, software, and network issues on the plant floor to minimize downtime and improve OEE.
Ensure all designs and installations comply with relevant safety standards, including NEC, NFPA 79, and UL 508A.
Conduct Factory Acceptance Tests (FAT) and Site Acceptance Tests (SAT) to validate system functionality and performance against design specifications.
Develop and implement control strategies for process control, including PID loops and advanced control algorithms.
Specify and procure all electrical and control components, such as sensors, actuators, safety devices, and control panels.
Lead efforts to upgrade and modernize legacy control systems, migrating old platforms to current technology with minimal production impact.
Collaborate with mechanical and process engineers to define control requirements and ensure seamless system integration.
Establish and maintain industrial communication networks, including EtherNet/IP, Profinet, and Modbus TCP/IP.
Provide expert technical support and training to maintenance technicians and operators to enhance their troubleshooting capabilities.
Perform risk assessments on new and existing machinery to identify and mitigate potential electrical and functional safety hazards.
Drive continuous improvement initiatives by identifying opportunities to enhance machine performance, reliability, and operator safety through controls solutions.
Develop standardized programming and design templates to improve engineering efficiency and maintain consistency across projects.

Secondary Functions

Support ad-hoc data requests and exploratory data analysis related to machine performance.
Contribute to the organization's data strategy and roadmap, particularly regarding machine data acquisition (e.g., from PLCs to databases).
Collaborate with business units to translate data needs into engineering requirements for MES and SCADA systems.
Participate in sprint planning and agile ceremonies within the engineering and project management teams.
Mentor junior engineers and technicians, providing guidance on technical challenges and best practices.
Participate in formal safety audits and incident investigations.

Required Skills & Competencies

Hard Skills (Technical)

PLC Programming: Advanced proficiency in programming Allen-Bradley (Rockwell) ControlLogix/CompactLogix using Studio 5000 and/or Siemens S7/TIA Portal.
HMI/SCADA Development: Expertise in developing applications with FactoryTalk View ME/SE, Wonderware InTouch/ArchestrA, or Ignition SCADA.
Electrical Design: Strong experience with AutoCAD Electrical, EPLAN, or similar CAD software for creating schematics and panel layouts.
Motion Control: In-depth knowledge of configuring and tuning servo drives and VFDs (e.g., Rockwell Kinetix, Siemens SINAMICS).
Industrial Networking: Solid understanding of Ethernet/IP, PROFINET, Modbus, and other industrial communication protocols.
Robotics Integration: Hands-on experience with programming and integrating industrial robots (Fanuc, ABB, KUKA, etc.).
Safety Standards: Familiarity with implementing safety circuits and complying with standards like NEC, NFPA 79, and ISO 13849-1.
Component Selection: Ability to select and size control system components, including sensors, PLCs, power supplies, and safety relays.
Database/Scripting: Basic knowledge of SQL for data logging and scripting languages (e.g., Python, VBA) for automation tasks is a strong plus.
Troubleshooting: Exceptional hands-on ability to diagnose and resolve issues in complex, integrated automation systems.

Soft Skills

Analytical Problem-Solving: Ability to logically and systematically troubleshoot complex, multidisciplinary problems under pressure.
Communication: Excellent verbal and written communication skills to effectively collaborate with technical and non-technical stakeholders.
Project Management: Strong organizational skills to manage multiple projects simultaneously, from conception to completion.
Collaboration: A team-player mindset with a proven ability to work effectively in cross-functional teams.
Attention to Detail: Meticulous approach to design, documentation, and programming to ensure accuracy and safety.
Adaptability: Flexibility to adapt to changing project requirements, new technologies, and fast-paced work environments.

Education & Experience

Educational Background

Minimum Education:

Bachelor of Science (B.S.) degree in a relevant engineering discipline.

Preferred Education:

Master of Science (M.S.) in Electrical Engineering or a related field.
Professional Engineer (PE) license or other relevant certifications (e.g., PMP).

Relevant Fields of Study:

Electrical Engineering / Electrical Engineering Technology
Computer Engineering
Mechatronics Engineering
Automation & Control Engineering

Experience Requirements

Typical Experience Range: 3-10 years of direct experience in an electrical controls, automation, or systems integration role.

Preferred: Experience in a high-volume manufacturing, material handling, automotive, or process-oriented industry is highly desirable. Proven track record of leading controls projects from start to finish.