Controls Engineer – Automation & Robotics Specialist

Ultra Corpotech Inc.•Conroe, TX

4d•Onsite

About The Position

We are seeking an experienced Controls Engineer – Automation & Robotics Specialist to design, program, integrate, troubleshoot, and continuously improve automated manufacturing equipment and robotic systems. The ideal candidate will have strong hands-on experience with ABB industrial robots, PLC programming, HMI/SCADA systems, servo/motion controls, industrial networks, sensors, and automated production equipment. This position will work closely with Production, Engineering, Maintenance, Quality, and Safety teams to maximize equipment reliability, improve cycle time and OEE, reduce downtime, and support new equipment and product launches.

Requirements

Bachelor's degree in Electrical Engineering, Controls Engineering, Automation Engineering, Mechatronics, Mechanical Engineering, or a related technical field.
5–10+ years of hands-on industrial controls and automation experience in a manufacturing environment preferred.
Demonstrated experience programming and troubleshooting ABB industrial robots.
Strong experience with PLC programming, preferably Allen-Bradley/Rockwell and/or Siemens.
Experience with robotic welding, automated assembly, material handling, press operations, or similar manufacturing processes is highly desirable.
Experience commissioning and troubleshooting automated manufacturing equipment.
Proficiency in: ABB robot programming, teaching, calibration, recovery, and troubleshooting
Proficiency in: PLC programming and troubleshooting
Proficiency in: Ladder Logic and Structured Text
Proficiency in: HMI/SCADA development
Proficiency in: Servo and motion control systems
Proficiency in: VFD configuration and troubleshooting
Proficiency in: Sensors, encoders, actuators, and instrumentation
Proficiency in: Industrial safety circuits and safety PLCs
Proficiency in: Electrical schematics and control panel design
Proficiency in: EtherNet/IP, PROFINET, Modbus, and industrial networking
Proficiency in: Robotic welding and automated manufacturing processes
Proficiency in: Root-cause analysis and equipment reliability improvement
Proficiency in: AutoCAD Electrical or equivalent electrical design software
Strong communication, analytical thinking, urgency, teamwork, and the ability to manage multiple automation projects in a fast-paced manufacturing environment are essential.

Nice To Haves

Python, SQL, C#, or similar programming/scripting experience is beneficial

Responsibilities

Design, develop, program, and maintain industrial automation and control systems.
Program, configure, teach, and troubleshoot ABB robotic systems, including robotic welding, material handling, machine tending, and other manufacturing applications.
Develop and troubleshoot PLC programs using Ladder Logic, Structured Text, Function Block, and other applicable programming languages.
Support PLC platforms such as Allen-Bradley/Rockwell, Siemens, or equivalent industrial control systems.
Develop and modify HMI and SCADA applications for machine operation, diagnostics, alarms, and production monitoring.
Integrate robots, PLCs, HMIs, servo drives, VFDs, safety systems, sensors, actuators, vision systems, and other automated equipment.
Troubleshoot electrical, controls, robotic, pneumatic, hydraulic, mechanical, and communication-related equipment issues.
Perform root-cause analysis on recurring equipment failures and implement sustainable corrective actions.
Optimize robotic paths, PLC logic, machine sequences, and cycle times to improve productivity and equipment performance.
Support robotic welding applications, including robot programming, weld sequencing, fixture interaction, and process optimization.
Develop and maintain electrical drawings, control schematics, I/O documentation, network architecture, and equipment documentation.
Support installation, startup, commissioning, validation, and acceptance testing of new equipment.
Participate in FAT/SAT, equipment qualification, PPAP, pilot production, and production-readiness activities.
Configure and troubleshoot industrial communication networks, including EtherNet/IP, PROFINET, Modbus, DeviceNet, and similar protocols.
Implement machine and robotic safety systems, including safety PLCs, interlocks, light curtains, safety scanners, emergency stops, and guarding.
Ensure control systems comply with applicable OSHA, NEC, NFPA, UL, and company safety standards.
Monitor equipment performance and support improvement of OEE, uptime, cycle time, quality, and throughput.
Provide technical training and troubleshooting support to maintenance technicians, operators, supervisors, and engineering personnel.
Maintain backups and version control for PLC, HMI, robot, drive, and other equipment programs.
Support continuous improvement, automation expansion, and Industry 4.0 initiatives.