Controls Engineer, Power Conversion System

Tesla•Fremont, CA

1d•$80,000 - $168,000

About The Position

As a Manufacturing Controls Engineer for the Power Conversion System line, you’ll play a key role in sustaining, improving, and developing advanced automation systems that assemble and validate Tesla’s next-generation battery packs. You’ll work at the intersection of high-voltage systems, precision fastening, leak testing, and functional validation — collaborating closely with equipment and test engineers to maintain and enhance automated equipment critical to Power Conversion System build reliability and throughput. This role demands strong PLC and controls fundamentals, hands-on debugging skills, and a drive to push process efficiency in a high-complexity, high-precision environment. The ideal candidate thrives in ambiguity, acts autonomously, and has a deep technical understanding of automation that supports electro-mechanical assemblies.

Requirements

Degree in Electrical, Controls, or Mechatronics Engineering, or equivalent experience
3+ years of hands-on experience in controls engineering for automated manufacturing or electro-mechanical assembly systems
Proficiency in IEC 61131-3 PLC programming languages, especially structured text and ladder logic
Experience with Siemens TIA Portal (S7 series PLCs) / Beckhoff TwinCAT, Safety PLCs (SIMATIC Safety or TwinSAFE), and HMI/SCADA (WinCC, TwinCAT HMI, or Ignition)
Strong knowledge of motion control, servo systems, Conveyors, VFDs and fieldbus communications (EtherCAT, Profinet, DeviceNet)
Familiarity with battery pack assembly processes, including high-voltage system safety, leak testing, and electrical validation
Experience integrating vision systems (iRVision, Cognex, Keyence) and industrial robots (Fanuc, KUKA SCARA)
Experience in programming Fanuc and KUKA robots for dispense and pick and place applications
Demonstrated ability to perform root cause analysis and implement permanent corrective actions under fast-paced, high-stakes conditions
Understanding of automation architecture, component selection (sensors, drives, relays, circuit protection), and design for maintainability

Responsibilities

Lead controls engineering activities across PCS2 assembly and end-of-line validation stations — including fastener automation, HV connection, seal verification, and leak testing systems
Develop and sustain PLC and HMI programs (Siemens TIA Portal or Beckhoff TwinCAT) that ensure high equipment uptime, safety compliance, and operator efficiency
Collaborate with test and equipment engineering to integrate new test sequences, data interfaces, and product change requirements into existing automation
Drive process improvement using data-driven insights (OEE, downtime, MTBF) to optimize cycle time, quality, and safety
Troubleshoot PLCs, servo drives, robots, and field networks (EtherCAT, Profinet, or CANOpen) in real time to minimize production downtime
Design and approve electrical schematics, ensuring compliance with high-voltage and functional safety standards (SIL/PL)
Integrate and maintain third-party devices such as Atlas Copco DC Tools, CTS Leak Testers, Hipot Testers, and Weld Controllers for PCS-specific manufacturing operations
Conduct safety risk assessments and support pre-launch design reviews for new process cells
Partner with cross-functional teams (test, product, quality, and process) to implement controls solutions aligned with next-gen pack design and manufacturing strategies
Support 24/7 manufacturing operations and provide rapid responses to equipment faults or production-critical issues

Benefits

Along with competitive pay, as a full-time Tesla employee, you are eligible for the following benefits at day 1 of hire:
Medical plans > plan options with $0 payroll deduction
Family-building, fertility, adoption and surrogacy benefits
Dental (including orthodontic coverage) and vision plans, both have options with a $0 paycheck contribution
Company Paid (Health Savings Accounts) HSA Contribution when enrolled in the High-Deductible medical plan with HSA
Healthcare and Dependent Care Flexible Spending Accounts (FSA)
401(k) with employer match, Employee Stock Purchase Plans, and other financial benefits
Company paid Basic Life, AD&D
Short-term and long-term disability insurance (90 day waiting period)
Employee Assistance Program
Sick and Vacation time (Flex time for salary positions, Accrued hours for Hourly positions), and Paid Holidays
Back-up childcare and parenting support resources
Voluntary benefits to include: critical illness, hospital indemnity, accident insurance, theft & legal services, and pet insurance
Weight Loss and Tobacco Cessation Programs
Tesla Babies program
Commuter benefits
Employee discounts and perks program