Senior Automation Engineer – RobotStudio, Rockwell PLCs & Vision Systems

Impact Solutions•Waukesha, WI

1d•Onsite

About The Position

The Senior Automation Engineer will lead the design, programming, integration, and deployment of custom industrial automation machinery for a certified systems integrator serving aerospace, medical, and consumer goods sectors. The role spans the complete project lifecycle, from concept development and virtual simulation through PLC and robot programming, physical shop-floor debugging, customer-site commissioning, and final client sign-off. The engineer works in a Waukesha-area facility where design engineering, software development, simulation, and physical assembly take place under one roof. The technical scope includes ABB RobotStudio and RAPID, Rockwell Allen-Bradley PLCs using Studio 5000 and FactoryTalk, multi-axis servo systems, machine vision, industrial Ethernet networks, and machine-safety systems. The position includes up to 30% domestic and international travel for client installations, commissioning, and Site Acceptance Testing. It is a direct-hire role with a first-shift schedule and a base compensation package of up to $120,000, plus performance incentive bonuses, paid travel expenses, and a corporate benefits package.

Requirements

At least 5 years of experience designing, programming, and deploying custom automated machinery in an automation integrator or custom OEM environment.
Demonstrated ability to program Rockwell PLCs using Studio 5000 and advanced ABB robots using RobotStudio/RAPID.
Working knowledge of servo motion systems, machine-vision calibration, industrial networking, and RIA/ISO safety regulations.
Valid U.S. passport and availability for up to 30% domestic and international travel; alternatively, readiness to obtain a passport is stated in the job overview.
Residence within daily commuting distance of Greater Waukesha, Wisconsin.
U.S. citizenship or Green Card holder status.
Bachelor’s degree in Electrical, Mechanical, or Automation Engineering is preferred; equivalent hands-on custom integration experience is valued.

Nice To Haves

Programming experience with FANUC (KAREL/TP), KUKA, or Yaskawa Motoman controllers.
Experience with 3D digital-twin or virtual-commissioning software to validate cycle times before physical builds.
Experience tuning high-speed multi-axis servo systems for precise part placement or high-speed insertion.

Responsibilities

Lead end-to-end automation project execution, from concept and simulation through shop-floor debugging and final customer sign-off.
Program, simulate, and refine multi-axis robotic paths using ABB RobotStudio and RAPID.
Write, test, and integrate master PLC logic and HMI applications, primarily with Rockwell Allen-Bradley Studio 5000 and FactoryTalk.
Configure industrial fieldbus communications, including EtherNet/IP and PROFINET, connecting robots, controllers, safety devices, and peripherals.
Design and implement machine-safety architectures, including Category 3/4 systems, safety PLCs, light curtains, and physical interlocks in accordance with RIA/ISO benchmarks.
Integrate machine-vision systems, servo motion drives, and End-of-Arm Tooling in collaboration with mechanical design teams.
Lead customer-site deployments, perform Site Acceptance Testing, and complete operational handoffs.
Travel to domestic and international customer sites for installations and commissioning, up to 30% of the year.