Senior Controls & ABB Robotics Engineer

Impact Solutions•Waukesha, WI

4d•$120,000•Onsite

About The Position

If you are an elite controls and robotics engineer feeling stifled by rigid corporate structures or repetitive plant maintenance, this direct-hire engineering seat is your ticket to true technical autonomy. Operating as a certified, premier custom industrial automation systems integrator in the Waukesha area, this organization maintains a robust backlog of custom contracts spanning aerospace, medical, and consumer goods sectors. Instead of repetitive production lines, you will own and architect custom, first-of-their-kind machinery tailored to complex application requirements. Operating out of a tech-driven facility where design engineering and physical assembly live under one roof, you will lead projects from blank-screen simulations and PLC logic architecture all the way to watching your physical machinery drive dynamic production on the floor.

Requirements

5+ Years Systems Integration Depth: Verifiable track record designing, programming, and deploying custom automated machinery within an automation integrator or custom OEM environment.
Dual Controls & Robotics Competency: Demonstrated capability writing Rockwell PLC programs (Studio 5000) combined with advanced ABB robot programming (RobotStudio / RAPID).
Hardware & Safety Architecture Mastery: Deep working knowledge of servo motion systems, machine vision calibration, industrial networking, and RIA/ISO safety regulations.
Engineering Foundation: Bachelor’s Degree in Electrical, Mechanical, or Automation Engineering preferred (equivalent hands-on custom integration depth fully valued).
Travel Flexibility: Valid U.S. Passport and complete availability to undertake up to 30% domestic and global field travel.
Location & Work Eligibility: Residence established within daily commuting distance of the Greater Waukesha, WI area, and US Citizenship or Green Card holder status.

Nice To Haves

Secondary Robot Platform Experience: Supplementary programming capabilities on FANUC (KAREL/TP), KUKA, or Yaskawa Motoman controllers.
Virtual Commissioning & Simulation: Experience utilizing advanced 3D digital twin or virtual commissioning software to validate cycle times prior to physical build.
Advanced Motion & Torque Tuning: Direct experience tuning high-speed multi-axis servo systems for precise part placement or high-speed insertion.

Responsibilities

Lead End-to-End Automation Execution: Serve as the lead controls authority, owning full project lifecycles from preliminary concept and simulation through shop floor debug and final client sign-off.
Develop ABB Robotics Systems: Program, simulate, and refine complex multi-axis robotic paths from scratch utilizing ABB RobotStudio and native RAPID coding structures.
Engineer Master Control Logic: Write, test, and integrate master PLC logic and HMI applications (primarily Rockwell Allen-Bradley Studio 5000 and FactoryTalk) to govern complete cell operations.
Architect Industrial Networks: Configure fieldbus network communications (EtherNet/IP, PROFINET) bridging multi-axis robots, central controllers, safety devices, and external peripherals.
Design Machine Safety Interlocks: Implement Category 3/4 safety architectures, safety PLCs, light curtains, and physical interlocks in strict adherence to RIA/ISO benchmarks.
Integrate Vision & Motion: Partner cross-functionally with mechanical design teams to integrate vision systems (Cognex, Keyence), servo motion drives, and specialized End-of-Arm Tooling (EOAT).
Execute Site Deployments: Lead customer site deployments up to 30% of the year worldwide to conduct Site Acceptance Testing (SAT) and complete client operational handoffs.