Senior Controls Engineer- Mobile Machinery

Federal Signal Openings•Elgin, IL

About The Position

The primary tasks are controls programming (50% or more of the role), with the remainder split between electrical schematic/harness design and HMI design. The position provides senior-level technical leadership through design reviews, verification, and mentoring. Controls Programming: Develop, test, and release embedded controller software, including interlocks, sequencing, fault handling, and CAN J1939 and Ethernet communications. Translate machine requirements into controls architecture application logic, function blocks, libraries, and diagnostic functions. Manage software source control, branching, versioning, and release documentation. Electrical Schematic and Harness Design: Design and release electrical schematics and vehicle wiring harnesses, including power distribution, circuit protection, connectors, and conductor sizing. Select and integrate controllers, displays, power-distribution modules, keypads, sensors, actuators, and related devices. HMI and Diagnostics: Design and develop operator display/HMI applications and keypad behavior. Define onboard diagnostics and fault reporting for operators and service technicians. Verification and Technical Leadership: Plan and execute bench and vehicle-level verification. Troubleshoot complex electrical, communications, and system-integration issues. Lead technical reviews of controls designs and provide mentoring. Support product development, production and service. Occasional travel to customers and trade shows. Flexibility to perform other duties and assignments as required.

Requirements

Bachelor’s Degree in Electrical, Controls, Mechatronics, Mechanical, or Computer Engineering, or a related engineering discipline.
5+ years of controls engineering experience on mobile machinery, vehicles, or industrial equipment, including both embedded controls programming and electrical design.
Experience leading controls design through release.
Proficiency programming embedded controllers in a controls-development environment such as CODESYS (IEC 61131-3), IQAN, MATLAB/Simulink, Raptor, or equivalent.
Experience with Git or equivalent version control.
Experience integrating electrical hardware with electronic control modules.
Experience designing and releasing electrical schematics and vehicle wiring harnesses.
Experience developing and executing bench and vehicle-level verification tests.
Experience developing operator display/HMI applications.

Nice To Haves

CODESYS 3.5 (IEC 61131-3), Structured Text, and Function Block Diagram experience.
Familiarity with FMEA, Functional Safety, and Vehicle Cybersecurity (e.g., ISO 26262, ISO 21434).
Experience with MIL/SIL/HIL, automated software testing, requirements management, or model-based development.
Scripting or programming experience (e.g., Python, C/C++) and use of AI-assisted engineering tools.
Experience with CAN J1939 and ethernet networks.

Responsibilities

Develop, test, and release embedded controller software, including interlocks, sequencing, fault handling, and CAN J1939 and Ethernet communications.
Translate machine requirements into controls architecture application logic, function blocks, libraries, and diagnostic functions.
Manage software source control, branching, versioning, and release documentation.
Design and release electrical schematics and vehicle wiring harnesses, including power distribution, circuit protection, connectors, and conductor sizing.
Select and integrate controllers, displays, power-distribution modules, keypads, sensors, actuators, and related devices.
Design and develop operator display/HMI applications and keypad behavior.
Define onboard diagnostics and fault reporting for operators and service technicians.
Plan and execute bench and vehicle-level verification.
Troubleshoot complex electrical, communications, and system-integration issues.
Lead technical reviews of controls designs and provide mentoring.
Support product development, production and service.
Occasional travel to customers and trade shows.
Flexibility to perform other duties and assignments as required.