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Job description
Job Description Job Description POSITION TITLE: Senior Controls and Automation Engineer
DEPARTMENT: Engineering
REPORTS TO: Engineering Manager
LOCATION: Viola
JOB SUMMARY:
A Senior Controls & Automation Engineer to design, build, and support custom automated test equipment, manufacturing systems, and embedded control solutions for powertrain development and production support.This role bridges industrial automation, embedded hardware/firmware, and system integration, supporting everything from robotic test cells and PLC-controlled machinery to ECU-integrated embedded devices and Windows-based engineering tools.
The ideal candidate is a hands-on engineer comfortable working across electrical design, firmware, PLCs, robotics, HMIs, and on-site commissioning of one-off and low-volume systems
ESSENTIAL FUNCTIONS:
Industrial Automation & Controls
Design, modify, and maintain automated test stands, endurance systems, and manufacturing equipment
Program and troubleshoot PLCs and HMIs for presses, test fixtures, and special-purpose machinery
Integrate industrial robots with presses and test systems, including interlocks and safety logic
Retrofit and modernize legacy equipment where original electronics or controls are obsolete
Support and repair custom, one-off automation equipment used in engineering and manufacturing
Embedded Hardware & Firmware
Design custom embedded control hardware for test systems and product prototypes
Develop firmware in C/C++ for microcontroller-based controllers
Implement CAN bus communication with ECUs and vehicle subsystems
Create embedded solutions for sensors, actuators, motor control, and data acquisition
Support prototype development through testing, iteration, and limited production readiness
Test Systems & Instrumentation
Develop automated engine and motorcycle test systems for endurance, EPA mileage accumulation, and performance testing
Build systems for dyno automation, robotic control, and long-duration unattended operation
Integrate sensors, cameras, and data acquisition hardware for mechanical and powertrain analysis
Develop data visualization and processing tools for test and lab environments
Software & Interfaces
Develop Windows-based engineering and test applications (Visual Studio / C#)
Interface off-the-shelf HMIs and custom hardware for operator control and remote monitoring
Support configuration and calibration tools for embedded and test systems
ECU & System Integration
Integrate and interface with automotive ECUs, including CAN messaging and control features
Support ECU feature development and experimentation for R&D projects
Work closely with engineering and manufacturing teams to support powertrain development
Reverse engineer CAN bus data in order to interface various ECUs with custom test equipment
QUALIFICATIONS:
Bachelor's degree in Electrical Engineering, Computer Engineering, Mechatronics, or equivalent experience
5+ years experience in industrial automation, controls engineering, or custom machinery
Strong experience with:
PLC programming and industrial I/O
Embedded firmware development (C/C++)
Electrical schematics and hardware design, PCB layout.
Sensors, actuators, motors, VFDs, and safety circuits
Hands-on experience commissioning and troubleshooting machines in real-world environments
Worksite address
viola, WI, 54664, US
Who can apply
Review the original listing for work authorization, qualifications and employer requirements.