Senior Controls Engineer - PLC and HMI Programming and Electrical Design

About the Position

Bronco Blast Equipment is seeking a hands-on Senior Controls Engineer to lead the development of electrical control systems for new and refurbished industrial shot blast machinery.

You will own controls projects from electrical design and sequence development through PLC/HMI programming, machine testing, and customer commissioning. You will also establish controls standards, guide component selection, review technical work, and provide technical guidance to engineering, assembly, and service personnel.

This position requires demonstrated experience independently delivering complete machine control systems, including original PLC/HMI programming and electrical design. Experience limited to equipment maintenance, electrical troubleshooting, or minor changes to existing programs does not meet the requirements of this role.

Required Qualifications

• Seven or more years of professional experience developing industrial machine control systems.
• Demonstrated ownership of complete controls projects, from initial requirements and electrical design through programming and successful commissioning.
• Strong proficiency developing original PLC programs using ladder logic and creating HMI screens, operating modes, alarms, and diagnostics.
• Ability to independently develop electrical schematics, I/O lists, component bills of materials, and controls architecture.
• Experience selecting and integrating PLCs, HMIs, VFDs, sensors, safety devices, and related controls components.
• Strong electrical troubleshooting skills and the ability to resolve complex machine sequencing, wiring, and device integration problems.
• Experience reviewing technical work, establishing controls standards, or mentoring other technical personnel.
• Bachelor’s degree in electrical engineering, electrical engineering technology, automation, or a closely related field; or an associate degree in a related technical field with substantial experience independently designing and programming industrial machine controls. The seven-year experience requirement applies to either education path.
• Ability to manage two to three concurrent projects, communicate project status, and identify risks before they affect completion.
• Ability to work on-site in Waukesha and travel to customer locations for commissioning and troubleshooting.

Responsibilities

• Lead controls development for new equipment, customized machines, retrofits, and rebuilds.
• Develop control system architecture, sequences of operation, electrical schematics, I/O lists, and component bills of materials.
• Write original PLC programs and develop HMI interfaces that support reliable operation and effective troubleshooting.
• Select, integrate, and configure PLCs, HMIs, VFDs, safety controllers, sensors, and related devices.
• Lead controls checkout, machine debugging, startup, and commissioning, including verification of safety circuits, interlocks, alarms, and auxiliary equipment.
• Establish and maintain reusable programs, electrical design practices, component standards, and documentation requirements.
• Review electrical designs and programs for reliability, maintainability, and consistency.
• Provide technical guidance to engineering, assembly, and service personnel.
• Resolve complex or recurring machine controls problems and implement lasting corrective actions.
• Coordinate controls scope, priorities, schedules, and technical risks with the Engineering Manager and project team.
• Maintain accurate drawings, program backups, revision records, and standard libraries.
• Support customer startups and field troubleshooting.

Preferred Qualifications

• Experience with an industrial equipment manufacturer or systems integrator.
• Horner OCS and Allen-Bradley programming experience.
• Function block programming experience.
• Knowledge of pneumatic and hydraulic controls.
• Electrical panel layout and hands-on panel assembly experience.

Work Environment and Travel

This position combines office-based engineering with hands-on work in our shop and at customer locations. The approximate workload is 70% programming, electrical design, and controls documentation; 20% machine build, debugging, and onsite startup support; and 10% field troubleshooting, typically within 150 miles.

Commissioning and startup require scheduling flexibility to complete projects successfully. Overnight travel: 1 week a quarter.

Why Join Bronco

Take ownership of complete machine controls projects and see your designs become operating equipment. You will work directly with the people designing, building, and servicing our machines and help shape the technical direction and standards of our growing controls department.

Bronco designs and manufactures standard and customized shot blast equipment and components. Learn more at www.broncoblast.com.

Benefits:

• 401(k)
• 401(k) matching
• Dental insurance
• Health insurance
• Paid time off
• Retirement plan

People with a criminal record are encouraged to apply

Application Question(s):

• How many years of professional experience do you have developing industrial machine control systems, including original PLC/HMI programming? Exclude experience limited to maintenance, troubleshooting, or minor edits to existing programs.
• Describe one machine controls project you personally led from initial requirements through commissioning. Identify the PLC/HMI platforms, the work you completed yourself, and the technical decisions you owned.
• Have you independently created electrical schematics, developed I/O lists, and selected controls components? Briefly describe your experience.
• Describe a controls standard, reusable program library, design improvement, or technical review process you introduced. How did it improve subsequent projects?
• What relevant degree or technical education have you completed?
• Can you work on-site in Waukesha, Wisconsin, and travel to customer locations for commissioning and troubleshooting as described in the posting?

Work Location: In person