Controls Engineer - Intellectt INC

Job Title: Controls Engineer
Location: Libertyville, IL
Job Type: Contract (12+ months)

Key Responsibilities:

• Design, program, and troubleshoot Allen Bradley Controllogix PLCs and Human Machine Interfaces (HMI/GUI) for manufacturing automation systems. Ensure that all systems meet regulatory and production requirements.
• Develop and integrate automation systems with manufacturing equipment and processes, ensuring optimal performance, reliability, and scalability.
• Lead and manage automation projects from concept through implementation, including planning, design, validation, and commissioning. Collaborate with cross-functional teams to meet project milestones and deliver high-quality results.
• Design systems with built-in fault tolerance, error handling, and recovery procedures to ensure continuous production uptime.
• Configure devices and automation systems to work within the factory's LAN/WAN Ethernet networks, setting up IP addresses, nodes, and secure communications between devices.
• Set up, tune, and troubleshoot Allen Bradley PowerFlex variable frequency drives and Kinetix multi-axis servo drives to ensure precise control of motors and machinery.
• Work with various industrial communication protocols such as ProfNet, DeviceNet, Ethernet/IP, and safety-rated field bus networks for seamless connectivity between control devices and production machinery.
• Implement and troubleshoot communication between PLCs, instruments, and data collection systems using RS-232, RS-422, RS-485, Profibus, Modbus RTU, and Ethernet protocols.
• Integrate and troubleshoot Cognex, Keyence, or Fanuc vision systems for product inspection and quality control.
• Tune PID controllers and implement closed-loop feedback systems to ensure process stability and precision in the manufacturing process.
• Specify and select appropriate control devices such as sensors, circuit protectors, safety hardware, and PLC hardware. Ensure that all safety standards and regulations are met in the design and implementation of control systems.
• Create detailed technical documentation, including control system designs, project plans, validation protocols, and troubleshooting guides in compliance with FDA and ISO regulations.
• Conduct in-depth root cause analysis (RCA) for automation-related issues, develop corrective actions, and implement solutions to prevent future occurrences.

Required Qualifications:

• Bachelor's degree in Electrical Engineering, Automation Engineering, or equivalent field.
• 7+ years of experience in a high-volume manufacturing or industrial automation environment, preferably in the medical device industry.
• Proven experience in programming and troubleshooting Allen Bradley PLCs using RSLogix5000, Studio 5000, FactoryTalk SE, and Ignition.
• Hands-on experience with Allen Bradley PowerFlex VFDs and Kinetix multi-axis servo drives.
• Proficiency in setting up devices on industrial Ethernet networks, as well as implementing serial communication between devices.
• Strong knowledge of ProfNet, DeviceNet, Ethernet/IP, and other industrial protocols.
• Experience in selecting and configuring control system components, including sensors, safety hardware, and remote I/O modules.
• Experience designing automation systems with fault detection, recovery, and error handling capabilities.

Desired Skills:

• Previous experience in the medical device manufacturing industry, with knowledge of regulatory standards such as FDA, cGMP, and ISO 13485.
• Familiarity with Cognex, Keyence, or Fanuc vision systems for automated inspection and quality control.
• Experience with Beckhoff or B&R (ABB) PLCs would be an asset.