Automation Controls Development Engineer

Job Description

The Role

We are looking for a highly motivated, meticulously detail-oriented individual to support the Automation Development Team in Brooklyn Park, Minnesota in designing and building the automation and robotic equipment that builds world-class battery packs and cars. This includes providing complete electrical and software design for automated machines. Controls engineers are responsible for owning and implementing the design from project concept to installation; this includes machine concepting, proof-of-principle, electrical design/layout, software design/programming, debug of hardware/software, acceptance testing, and installation/integration on the line at the factory. Because of each Tesla machine is a custom design and build, the controls engineer must have a desire to learn and implement rapidly changing technology to deliver the best possible solution. This full-time role requires the flexibility of being able to travel to other Tesla facilities.

The ideal candidate takes pride in their ability to play numerous roles as a project advances through its many phases (concept, detailed design, proof-of-principle testing, integration, deployment, and validation). Communication skills, analytical ability, and great attention to detail while working under tight deadlines are of paramount importance. This candidate is familiar with and appreciates an environment where individuals carry tremendous responsibility and where superior work is encouraged, noticed, and rewarded. This candidate enjoys cheerfully engaging and productively contributing with other engineers, and thrives on daily interaction with high-caliber people. This candidate also has a keen understanding of how to work with and/or motivate diverse engineering teams.

The primary role of a Controls Engineer is to lead all controls aspects (concept, electrical design, programming, debug, installation, and integration) of mid-size ($500k - $5M) custom machine design and build projects. This includes mentoring and developing less experienced controls engineers to become strong leaders. A Controls Engineer normally receives little instruction on day-to-day work and minimal instruction on new assignments. This individual should have a full understanding of controls engineering and can solve most problems on their own, and will network with peers for issues they do not have experience with. This individual will work on a diverse set of problems where analysis is required. A Controls Engineer leads projects to completion unassisted or with a small team of controls engineers. Failure to obtain results or erroneous decisions or recommendations of a Controls Engineer typically results in a considerable expenditure of resources to meet schedule.

Responsibilities

Electrical Design

• Prototyping using overnight machined parts from our fabrication shop, cardboard and duct tape, or other readily available materials is strongly encouraged.
• Participate in machine risk assessments and ensure OSHA and RIA15.06 safety standards are met.
• Create electrical schematics and bill of materials to meet project requirements.
• Interface with panel shop to ensure electrical panels meet project requirements.
• Support assembly department by clarifying any design questions they may have.

Software Design

• Create application design documentation/flow charts and lead software design reviews.
• Program all software for unique projects with a variety of needs (PLC, HMI/SCADA, Servo, Robotics, Vision, Laser, etc.).

Start-up and Debug

• Test and verify all electrical wiring for the entire system: safety circuit, IO, communications, etc.
• Work with assembly personnel and mechanical design engineer to ensure all mechanical setups and alignments are properly completed.
• Debug and test all software to meet project requirements.
• Work to ensure the machine requirements are fulfilled and the machine is satisfactory before it is shipped to the factory.

Acceptance

• Assist in testing and documenting final machine operation.
• Provide training and support as needed.

Documentation

• Assist technical writer with the creation of user manual for the machine.
• Validation and/or GAMP documentation and testing where required.

Installation

• Travel to the Tesla factory and ensure smooth installation and startup.
• Train local factory controls engineers to support equipment during production.

Desired Experience

• Electrical schematic design and drafting using AutoCAD Electrical
• PLC controls (primarily Allen Bradley CompactLogix & ControlLogix)
• HMI/SCADA (preferably Ignition)
• Servo Motion (preferably Allen Bradley servos)
• Vision Inspection & Vision-guided motion (preferably Cognex VisionPro or InSight or Keyence)
• Robots: 6-axis & SCARA (preferably FANUC and Kuka)
• Industrial networking protocols: Ethernet/IP, RS232, Profinet, Ethernet TCP/IP, EtherCAT, etc.
• Industrial instrumentation and PID loop control

Requirements

• BS Electrical Engineering (or equivalent – Majors in: Controls and Computer Control Systems, Mechatronic Engineering, Automation Engineering, Mechanical Engineering, etc.)
• 2 – 20+ years of experience in custom automation.

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