Overview

Senior Controls Engineer Location: Norcross, GAEmployment: Full-TimeReports To: Operations Manager Compensation: Competitive, Based on ExperienceTravel: Approximately 10-15%, for on-site commissioning and system integration Position Overview We are seeking a Senior Controls Engineer with strong software development skills to design, build, and deploy next-generation motion control, machine vision, and robotic systems. This is a hands-on engineering role centered on writing and architecting production-grade code not just configuring existing systems. The ideal candidate combines deep expertise in Beckhoff TwinCATmotion and control programming with real software development experience building AI-based vision applications, and brings a mechatronics mindset that spans mechanical, electrical, and software disciplines. This role owns the full development lifecycle for control and vision software: architecture, coding, testing, integration, deployment, and ongoing support working closely with mechanical, electrical, and robotics engineers to bring automated systems from concept to production. Key Responsibilities Design, develop, and maintain motion control and machine control software using Beckhoff TwinCAT 3, including structured text, function block, and object-oriented PLC programming (IEC 61131-3). Develop and integrate AI-based machine vision software for part inspection, guidance, defect detection, and qualitycontrol, using tools such as OpenCV, TensorFlow, PyTorch, Cognex VisionPro, Keyence, or Halcon. Build and train vision models (classification, object detection, defect segmentation) and integrate them into real-time production control systems. Program and integrate industrial and collaborative robots (e.g., Universal Robots, FANUC, ABB, KUKA) for pick-and-place, assembly, inspection, and material handling applications. Architect mechatronic systems that unify motion control, sensing, vision, and robotics into cohesive, reliable automated machines. Write clean, modular, well-documented, and version-controlled code (Git) for control and vision applications, following software engineering best practices. Develop and maintain automated testing, validation, and simulation frameworks to verify system behavior prior to on-site deployment. Design and implement communication architectures between PLCs, vision systems, robots, and higher-level software (EtherCAT, EtherNet/IP, OPC-UA, TCP/IP, REST APIs). Collaborate with mechanical and electrical engineers throughout the design process to ensure control, vision, and roboticsystems are integrated from the ground up rather than bolted on after the fact. Commission new systems on-site, including software deployment, calibration of vision systems, robot path tuning, and full system integration testing. Troubleshoot and debug complex control, vision, and robotic system issues in both development and live production environments. Conduct root cause analysis on system failures and implement software and hardware improvements to increase reliability, throughput, and accuracy. Create and maintain technical documentation including software architecture diagrams, code documentation, visionmodel performance reports, and commissioning records. Mentor junior engineers on coding practices, motion control theory, and vision/robotics system design. Stay current with advances in industrial AI, machine vision, and motion control platforms, recommending new tools and approaches to improve system capability. Required Qualifications 8+ years of experience in controls engineering with a strong software/programming component, ideally including motioncontrol and machine vision or robotics development. Hands-on software development experience with Beckhoff TwinCAT 3 motion and control platforms, including structured text and object-oriented programming approaches. Demonstrated experience developing or integrating machine vision software, including familiarity with AI/ML-based vision tools (OpenCV, TensorFlo