Controls Engineer

<p><span data-contrast="none">Vulcan Elements is manufacturing American rare-earth permanent magnets for a secure, resilient future. With a focus on national security and economic resiliency, we serve critical industries such as defense, aerospace, and automotive powering a high-technology future. Vulcan Elements is building a team of ambitious professionals committed to Mission Focus, Technical Excellence, and Transparency.</span><span data-ccp-props="{"201341983":0,"335551550":6,"335551620":6,"335557856":16777215,"335559739":0,"335559740":240}"> </span></p> <p><span data-contrast="none">As the Controls Engineer you will own controls execution for the magnet equipment portfolio within a massive </span><strong><span data-contrast="none">1 million square foot manufacturing facility expansion</span></strong><span data-contrast="none">. You will own your equipment packages cradle-to-grave - design review, FAT witness, site commissioning, and sustaining support This is a high-impact, high-ownership leadership role requiring technical expertise in industrial automation. The role includes hands-on implementation and domestic travel to OEM FATs up to ~50% during test campaigns.</span><span data-ccp-props="{"201341983":0,"335551550":6,"335551620":6,"335557856":16777215,"335559739":0,"335559740":240}"> </span></p> <p><span data-contrast="none">This role begins in Durham, NC and is expected to move to Benson, NC upon completion of new facility.</span><span data-ccp-props="{"201341983":0,"335551550":6,"335551620":6,"335557856":16777215,"335559739":0,"335559740":240}"> </span></p> <p><strong><span data-contrast="none">Responsibilities</span></strong><span data-ccp-props="{"201341983":0,"335551550":6,"335551620":6,"335557856":16777215,"335559739":0,"335559740":240}"> </span></p> <ul> <li><span data-contrast="none">PLC Programming &amp; Commissioning</span><strong><span data-contrast="none">:</span></strong><span data-contrast="none"> Execute hands-on programming, debugging, and commissioning of Siemens and AllenBradley/Rockwell PLCs and HMIs for new and existing automation equipment.</span><span data-ccp-props="{"201341983":0,"335551550":6,"335551620":6,"335557856":16777215,"335559739":0,"335559740":240}"> </span></li> <li><span data-contrast="none">Advanced Automation &amp; System Integration</span><strong><span data-contrast="none">:</span></strong><span data-contrast="none"> Drive the integration and commissioning of robotics, conveyors, and motion control systems - including servos and VFDs - to enable seamless material flow and high reliability production operations.</span><span data-ccp-props="{"201341983":0,"335551550":6,"335551620":6,"335557856":16777215,"335559739":0,"335559740":240}"> </span></li> <li><span data-contrast="none">SCADA/MES Connectivity</span><strong><span data-contrast="none">:</span></strong><span data-contrast="none"> Configure and maintain communications between PLCs/HMIs and SCADA/Batch systems. Support tag mapping, alarming, and data acquisition to the site SCADA platform as required.</span><span data-ccp-props="{"201341983":0,"335551550":6,"335551620":6,"335557856":16777215,"335559739":0,"335559740":240}"> </span></li> <li><span data-contrast="none">Vendor Technical Support &amp; FATs</span><strong><span data-contrast="none">:</span></strong><span data-contrast="none"> Review vendor electrical schematics, controls architectures, and PLC/HMI logic. Participate in and support Factory Acceptance Tests (FATs) and Site Acceptance Tests (SATs) to ensure full compliance with functional and safety requirements.</span><span data-ccp-props="{"201341983":0,"335551550":6,"335551620":6,"335557856":16777215,"335559739":0,"335559740":240}"> </span></li> <li><span data-contrast="none">Troubleshooting &amp; Technical Escalation</span><strong><span data-contrast="none">:</span></strong><span data-contrast="none"> Serve as the first-line, hands-on responder for diagnosing complex automation issues involving networks, motion systems, instrumentation, and industrial communication protocols.</span><span data-ccp-props="{"201341983":0,"335551550":6,"335551620":6,"335557856":16777215,"335559739":0,"335559740":240}"> </span></li> </ul> <p><span data-contrast="none">Deliverables You Will Develop, Review, or Support </span></p> <ul> <li><span data-contrast="none">Controls &amp; IT</span><strong><span data-contrast="none">:</span></strong><span data-contrast="none"> PLC code architecture, HMI screens, vision inspection programs, tag databases, network lists, and system backups.</span><span data-ccp-props="{"201341983":0,"335551550":6,"335551620":6,"335557856":16777215,"335559739":0,"335559740":240}"> </span></li> <li><span data-contrast="none">Risk &amp; Safety</span><strong><span data-contrast="none">:</span></strong><span data-contrast="none"> Controls risk assessments, interlock/guarding logic, and safety rated PFMEA inputs.</span><span data-ccp-props="{"201341983":0,"335551550":6,"335551620":6,"335557856":16777215,"335559739":0,"335559740":240}"> </span></li> <li><span data-contrast="none">Process Design</span><strong><span data-contrast="none">:</span></strong><span data-contrast="none"> Controls layouts, network topology layouts, station cycle times, sequence diagrams, and automation simulations.</span><span data-ccp-props="{"201341983":0,"335551550":6,"335551620":6,"335557856":16777215,"335559739":0,"335559740":240}"> </span></li> <li><span data-contrast="none">Engineering Diagrams</span><strong><span data-contrast="none">:</span></strong><span data-contrast="none"> Electrical schematics, pneumatic drawings, controls panel layouts, and industrial network architecture.</span><span data-ccp-props="{"201341983":0,"335551550":6,"335551620":6,"335557856":16777215,"335559739":0,"335559740":240}"> </span></li> <li><span data-contrast="none">Operations &amp; Maintenance</span><strong><span data-contrast="none">:</span></strong><span data-contrast="none"> Calibration procedures, I/O lists, instrumentation documentation, and controls hardware maintenance manuals.</span></li> </ul> <p><em><span data-contrast="none">Responsibilities and tasks outlined are not exhaustive and may change as determined by the needs of the business</span></em><span data-contrast="none"> </span><span data-ccp-props="{"201341983":0,"335551550":6,"335551620":6,"335557856":16777215,"335559739":0,"335559740":240}"> </span></p> <p><strong><span data-contrast="none">Qualifications</span></strong><span data-ccp-props="{"201341983":0,"335551550":6,"335551620":6,"335557856":16777215,"335559739":0,"335559740":240}"> </span></p> <ul> <li><span data-contrast="none">Bachelor’s or Masters degree in electrical engineering, Automation Engineering, Mechatronics, or related field with </span><span data-contrast="none">3+ years of direct industrial automation and controls engineering experience.</span><span data-ccp-props="{"201341983":0,"335551550":6,"335551620":6,"335557856":16777215,"335559739":0,"335559740":240}"> </span></li> <li><span data-contrast="none">Strong hands on experience programming and commissioning </span><span data-contrast="none">Siemens and AllenBradley/Rockwell </span><span data-contrast="none">PLCs and HMIs.</span><span data-ccp-props="{"201341983":0,"335551550":6,"335551620":6,"335557856":16777215,"335559739":0,"335559740":240}"> </span></li> <li><span data-contrast="none">Deep understanding of servos, VFDs, highspeed conveyors, robotic cells, and automated material handling systems.</span><span data-ccp-props="{"201341983":0,"335551550":6,"335551620":6,"335557856":16777215,"335559739":0,"335559740":240}"> </span></li> <li><span data-contrast="none">Proficiency with Ethernet/IP, Profinet, EtherCAT, OPCUA, and similar industrial communication standards.</span><span data-ccp-props="{"201341983":0,"335551550":6,"335551620":6,"335557856":16777215,"335559739":0,"335559740":240}"> </span><span data-contrast="none"> </span></li> <li><span data-contrast="none">Analog loop fundamentals, gas analyzer integration (O₂, pressure, flow), loop tuning, and the literacy to read and validate safety-rated circuits and safety PLC </span><span data-ccp-props="{"201341983":0,"335551550":6,"335551620":6,"335557856":16777215,"335559739":0,"335559740":240}"> </span></li> </ul> <p><em><span data-contrast="none">Must be a U.S. Person due to required access to U.S. export-controlled information or facilities</span></em><span data-contrast="none"> </span><span data-ccp-props="{"201341983":0,"335551550":6,"335551620":6,"335557856":16777215,"335559739":0,"335559740":240}"> </span></p> <p><strong><span data-contrast="none">Preferred Skills</span></strong><span data-ccp-props="{"201341983":0,"335551550":6,"335551620":6,"335557856":16777215,"335559739":0,"335559740":240}"> </span></p> <ul> <li><span data-contrast="none">Working experience with multiaxis robotic systems and machine vision platforms such as Cognex or Keyence. AGV experience is a strong plus.</span><span data-ccp-props="{"201341983":0,"335551550":6,"335551620":6,"335557856":16777215,"335559739":0,"335559740":240}"> </span></li> <li><span data-contrast="none">Experience in heavy industrial, greenfield, chemical, or metallurgical manufacturing environments.</span><span data-ccp-props="{"201341983":0,"335551550":6,"335551620":6,"335557856":16777215,"335559739":0,"335559740":240}"> </span></li> <li><span data-contrast="none">Experience developing SCADA applications in Ignition, Wonderware, or similar platforms.</span><span data-ccp-props="{"201341983":0,"335551550":6,"335551620":6,"335557856":16777215,"335559739":0,"335559740":240}"> </span></li> <li><span data-contrast="none">Powder or bulk-solids handling controls (pneumatic conveying, gravimetric dosing, milling), hazardous-atmosphere or reactive-material environments (combustible dust, inert-gas blanketing, hydrogen service), or furnace/vacuum/thermal process controls.</span><span data-ccp-props="{"201341983":0,"335551550":6,"335551620":6,"335557856":16777215,"335559739":0,"335559740":240}"> </span></li> <li><span data-contrast="none">Familiarity with Python, C++, or other high level languages for automation or data analytics.</span><span data-ccp-props="{"201341983":0,"335551550":6,"335551620":6,"335557856":16777215,"335559739":0,"335559740":240}"> </span></li> <li><span data-contrast="none">Experience in regulated industries such as Defense, Aerospace, or Automotive.</span><span data-ccp-props="{"201341983":0,"335551550":6,"335551620":6,"335557856":16777215,"335559739":0,"335559740":240}"> </span></li> </ul> <p><strong>Physical and Environmental Requirements</strong></p> <p>The position requires regular presence on the production floor and the ability to navigate all areas of the facility. Candidates must be able to climb stairs, stand and walk for extended periods, and work in environments that may be hot, humid, or noisy. The role also requires the use of personal protective equipment, including respirators, and adherence to all applicable safety policies, procedures, and regulatory requirements. Employees must be able to complete required fit testing, wear appropriate PPE for the duration of assigned tasks, and respond safely to changing conditions within the production environment.</p> <p><span data-ccp-props="{"201341983":0,"335551550":6,"335551620":6,"335557856":16777215,"335559739":0,"335559740":240}"> </span></p>