Automation Controls Development Engineer
Company: Tesla Motors
Location: Elgin
Posted on: January 5, 2021
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Job Description:
The RoleTesla is seeking a highly motivated Controls Engineer to
contribute to the design and development of new automation
equipment and assembly lines.The Controls Engineer will work to
develop machine and process concepts along with several
Manufacturing Engineering peers. Candidate will create a robust
system architecture to support the concept, and then layout
electrical/pneumatic schematics. Once the electrical panel is
built, he/she will program all controls components such as PLC,
safety devices, HMI, servo drives, process hardware and robots from
power-on to debug, and finally to process fine tuning and
validation.The Controls Engineer will also work with
cross-functional teams throughout the entire life cycle of the
product and processes. He/She will work closely with Product Design
Engineering, Quality, Production and Maintenance to bring
components from initial design, through prototype development and
finally into full production.ResponsibilitiesIn-house equipment
development: Participate in initial equipment conceptual
development and carefully balance product specifications, process
control requirements, layout complexity, cost, quality and
lead-time limits. Lay out new industrial electrical control panels
which are NFPA79/NEC/UL508A compliant, and create electrical,
pneumatic and fluid schematics. Architect, write, and debug PLC
ladder logic with an emphasis on generating code that is organized,
structured, documented, maintainable and reusable. PLC code will
interact with subsystems such as conveyors, robots, Manufacturing
Execution System (MES), LabView, machine vision, and 3rd party
equipment. Implement (ANSI/RIA15.06/OSHA compliant) control
reliable safety systems for safeguarding robots, gantries,
conveyors, and other high volume manufacturing equipment. Generate
aesthetically simple HMI screens for complex machinery while
providing sufficient feedback for troubleshooting. Manage
electrical cabinet builds, field wiring, pneumatic and fluid
plumbing. Select and size electrical and electromechanical
components such as servos. Introduce automated processes into
production, and train and Maintenance and Production Teams to
support after deployment into production Create machine
interactions with plant-wide Manufacturing Execution System (MES)
to communicate product acceptability, machine status, and process
variables.Outsourced automation equipment development: Participate
in Tesla specification and standard creation, release to Vendor and
quote technical evaluation Enforce application of Tesla standards,
Manage suppliers during specification, design review, design
approval Establish test plans and control test plan execution at
Vendor and at Tesla facility during installation and buy-off
Characterize and validate new automated process equipment for
deployment into productionExisting automation equipment refinement:
Debug and optimize automated processes to maximize cycle time,
improve availability and yield. Characterize and validate automated
processes using a data driven approach such as simulation, Capacity
and Capability statistical test (Gage Repeatability and
Reproducibility test, Cpk, etc), Assembly Line Development and
Implementation Create detailed utility layouts for entire assembly
lines and interface with facilities teams for implementation Create
data management and tracking communications network architecture
and interface with cross-functional teams for product, processes
and quality traceability control implementation The ideal candidate
takes pride in his/her hands-on work, analytical ability,
organizational skills and attention to detail. He/She appreciates
an environment where superior work is encouraged, noticed and
rewarded and where individuals carry tremendous responsibility.
He/She looks forward to learning an incredible amount on the
job.Requirements: Proficiency with process integration and
electromechanical / mechatronic systems In depth knowledge of
Electrical Standards (NFPA79, National Electric code, UL508A). In
depth knowledge of Safety standards (ANSI/RIA15.06, OSHA). Advanced
proficiency programming industrial equipment: Ladder logic PLCs
(Allen Bradley ControlLogix, CompactLogix and RSLogix 5000) Safety
PLCs (Allen Bradley ControlLogix, SmartGuard) Human Machine
Interface (HMI / GUI - AB Panelview, FactoryTalk, LabView,
Ignition) Field bus Networks (AB DeviceNet, Ethernet IP, Safety
rated field bus networks) Serial communication (RS-232) between
PLCs and instruments Ethernet communications between machine PLCs
and database systems Demonstrated excellence in programming PLCs.
Must have a well-defined methodology for maintaining code structure
and organization. Ability to program state machines for complex
processes which involve multi-station parallel processing, pick and
place automation, data acquisition, and PID control. Proven ability
to design fault-tolerant systems with error handling and recovery.
Proficiency selecting appropriate circuit protectors, wire and
cable, sensors, safety hardware, PLC hardware, remote I/O, VFD and
servo systems. Proficiency creating detailed electrical and fluid
schematics in CAD (AutoCAD Electrical preferred) Proficiency
programming and tuning variable frequency drives Exposure to a wide
variety of production machinery, industrial sensors, and equipment
(LVDT and pressure transducers, dispense systems, temperature
controllers, DC nutrunner torque controllers, current and power
meters, etc) Experience programming Cartesian, SCARA and
Articulated robots is highly desired (Fanuc, Kuka, Motoman, Epson)
Experience with Vision systems (Cognex, Keyence, Fanuc) Experience
creating technical specifications for automated manufacturing
equipment is highly desired Experience transitioning products and
processes from prototype to production desired Knowledge of
production quality metrics is a plus Ability to use 3D CAD packages
such as with SolidWorks and CATIA is a plusQualifications BS/MS
Electrical Engineering (or equivalent - Majors in: Controls and
Computer Control Systems, Mechatronic Engineering, Automation
Engineering, etc.) 2-4 years of experience as a hands-on Controls
Engineer or Applications Engineer working on automation and/or
electromechanical systems
Keywords: Tesla Motors, Elgin , Automation Controls Development Engineer, Engineering , Elgin, Illinois
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