Controls Engineer

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. 

As the Controls Engineer you will own controls execution for the magnet equipment portfolio within a massive 1 million square foot manufacturing facility expansion. 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. 

This role begins in Durham, NC and is expected to move to Benson, NC upon completion of new facility. 

Responsibilities 

• PLC Programming & Commissioning: Execute hands-on programming, debugging, and commissioning of Siemens and AllenBradley/Rockwell PLCs and HMIs for new and existing automation equipment. 
• Advanced Automation & System Integration: 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. 
• SCADA/MES Connectivity: 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. 
• Vendor Technical Support & FATs: 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. 
• Troubleshooting & Technical Escalation: Serve as the first-line, hands-on responder for diagnosing complex automation issues involving networks, motion systems, instrumentation, and industrial communication protocols. 

Deliverables You Will Develop, Review, or Support 

• Controls & IT: PLC code architecture, HMI screens, vision inspection programs, tag databases, network lists, and system backups. 
• Risk & Safety: Controls risk assessments, interlock/guarding logic, and safety rated PFMEA inputs. 
• Process Design: Controls layouts, network topology layouts, station cycle times, sequence diagrams, and automation simulations. 
• Engineering Diagrams: Electrical schematics, pneumatic drawings, controls panel layouts, and industrial network architecture. 
• Operations & Maintenance: Calibration procedures, I/O lists, instrumentation documentation, and controls hardware maintenance manuals.

Responsibilities and tasks outlined are not exhaustive and may change as determined by the needs of the business  

Qualifications 

• Bachelor’s or Masters degree in electrical engineering, Automation Engineering, Mechatronics, or related field with 3+ years of direct industrial automation and controls engineering experience. 
• Strong hands on experience programming and commissioning Siemens and AllenBradley/Rockwell PLCs and HMIs. 
• Deep understanding of servos, VFDs, highspeed conveyors, robotic cells, and automated material handling systems. 
• Proficiency with Ethernet/IP, Profinet, EtherCAT, OPCUA, and similar industrial communication standards.  
• Analog loop fundamentals, gas analyzer integration (O₂, pressure, flow), loop tuning, and the literacy to read and validate safety-rated circuits and safety PLC  

Must be a U.S. Person due to required access to U.S. export-controlled information or facilities  

Preferred Skills 

• Working experience with multiaxis robotic systems and machine vision platforms such as Cognex or Keyence. AGV experience is a strong plus. 
• Experience in heavy industrial, greenfield, chemical, or metallurgical manufacturing environments. 
• Experience developing SCADA applications in Ignition, Wonderware, or similar platforms. 
• 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. 
• Familiarity with Python, C++, or other high level languages for automation or data analytics. 
• Experience in regulated industries such as Defense, Aerospace, or Automotive.