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Control Systems Specialist

BW Systems

South Saint Paul, Minnesota

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JOB DETAILS
SKILLS
Acceptance Testing, Algorithms, Allen-Bradley, American National Standards Institute (ANSI), Automotive Automation, Commissioning, Control Systems, Conveyor Systems, Debugging Skills, Ethernet, Extrusion, Hardware Design, High Throughput, Human Machine Interface (HMI), IP (Internet Protocol), ISA Standards, ISO (International Organization for Standardization), Identify Issues, Industry Standards, Instrumentation, Logistics, Manufacturing Operations, Motion Control, Network Protocols, Pallet Jack, Product Flow, Programmable Logic Controller (PLC), Project/Program Coordination, Radio Frequency Identification (RFID), Regulations, Robotics, Safety Compliance, Safety Systems, Servomechanism, Supervisory Control and Data Acquisition (SCADA), System Architecture, System Integration (SI), System Start-Up, Systems/Internals Programming, Testing
LOCATION
South Saint Paul, Minnesota
POSTED
4 days ago

Key Responsibilities

System Architecture & Programming: Design, develop, and deploy comprehensive PLC and HMI/SCADA programs utilizing the Allen-Bradley Logix platform (Studio 5000 / RSLogix 5000).

Motion Control & Coordination: Program and commission high-speed, multi-axis synchronized motion systems (Kinetix servo drives, virtual master axes, electronic gearing, and camming) for precision manufacturing operations.

  • Conveyor & Material Handling Integration:
    • Design, program, and optimize complex material handling systems, including accumulation conveyors, sortation systems, palletizers, and automated guided vehicle (AGV) or autonomous mobile robot (AMR) handoffs.
    • Implement tracking, merging, diverting, and barcode/RFID scanning logic to ensure seamless product flow through high-throughput logistics and production lines.
  • Process & Web Handling Control:
    • Design and optimize control strategies for web handling (webline) applications, including tension control, winding/unwinding, and registration.
    • Engineer control algorithms for extrusion processes, ensuring tight temperature regulation, pressure control, and line speed synchronization.
    • Implement complex batch process sequences adhering to industry standards (e.g., ISA-88 principles).

Advanced Control Loops: Design, tune, and troubleshoot complex PID control loops, including cascade loops, ratio control, and advanced feed-forward control strategies to minimize disturbance and maximize process stability.

System Integration: Integrate third-party equipment, robotics, instrumentation, and vision systems into the primary control network using industrial protocols (EtherNet/IP, ControlNet, DeviceNet).

Debugging & Commissioning: Conduct rigorous on-site factory acceptance testing (FAT), site acceptance testing (SAT), troubleshooting, and system startup.

Safety Integration: Design and implement hardware and software safety systems compliant with relevant standards (ISO 13849 / ANSI B11.19) using Allen-Bradley GuardLogix controllers and safety-rated components.

Documentation: Create and maintain robust engineering documentation, including functional design specifications (FDS), control philosophy documents, I/O lists, cause-and-effect matrices, and as-built code comments.

 

About the Company

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BW Systems

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