Virtual Commissioning Engineer, Controls Engineering

The Virtual Commissioning Engineer develops and deploys high‑fidelity simulation and digital‑twin environments to validate automated equipment PLC logic, motion control, and system behavior prior to commissioning. You will integrate physics‑based models with real‑time control systems, execute model‑in‑loop and hardware‑in‑loop testing, build reusable component libraries, and contribute to predictive model‑driven engineering workflows. This role sits at the intersection of controls engineering, automation, and system modeling, requiring the ability to reason across both the virtual and physical domains. The ideal candidate is equally comfortable with PLC logic and with high‑fidelity simulation or digital‑twin development.

Responsibilities:

• Develop 2D/3D and physics‑based simulation environments for automated machinery and industrial equipment.
• Build and validate MIL (model‑in‑loop), SIL (software‑in‑loop), and HIL (hardware‑in‑loop) test setups for PLC‑controlled systems.
• Create and maintain simulation/VC component libraries representing automation hardware and controllers.
• Implement automated test frameworks to validate logic behavior before deployment.
• Validate PLC HMI and supervisory system interactions within a virtual commissioning environment.
• Conduct virtual FATs and pre‑startup validation to reduce onsite commissioning time.
• Develop multi‑domain digital twins capturing mechanical motion, web‑handling, roll‑to‑roll, or other coupled physics.
• Build model identification and calibration pipelines, including parameter estimation, uncertainty analysis, and automated regression testing.
• Combine evidence from first‑principles models, reduced‑order models, empirical data, and experiment‑driven methods to achieve robust model fidelity.
• Integrate digital twins with real‑world telemetry, instrumentation, logging systems, and data pipelines to support prediction and what‑if analysis.

Requirements:

• Bachelors degree or equivalent experience in mechatronics, automation, controls engineering, or related field.
• Experience with digital twins, system modeling, or virtual commissioning.
• Hands‑on experience with PLC commissioning - Beckhoff TwinCAT, Siemens, or other platforms beneficial.
• Experience working with industrial networks e.g., EtherCAT, OPC UA, ADS, Ethernet/IP, PROFINET.
• Strong programming ability in Python, C, MATLAB, SIMULINK, or similar.
• Strong analytical and problem‑solving skills with the ability to work across both simulated and real systems.
• Experience with virtual commissioning tools such as iPhysics, Process Simulate, WinMOD, MapleSim, Emulate3D, EKS, or equivalent.
• Experience integrating simulation with supervisory systems e.g., MES, SCADA, GRAFANA.
• Experience with physics‑informed neural networks (PINNs) for modeling, system identification, or surrogate modeling is preferred.
• Familiarity with machine learning for parameter estimation or surrogate modeling.
• Experience in automation‑intensive industries: automotive, packaging, high‑volume manufacturing, robotics, etc.

Benefits: Along with competitive pay as a full-time Tesla employee, you are eligible for the following benefits at day 1 of hire:

• Medical plans: Plan options with 0 payroll deduction.
• Family-building: Fertility, adoption, and surrogacy benefits.
• Dental: Including orthodontic coverage.
• Vision plans: Both have options with a 0 paycheck contribution.
• Company Paid Health Savings Accounts (HSA): Contribution when enrolled in the High-Deductible medical plan with HSA.
• Healthcare and Dependent Care Flexible Spending Accounts (FSA).
• 401k with employer match.
• Employee Stock Purchase Plans and other financial benefits.
• Company paid Basic Life, AD&D, Short-term, and long-term disability insurance (90 day waiting period).
• Employee Assistance Program.
• Sick and Vacation time.
• Flex time for salary positions.
• Accrued hours for Hourly positions and Paid Holidays.
• Back-up childcare and parenting support resources.
• Voluntary benefits to include critical illness, hospital indemnity, accident insurance, theft & legal services, and pet insurance.
• Weight Loss and Tobacco Cessation Programs.
• Tesla Babies program.
• Commuter benefits.
• Employee discounts and perks program.

Expected Compensation: $91,600 - $164,400 annual salary, cash, and stock awards, benefits.

Pay offered may vary depending on multiple individualized factors including market location, job-related knowledge, skills, and experience. The total compensation package for this position may also include other elements dependent on the position offered. Details of participation in these benefit plans will be provided if an employee receives an offer of employment.