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.