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.
• Physical and Environmental Requirements

The position requires regular presence on the production floor and the ability to navigate all areas of the facility. Candidates must be able to climb stairs, stand and walk for extended periods, and work in environments that may be hot, humid, or noisy. The role also requires the use of personal protective equipment, including respirators, and adherence to all applicable safety policies, procedures, and regulatory requirements.

Employees must be able to complete required fit testing, wear appropriate PPE for the duration of assigned tasks, and respond safely to changing conditions within the production environment.