Sr.Control Engineer

Intello Labs Pvt Ltd

Gurugram4 yrs - 8 yrs expNot SpecifiedIn Office12 - 18 LPA

Posted 14 days ago

Control System DesignProcess OptimizationProject LeadershipComplex Problem Solving

Role Overview

We are looking for a hands-on Senior Controls Engineer to develop, commission, and troubleshoot industrial automation machines. The ideal candidate should have strong expertise in machine control systems, PLC programming, servo motion, electrical debugging, and machine commissioning.

This role requires someone who is comfortable working on the shop floor, diagnosing machine issues, debugging control panels, modifying PLC logic, and ensuring machines operate safely and reliably.


Key Responsibilities

Machine Control & Commissioning

  1. Develop, modify, and debug control logic for industrial automation machines.
  2. Implement machine sequences including:
  3. Start/Stop
  4. Reset
  5. Homing
  6. Jogging
  7. Manual Mode
  8. Auto Cycle
  9. Fault Handling & Recovery
  10. Commission machines and troubleshoot hardware issues on the shop floor.
  11. Debug PLC logic, sensors, actuators, servo drives, VFDs, and I/O systems.
  12. Ensure reliable operation in manual, semi-automatic, and automatic modes.


Motion Control

  1. Configure and troubleshoot:
  2. Servo Motors
  3. Stepper Motors
  4. VFDs
  5. Encoders
  6. Limit Switches
  7. Home Sensors
  8. Proximity Sensors
  9. Implement and optimize:
  10. Homing
  11. Position Control
  12. Velocity Control
  13. Indexing
  14. Jogging
  15. Multi-axis synchronized motion
  16. Tune servo drives for improved repeatability and reduced cycle time.
  17. Diagnose motion-related issues including:
  18. Following Errors
  19. Homing Errors
  20. Communication Errors
  21. Drive Faults
  22. Support automation systems such as:
  23. Cartesian Robots
  24. Pick & Place Machines
  25. Conveyors
  26. Feeders
  27. Indexing Units


PLC & Control Logic

  1. Develop and modify PLC programs using:
  2. Ladder Logic
  3. Structured Text
  4. Function Block
  5. Implement:
  6. Machine Interlocks
  7. Alarms
  8. Timers
  9. Counters
  10. State Logic
  11. Fault Recovery
  12. Work with industrial communication protocols including:
  13. EtherCAT
  14. Modbus TCP
  15. Ethernet/IP
  16. Profinet
  17. CAN
  18. Serial Communication
  19. Integrate drives, remote I/O modules, sensors, pneumatic valves, conveyors, weighing systems, and VFDs.
  20. Maintain clean I/O mapping and machine documentation.


Electrical & I/O Debugging

  1. Read and interpret:
  2. Electrical Drawings
  3. Control Panel Wiring
  4. I/O Lists
  5. Device Manuals
  6. Troubleshoot:
  7. Digital & Analog I/O
  8. Relay Outputs
  9. Communication Status
  10. Safety Signals
  11. Coordinate with electrical teams for:
  12. Wiring Modifications
  13. Panel Corrections
  14. Device Replacement
  15. Site Troubleshooting
  16. Verify sensor positioning, actuator response, and machine timing.


Machine Safety & Reliability

  1. Implement and validate:
  2. Emergency Stop Logic
  3. Safety Interlocks
  4. Safe Stop Behaviour
  5. Air Pressure Monitoring
  6. Drive Fault Handling
  7. Ensure predictable machine behavior during:
  8. Power-Up
  9. Reset
  10. Pause
  11. Emergency Stop
  12. Fault Recovery
  13. Improve machine reliability by identifying and resolving practical failure modes.
  14. Support FAT, installation, commissioning, and field service activities.


Required Skills

  1. 4–8 years of hands-on experience in Industrial Automation or Machine Control.
  2. Strong experience in:
  3. PLC Programming
  4. Motion Control
  5. Servo Drives
  6. Sensors & Actuators
  7. Pneumatics
  8. Relays
  9. I/O Systems
  10. VFDs
  11. Hands-on experience in machine commissioning and troubleshooting.
  12. Ability to read electrical schematics and debug control panels.
  13. Experience with at least one PLC/controller platform:
  14. Siemens
  15. Omron
  16. Mitsubishi
  17. Beckhoff
  18. Schneider
  19. Delta
  20. Leadshine
  21. Equivalent Platforms
  22. Knowledge of industrial communication protocols:
  23. EtherCAT
  24. Modbus TCP
  25. CAN
  26. Ethernet/IP
  27. OPC-UA
  28. Profinet
  29. Strong shop-floor troubleshooting capability.
  30. Ability to collaborate with Mechanical, Electrical, Software, and Production teams.
  31. Experience guiding junior engineers during commissioning.


Preferred Skills

  1. Experience with:
  2. Packaging Machines
  3. Pick & Place Systems
  4. Conveyors
  5. Sorting Machines
  6. Weighing Systems
  7. Robotic Automation
  8. Servo tuning and EtherCAT-based motion systems.
  9. Basic Python or C++ for diagnostics and utility scripts.
  10. HMI development and alarm management.
  11. Safety PLCs, safety relays, and emergency stop systems.
  12. Pneumatic cylinders, vacuum systems, grippers, and solenoid valves.


Qualifications

  1. Diploma / B.E. / B.Tech / M.Tech in:
  2. Electrical Engineering
  3. Electronics Engineering
  4. Mechatronics
  5. Automation
  6. Robotics
  7. Instrumentation
  8. Related Engineering Discipline
  9. 4–8 years of experience in:
  10. Industrial Automation
  11. PLC Programming
  12. Motion Control
  13. Machine Commissioning
  14. Controls Engineering


Ideal Candidate

The ideal candidate should be a practical, hands-on engineer capable of standing in front of a machine, identifying faults, checking PLC logic, verifying I/O signals, inspecting sensors and drives, and bringing the machine back into reliable operation with minimal downtime.


Key Success Metrics

  1. Reliable and maintainable machine control logic.
  2. Stable servo and actuator performance.
  3. Faster machine commissioning.
  4. Reduced machine downtime.
  5. Improved fault handling and recovery.
  6. Well-documented PLC programs and I/O mapping.