An Electrical Controls Engineer is a professional who specializes in designing, developing, and implementing electrical control systems for various applications. These engineers play a critical role in ensuring the efficient operation and automation of electrical processes in industries such as manufacturing, automation, and energy. In this blog post, we will describe the primary responsibilities and the most in-demand hard and soft skills for Electrical Controls Engineers.

Get market insights and compare skills for other jobs here.

Main Responsibilities of an Electrical Controls Engineer

The following list describes the typical responsibilities of an Electrical Controls Engineer:

Assist in

• Assist in preparing estimates and quotes.

• Assist in transition of new equipment installation to manufacturing facilities.

• Assist other departments by providing technical engineering opinions and data.

Collaborate with

• Collaborate with cross-functional teams to understand project requirements.

• Collaborate with equipment suppliers and vendors for system integration.

• Collaborate with external consultants or contractors when necessary.

• Collaborate with Mechanical Engineering on station flow charts.

• Collaborate with project managers to meet project deadlines and budgets.

Complete

Complete circuit design and layout of PCBAs, logic, and power systems.

Conduct

• Conduct feasibility studies for control system upgrades or retrofits.

• Conduct performance evaluations and optimize system efficiency.

• Conduct power, analog, and digital system design.

• Conduct risk assessments and develop safety protocols for control systems.

• Conduct system upgrades and modifications as required.

• Conduct testing and validation of control system functionality.

• Conduct user acceptance testing and system commissioning.

Control

Control logic testing and debug.

Create

• Create BOMs from customer requirements.

• Create design documentation.

• Create documents to transfer information to the Electrical Assembly.

• Create electrical schematics, wiring diagrams, and control panel layouts.

• Create testing and run off parameters to verify machine operating as.

Design

• Design and build control systems for process control and automation projects.

• Design and develop electrical control systems for industrial applications.

• Design and develop robotic interface that integrates the robot into the system.

• Design and implement human-machine interface (HMI) systems.

• Design / develop control software for PLCs, PCs, Industrial HMIs, robotic, steppers etc..

• Design HMI & PLC programs (primarily on Allen Bradley platforms).

• Design schematics, electrical panels, and develop BOMs to meet.

Determine

Determine equipment capabilities for new or revised factory layouts.

Develop

• Develop and configure SCADA (Supervisory Control and Data Acquisition) systems.

• Develop and implement preventive maintenance plans for control systems.

• Develop and maintain designs layouts in the computerized system.

• Develop and maintain technical documentation and manuals.

• Develop and program PLC (Programmable Logic Controller) systems.

• Develop electrical control panel drawings and generates bills of material.

• Develop ideas and projects to reduce utility and energy costs.

• Develop, monitor and control the annual capital budget, maintenance expenses, and utility budgets.

• Develop real-time embedded PSI Automation machine's control software.

Direct

Direct the activities of staff assigned to assist with projects.

Ensure

• Ensure adherence to safety protocols during system implementation and maintenance.

• Ensure compliance with electrical codes, standards, and regulations.

• Ensure conformance to codes and to company standards for quality and manufacturability.

• Ensure equipment meets all safety rules, applicable regulations, and relevant.

Establish

Establish departmental goals that maintain focus on improving line efficiencies and product quality.

Evaluate

• Evaluate and select components and parts for products.

• Evaluate production and packaging needs for Capital Equipment.

Forecast

Forecast and control plant capital spend to maximize investment value.

Generate

Generate and manage project documentation.

Identify

• Identify and resolve readily identifiable, clearly-defined problems.

• Identify the scope of the work, provide initial estimates.

Implement

• Implement electric controls design by providing installation, start-up, and technical support.

• Implement real-time embedded system programming using C and Assembly programming languages.

Improve

Improve and troubleshoot controls on existing machinery.

Integrate

Integrate electrical control systems with mechanical and electrical components.

Keep

• Keep abreast of emerging technologies and industry trends.

• Keep informed of new applications / methods to improve systems / products.

Manage

Manage multiple projects simultaneously and prioritize tasks.

Meet

Meet and interact with vendors in various capacities.

Monitor

Monitor and analyze system data to identify areas for improvement.

Optimize

Optimize control system performance and efficiency.

Organize

Organize design project by identifying short-term and long-range issues.

Perform

• Perform automation debug and commissioning.

• Perform engineering design calculations.

• Perform programming on PLCs, robots, HMIs, and vision systems.

• Perform root cause analysis for control system failures.

• Perform system analysis and develop control strategies.

Produce

Produce layout drawings, plans, and specifications for improvement projects as assigned.

Provide

• Provide advice and consultancy support.

• Provide 'Hands on' trouble shooting and machine start up.

• Provide technical support and guidance to other team members.

• Provide technical support for production departments.

• Provide thorough testing of machine functionality to verify software program completeness.

Redesign

Redesign standard products, improving quality and productivity, while reducing costs.

Refer

Refer semi-complex, unusual problems to others.

Research

Research components and integrated equipment and select electrical.

Review

Review and interpret customer specifications and sales agreements.

Select

Select appropriate electrical components and equipment for control systems.

Support

• Support installation of equipment and equipment startup at customers' sites.

• Support Sales team in pre-sales technical concept and costing activities.

Test

Test, troubleshoot issues, maintain and modify existing electrical control systems.

Train

• Train and provide support to operations and maintenance personnel.

• Train maintenance staff as needed to service critical equipment components.

Translate

Translate flow chart to sequence steps in Controls Document.

Travel

Travel to various sites to aid in installing various electrically controlled machines.

Troubleshoot

Troubleshoot and resolve electrical control system issues.

Work with

• Work collaboratively with design engineers, operation engineers, purchasers and other internal staff.

• Work with customers and vendors on equipment design.

Write

• Write engineering documentation.

• Write machine controls code and check controls operations of machines.

Most In-demand Hard Skills

The following list describes the most required technical skills of an Electrical Controls Engineer:

1. Proficiency in PLC programming languages (e.g., ladder logic, structured text).

2. Knowledge of electrical control systems design and implementation.

3. Competence in developing HMI and SCADA systems.

4. Proficiency in using PLC programming software (e.g., Siemens, Allen-Bradley).

5. Familiarity with electrical schematic and diagramming software (e.g., AutoCAD, EPLAN).

6. Competence in selecting and specifying electrical components for control systems.

7. Skill in integrating electrical control systems with mechanical and electrical components.

8. Knowledge of electrical codes, regulations, and industry standards.

9. Competence in troubleshooting electrical control system issues.

10. Proficiency in conducting system testing and validation.

11. Familiarity with industrial communication protocols (e.g., Modbus, Ethernet/IP).

12. Competence in analyzing system data and conducting performance optimization.

13. Skill in designing and implementing preventive maintenance plans for control systems.

14. Proficiency in conducting system upgrades and modifications.

15. Knowledge of safety protocols and procedures for control system implementation.

16. Competence in using electrical testing and measurement equipment.

17. Familiarity with motor control systems and drives.

18. Skill in conducting root cause analysis for control system failures.

19. Proficiency in project management methodologies and tools.

20. Knowledge of emerging technologies in the field of electrical controls.

Most In-demand Soft Skills

The following list describes the most required soft skills of an Electrical Controls Engineer:

1. Excellent problem-solving and analytical skills.

2. Strong attention to detail and accuracy in system design and implementation.

3. Effective communication and interpersonal skills.

4. Collaboration and teamwork in a multidisciplinary environment.

5. Adaptability and flexibility to handle changing project requirements.

6. Time management and organizational skills to meet project deadlines.

7. Strong critical thinking and decision-making capabilities.

8. Commitment to continuous learning and professional development.

9. Leadership and project management abilities.

10. Commitment to workplace safety and adherence to protocols.

Conclusion

Electrical Controls Engineers are essential in the design and implementation of electrical control systems. By possessing the necessary hard and soft skills, these professionals ensure the efficient operation and automation of processes, contributing to improved productivity and safety in various industries.