Controls Engineer, Cell Engineering


April 22, 2021

The Role
The Controls Engineer will work to improve and maintain manufacturing equipment for our battery cell pilot production. The candidate will contribute to/modify robust system architecture to support machine development and process concepts, and layout electrical/pneumatic schematics. They will program all controls components such as PLC, safety devices, HMI, servo drives, process hardware and robots from power-on to debug, and finally to process fine tuning and validation. You will work closely with Design Engineering, Quality and Production to take battery design changes and new cell recipes from initial concept through prototype development and into full production. You will also work with cross-functional teams throughout the entire product lifecycle.


Existing automation equipment refinement:
  • Debug and optimize automated processes to maximize cycle time, improve availability and yield.
  • Characterize and validate automated processes using a data driven approach such as simulation, Capacity and Capability statistical test (Gage Repeatability and Reproducibility test, Cpk, etc),
  • Create detailed utility layouts for entire assembly lines and interface with facilities teams for implementation
  • Create data management and tracking communications network architecture and interface with cross-functional teams for product, processes and quality traceability control implementation

Outsourced automation equipment development:

  • Participate in Tesla specification and standard creation, release to Vendor and quote technical evaluation
  • Enforce application of Tesla standards, Manage suppliers during specification, design review, design approval
  • Establish test plans and control test plan execution at Vendor and at Tesla facility during installation and buy-off
  • Characterize and validate new automated process equipment for deployment into production

In-house equipment development:

  • Participate in initial equipment conceptual development and carefully balance product specifications, process control requirements, layout complexity, cost, quality and lead-time limits.
  • Lay out new industrial electrical control panels which are NFPA79/NEC/UL508A compliant, and create electrical, pneumatic and fluid schematics.
  • Architect, write, and debug PLC ladder logic with an emphasis on generating code that is organized, structured, documented, maintainable and reusable. PLC code will interact with subsystems such as conveyors, robots, Manufacturing Execution System (MES), machine vision, and 3rd party equipment.
  • Implement (ANSI/RIA15.06/OSHA compliant) control reliable safety systems for safeguarding robots, gantries, conveyors, and other high volume manufacturing equipment.
  • Generate aesthetically simple HMI screens for complex machinery while providing sufficient feedback for troubleshooting.
  • Manage electrical cabinet builds, field wiring, pneumatic and fluid plumbing.
  • Select and size electrical and electromechanical components such as servos.

  • Proficiency with process integration and electromechanical / mechatronic systems
  • Advanced proficiency programming industrial equipment:
  • Ladder logic PLCs (Beckhoff, Siemens, Rockwell, Omron, Mitsubishi)
  • Safety PLCs (Beckhoff, Siemens, Rockwell, Mitsubishi)
  • Human Machine Interface (HMI / GUI, FactoryTalk, Ignition)
  • Field bus Networks (EtherCAT, Profinet, Ethernet/IP, Safety rated field bus networks)
  • Serial communication (RS-232) between PLCs and instruments
  • Ethernet communications between machine PLCs and database systems
  • Exposure to a wide variety of production machinery, industrial sensors, and equipment (LVDT and pressure transducers, dispense systems, temperature controllers, DC nutrunner torque controllers, current and power meters, etc)
  • Experience creating technical specifications for automated manufacturing equipment is highly desired
  • Knowledge of production quality metrics is a plus