Controls Engineer

You’ll be our: Controls Engineer - Battery

You’ll be based at: IBC - Bengaluru / Chhatrapati Sambhajinagar, Maharashtra (MH)

You’ll be Aligned with: ME Assembly - F&T Lead

You’ll be a member of: Manufacturing Engineering - Assembly

What you’ll do at Ather: You will be responsible for designing, developing, and deploying advanced control strategies that not only rely on traditional methods but also leverage data-driven insights to optimize performance, predict failures, and automate complex processes. In this role, you'll be at the forefront of integrating cutting-edge artificial intelligence (AI) and machine learning (ML) techniques into our control systems.

Key Responsibilities

System Design and Development:

• Design, develop, and integrate Programmable Logic Controller (PLC), Human-Machine Interface (HMI), testing setups scripts (Labview/Python) and Supervisory Control and Data Acquisition (SCADA) systems for new or modified production lines.
• Create detailed control schematics, wiring diagrams, and bill of materials (BOM) using Computer-Aided Design (CAD) software.
• Develop and implement robot programs (e.g., Mitsubishi, ABB) for various assembly tasks, including welding, painting, material handling, and part insertion.
• Integrate AI and ML models into existing and new control architectures to enhance system performance, efficiency, and reliability.
• Develop algorithms for predictive maintenance, anomaly detection, and real-time optimization.
  
  

Vision System Deployment:

• Design, integrate, and configure industrial 2D and 3D vision systems (e.g., Cognex, Keyence, Sick) for critical quality checks, including weld inspection, presence/absence verification, error-proofing, and dimensional gauging.
• Develop and validate vision algorithms and recipes for various lighting conditions, part variations, and production speeds.
• Solid understanding of optics, lighting techniques, camera selection, and image processing fundamentals.
  
  

Programming and Configuration:

• Configure and program industrial networking protocols (Ethernet/IP, Profinet, Modbus) for reliable communication between control devices, robots, and plant management systems (MES/ERP).
• Develop and modify HMI applications for operator control, monitoring, and data logging.
  
  

Installation, Testing, and Commissioning:

• Oversee the installation and commissioning of new automated equipment and robotic cells.
• Conduct rigorous testing, validation, and acceptance procedures to ensure systems meet safety, quality, and performance standards.
• Provide technical leadership and support during system start-ups and production ramp-ups.
  
  

Maintenance and Optimization:

• Perform advanced troubleshooting and root cause analysis on control systems, robots, and automation hardware to quickly resolve downtime incidents.
• Implement continuous improvement initiatives to enhance system reliability, cycle time, quality metrics, and energy efficiency.
• Manage system backups, software revisions, and hardware upgrades for all controls and robotic assets.
  
  

Safety and Compliance:

• Ensure all automated and robotic systems are designed and maintained in strict compliance with safety regulations (e.g., OSHA, ISO standards (ISO 13849-1, ISO 10218) and plant-specific safety protocols.
• Implement and verify safety circuits, interlocks, and risk reduction measures, including Safe Torque Off (STO) functions.
  
  

Project Management & Execution:

• Develop project timelines, budgets, and resource allocation plans.
• Manage cross-functional teams, including production, quality, maintenance, and logistics, to ensure project goals are met on time and within budget.
• Present project updates and performance metrics to senior management.
  
  

Advance Technology and Smart manufacturing:

• Utilize mechatronics principles for the design and implementation of automated and semi-automated assembly systems, robotics, and smart tooling.
  
  

What You bring to Ather:

Education: Bachelor's or Master's degree in Mechatronics, Electrical Engineering, Mechanical Engineering, Computer Science, or a related field.

Technical Skills:

• Proficiency in programming languages like Python (Essential for AI/ML), C++, and ladder logic.
• Deep understanding of control systems, including PID control, state-space models, and system identification.
• Exposure to ML frameworks and libraries such as Tensor Flow, PyTorch, or Scikit-learn.
• Knowledge of data acquisition, signal processing, and time-series analysis.
• Experience with industrial communication protocols (e.g., Modbus, OPC UA, EtherNet/IP).
• Familiarity with HMI/SCADA systems development.
• Knowledge of cloud platforms (AWS, Azure, GCP) and IoT technologies is a plus.
• Specific experience with robotic programming (e.g., Mitsubishi, FANUC, KUKA, ABB, UR) and an understanding of robot kinematics and dynamics.
• Soft Skills: Strong problem-solving abilities, excellent communication skills, and the capacity to work both independently and as part of a collaborative team.