Controls Engineer

Description

At General Motors, our product teams are redefining mobility. Through a human-centered design process, we create vehicles and experiences that are designed not just to be seen, but to be felt. We're turning today's impossible into tomorrow's standard -from breakthrough hardware and battery systems to intuitive design, intelligent software, and next-generation safety and entertainment features.

Every day, our products move millions of people as we aim to make driving safer, smarter, and more connected, shaping the future of transportation on a global scale.

The Role

Controls Engineer - Robotics Technology Development

The Controls Engineer within the Robotics Technology Development team is responsible for designing, implementing, and supporting controls solutions for advanced robotic and automation systems that enable GM's future manufacturing capabilities. This role focuses on applying GM controls standards and Global Common Controls Hardware (GCCH) to develop robust, maintainable, and production-ready controls designs for new and evolving technology platforms.

The successful candidate will contribute to the development, integration, and validation of robotic cells and automation systems, ensuring alignment with GM standards, safety requirements, and plant maintainability expectations.

What You'll Do

• Design, implement, and commission controls solutions for robotic cells and automation projects within RTD, following GM controls standards and GCCH guidelines.
• Develop and maintain PLC, HMI, and related control logic, including standardized function blocks, fault handling, and diagnostics consistent with GM practices and GCCS.
• Integrate industrial robots (e.g., FANUC) with PLCs, safety systems, and field devices to meet functional, safety, and throughput requirements.
• Apply GM safety standards and risk assessment processes to ensure compliance with applicable safety codes and internal requirements.
• Collaborate with engineering design, robotics intelligence, advanced robotics development, and advanced systems development to define control system requirements, I/O, and network architecture for development cells and pilot systems.
• Support system bring-up, debug, and optimization at the Global Technical Center and, when required, at manufacturing sites.
• Create and maintain documentation (electrical schematics in ePLAN or similar tools, I/O lists, sequence of operations, network layouts, standards-compliant code templates) that align with GM controls and GCCH expectations.
• Provide technical support and knowledge transfer to manufacturing engineering and plant personnel as new solutions transition from development to production.
• Contribute feedback to continuous improvement of GM controls standards and GCCH/GCCS usage, based on lessons learned from RTD projects.

• Bachelor's degree in Electrical Engineering, Controls Engineering, Mechatronics, Computer Engineering, or related field, or equivalent practical experience.
• 3+ years of experience in industrial controls and/or robotics engineering, with direct involvement in commissioning robotic or cobot systems in manufacturing environments.
• Hands-on experience programming and integrating industrial robots or cobots (e.g., FANUC, Universal Robots, KUKA, ABB) including motion programming, safety zoning, and I/O integration.
• Strong background in PLC/HMI programming and industrial networks, preferably Rockwell / Allen-Bradley (ControlLogix, GuardLogix, FactoryTalk) with common fieldbuses such as EtherNet/IP, Profinet, or similar.
• Demonstrated experience implementing safety-related control systems (e.g., safety PLCs, interlocks, light curtains, safety scanners, E-stops) and working with safety standards for industrial robots/cobots (e.g., ISO 10218-1 and -2, ISO/TS 15066 or equivalent), including validation and documentation of safety functions.
• Ability to read and create electrical schematics, panel layouts, and network architectures, and to support panel build, power-up, and debug in lab and plant environments. E-plan experience.
• Proven troubleshooting and root-cause analysis skills for automation systems (robots, PLCs, vision, sensors, networks) under time-constrained manufacturing conditions.
• Strong communication and collaboration skills, with the ability to work across disciplines (mechanical, software, operations, safety) and with suppliers and plant stakeholders.

• 5+ years of controls/robotics experience in automotive manufacturing or high-volume industrial automation, including exposure to body shop or general assembly automation programs.
• Direct experience deploying cobot applications in proximity to operators, including risk assessment, zoning, speed/force tuning, and optimization of cycle time vs. safety constraints.
• Familiarity with GM automation standards and processes, such as GCCH, GCCS, GRS, PSS, g-Comply checklists, NAX/SOR workflows, and plant buy-off practices.
• Experience integrating cobots with 2D/3D vision, force control, and advanced sensing for guidance, inspection, and adaptive processes.
• Working knowledge of CODESYS and soft/virtual PLC experience.
• Exposure to simulation and digital twin tools for robotic cell design and validation (e.g., robot simulation, emulation, offline programming) and to modern robotics stacks (ROS/ROS2, MoveIt2) is a plus.
• Demonstrated ability to standardize solutions, write clear technical documentation, and mentor junior engineers or partners on controls and cobot best practices.