Senior Controls Engineer in Appleton, WI at ITW Welding

Date Posted: 8/18/2019

Job Snapshot

Job Description


ITW Welding continues to build its capabilities in embedded systems development as a core competency in digitally controlled welding equipment, processes, and systems. To support this effort, we are looking for a Senior Controls Engineer to play a key role in both R&D and New Product Development for welding and heating equipment. The Senior Controls Engineer will be a key contributor in the investigation, development, and implementation of digital control systems for new and innovative products with three key areas of focus; power conversion, wire feed delivery, and weld process control. This position requires a highly motivated individual with exceptional communication and interpersonal skills to work collaboratively across multi-discipline project teams consisting of electrical, software, mechanical and welding engineers.


  • Establish controls architectures for a variety of welding equipment platforms.
  • Model and derive transfer functions (Laplace and Z-domain) for power conversion control, wire feed motor control and various weld process controls
  • Design PID, LEAD/LAG and other forms of compensators to meet steady state and dynamic requirements
  • Work closely with power conversion and software engineers to validate control loop performance and stability. Develop simulation models correlating with measured results

Job Requirements


  • Bachelor’s Degree in Electrical Engineering (Master’s Degree with Controls emphasis preferred) with a minimum of 7 years of experience.
  • Experience designing control systems for power conversion equipment
  • Experience designing control systems for brushed and brushless DC motors
  • Experience with Z-transforms using backward, forward and trapezoidal approximation rules
  • Knowledgeable on analog signal conditioning and digital sampling requirements
  • Knowledgeable on digital signal processing and filter design (FIR, IIR, Kalman, etc.)
  • Knowledgeable on modern, classic and state variable feedback techniques
  • Knowledgeable on tools and techniques for control loop stability analysis (analog and digital)

Desired Qualifications:

  • Experience implementing digital control loops in embedded C/C++ on resource limited 16/32-bit DSP or microcontroller, and/or VHDL on FPGA or CPLD
  • Experience developing embedded firmware for power conversion and/or motor controls
  • Experience developing embedded firmware with critical deterministic timing requirements