Senior / Staff Automation Controls Engineer

WHAT TO EXPECT Heron Power is a startup company building cutting-edge power electronics for the 21st-century grid. We aim to debottleneck the growth of electricity generation and consumption with scalable, innovative, and less costly hardware solutions, accelerating the electrification of everything. Our first goal is to build better converters (inverters & rectifiers) to connect large-scale renewables, storage, and loads to the grid. Heron Power’s leadership team is made up of seasoned veterans who have designed and shipped gigawatts of power conversion products over the past decade. We understand that no one individual knows everything. We will all learn a lot together and from each other. We strive to build a collaborative, enriching environment conducive to personal, technical, and career growth. You can expect to work in a dynamic and collaborative environment, driven by first principles engineering, solving difficult problems. JOB OVERVIEW At Heron Power, we are building the future of scalable power electronics. Our mission is to enable high-volume, capital-efficient manufacturing of advanced energy systems. We believe that robust automation and controls are foundational to achieving this vision. As an Automation Controls Engineer, you will take full ownership of the control systems that power our custom manufacturing equipment. You will define the controls architecture, set the technical trajectory, and ensure our systems deliver precision, reliability, and throughput at scale. This is a hands-on role for someone who holds a high standard for automation performance and safety and is motivated by the challenge of building control systems that are robust, maintainable, and built to last. HOW YOU WILL CONTRIBUTE - Define controls architecture for Heron Power’s factories, including platforms, devices, safety systems, and communication protocols - Lead virtual commissioning efforts to simulate, test, and validate controls logic prior to deployment - Design, program, and commission in-house control systems for custom manufacturing equipment - Write clean, scalable, and maintainable control code for long-term flexibility and reuse - Set up industrial robots, including programming, safety zoning, and cycle optimization - Conduct risk assessments and hazard analyses to identify potential safety issues and develop mitigation strategies for new and existing automation cells - Troubleshoot controls-related issues and drive resolution on the production floor - Manage supplier controls performance, ensuring alignment with system requirements, quality standards, and safety expectations - Identify and mitigate risks, including compliance gaps, integration challenges, and long-term maintainability WHAT YOU WILL BRING We have a short list of must-have requirements. We prioritize a strong grip on first principles, hands-on skills, and a sense of initiative. Domain-specific knowledge and experience will help determine the career level for each hire. MUST-HAVE REQUIREMENTS - Bachelor’s degree in Electrical Engineering, Mechatronics, Controls Engineering, or a related field. - 7+ years of experience in industrial automation, with a focus on safety systems and controls engineering. - Expert-level proficiency in PLC programming across multiple platforms, specifically: - Beckhoff TwinCAT - Rockwell Automation / Allen-Bradley - Siemens TIA Portal - Strong command of programming languages: - Ladder Logic - Structured Text - Function Block Diagram - Extensive experience with 6-axis robots, gantry systems, and inspection methods - Subject matter expert in evolving safety standards and technologies - Deep experience with risk assessments and functional safety validation - Experience with high volume manufacturing process equipment such as fastening, dispensing, thermal processes, laser welding, material handling, and inspection systems - Willingness to work in a hands-on role - Excellent communication and interpersonal skills - Ability to work indep