Controls Engineer- Virtual PLCs
Actalent
Posted Tuesday, April 28, 2026
Posting ID: JP-005991472
Job Title: Controls Engineer – Virtual PLCs
Job Description
This role focuses on designing, implementing, and validating virtual PLC (vPLC) and virtual commissioning environments that enable early development, debugging, and verification of robotic and automation systems for manufacturing plants. You will create high-fidelity digital representations of control systems and robotic cells to reduce deployment risk, shorten launch timelines, and improve safety and quality for advanced manufacturing solutions. You will work closely with cross-functional teams in engineering design, robotics intelligence, advanced robotics development, and advanced systems development to ensure robust, production-ready control architectures and workflows.
Responsibilities
- Design and integrate virtual PLC architectures that accurately mirror production systems, including safety PLCs, HMIs, industrial Ethernet networks, and robot controllers, to enable offline development, debugging, and testing of control logic and safety functions.
- Develop and maintain virtual commissioning environments by coupling vPLCs with robot simulation, emulation, and digital twin models (such as Process Simulate or equivalent) to validate sequences, I/O, and safety behavior before equipment is built or installed.
- Model and test robotic workcells virtually for manufacturing applications such as assembly, material handling, fastening, and inspection, including PLC and robot interfaces, conveyors, vision systems, and safety devices such as light curtains, scanners, and emergency stops.
- Implement and verify safety-related control functions in the virtual environment, including interlocks, safety zones, safe speed and position monitoring, and emergency stop behavior, to support risk assessments and safety validation prior to on-site trials.
- Develop and validate PLC and HMI logic on vPLC platforms, such as Siemens software and virtual controllers or Rockwell emulation, covering I/O mapping, sequence logic, error handling, fault injection, diagnostics, and regression testing, and then support deployment to physical controllers.
- Integrate sensing and vision models, including 2D and 3D vision, proximity sensors, force/torque sensors, and barcode readers, into virtual workcells for guidance, error proofing, and process verification, while leveraging established control and vision standards where applicable.
- Reuse virtual models to support lab and plant activities, including system bring-up, debugging, change management, and “what if” studies as hardware and processes evolve throughout the project lifecycle.
- Collaborate with robotics, perception, and planning teams to integrate motion planning, perception, and advanced control algorithms into virtual environments, ensuring they are robust, validated, and ready for production deployment.
- Drive standardization and reuse by creating vPLC templates, simulation libraries, signal mapping conventions, and clear documentation such as logic guides, test cases, and checklists aligned to global controls and robot simulation standards.
- Provide technical support and training to internal customers, including plant personnel, manufacturing engineering, and maintenance teams, on vPLC and virtual commissioning workflows so they can use virtual models for troubleshooting, training, and validating changes before implementation in the plant.
- Contribute to technology roadmaps and evaluations for virtual PLC technologies, safe software controllers, and digital twin solutions, helping define future controls architectures and execution standards for virtual engineering.
- Apply strong PLC programming, automation, and Codesys experience where relevant to improve virtual commissioning workflows and enhance overall system reliability and performance.
Essential Skills
- Bachelor’s degree in Electrical Engineering, Controls Engineering, Mechatronics, Computer Engineering, or a related field, or equivalent practical experience.
- At least 3 years of experience in industrial controls and/or robotics engineering, including direct involvement in commissioning automated equipment or robotic systems.
- 1–2 or more years of hands-on experience with virtual PLCs, software-based controllers, or virtual commissioning tools such as Siemens virtual PLC/S7-1500V, Rockwell or Siemens PLC emulation, or comparable platforms.
- Strong experience in PLC and HMI programming and industrial networks, preferably with Rockwell technologies such as ControlLogix, GuardLogix, and FactoryTalk, and/or Siemens platforms.
- Experience setting up simulated PLC and HMI connections for controls testing in virtual environments.
- Experience programming and integrating industrial robots or collaborative robots with PLCs, including I/O interfacing, fault handling, and basic motion and safety interactions, ideally with some use of virtual robot controllers or offline programming tools.
- Demonstrated experience with safety-related control systems, including safety PLCs, interlocks, light curtains, safety scanners, and emergency stops, with the ability to represent these behaviors accurately in virtual models and tests.
- Ability to read and create electrical schematics, panel layouts, and network architectures, and to translate them into accurate virtual models for simulation and testing.
- Proven troubleshooting and root cause analysis skills for automation systems, including robots, PLCs and vPLCs, vision systems, sensors, and industrial networks, using virtual environments for fault injection, scenario exploration, and regression testing.
- Strong communication and collaboration skills, with the ability to explain virtual commissioning workflows, results, and recommendations clearly to diverse stakeholders such as controls engineers, mechanical engineers, IT professionals, plant operations teams, and suppliers.
Additional Skills & Qualifications
- Experience with automation engineering and PLC programming in environments that leverage Codesys or similar platforms.
- Familiarity with robot simulation tools and digital twin technologies such as Process Simulate or equivalent systems.
- Knowledge of global controls standards and robot simulation standards, with the ability to align virtual models and documentation to these guidelines.
- Experience developing reusable templates, simulation libraries, and standardized signal mapping conventions to support scalable virtual commissioning practices.
- Ability to create clear documentation, including logic guides, test cases, and checklists, to support consistent implementation and validation of control systems.
- Comfort working in cross-functional teams that include robotics, perception, planning, and advanced systems development, with a focus on integrating advanced algorithms into practical, production-ready solutions.
Work Environment
This role operates in a highly technical engineering environment focused on advanced robotics, automation, and digital manufacturing. You will work primarily in office, lab, and virtual simulation settings, using tools such as virtual PLC platforms, PLC and HMI programming environments, robot simulation software, and digital twin technologies. Collaboration with cross-functional teams is frequent, and you will regularly interface with plant engineering and maintenance teams to support commissioning and troubleshooting activities. Work may involve both virtual development and occasional on-site support at manufacturing facilities to validate and deploy solutions. The environment emphasizes innovation, standardization, and continuous improvement in controls engineering and virtual commissioning practices.
Job Type & LocationThis is a Contract to Hire position based out of Warren, MI.
Pay and BenefitsThe pay range for this position is $50.00 - $60.00/hr.
Eligibility requirements apply to some benefits and may depend on your job
classification and length of employment. Benefits are subject to change and may be
subject to specific elections, plan, or program terms. If eligible, the benefits
available for this temporary role may include the following:
• Medical, dental & vision
• Critical Illness, Accident, and Hospital
• 401(k) Retirement Plan – Pre-tax and Roth post-tax contributions available
• Life Insurance (Voluntary Life & AD&D for the employee and dependents)
• Short and long-term disability
• Health Spending Account (HSA)
• Transportation benefits
• Employee Assistance Program
• Time Off/Leave (PTO, Vacation or Sick Leave)
This is a hybrid position in Warren,MI.
Application DeadlineThis position is anticipated to close on May 12, 2026.
Diversity, Equity & Inclusion
At Actalent, diversity and inclusion are a bridge towards the equity and success of our people. DE&I is embedded into our culture through:
- Hiring diverse talent
- Maintaining an inclusive environment through persistent self-reflection
- Building a culture of care, engagement, and recognition with clear outcomes
- Ensuring growth opportunities for our people
Actalent is an equal opportunity employer.
About Actalent
Actalent is a global leader in engineering and sciences services. For more than 40 years, we’ve helped visionary companies advance their goals. Headquartered in the United States, our teams span 150 offices across North America, EMEA, and APAC—with four delivery centers in India led by 1,000+ extraordinary employees who connect their passion with purpose every day.
Our Bangalore, Hyderabad, Pune, and Chennai delivery centers are hubs of engineering expertise, with core capabilities in mechanical and electrical engineering, systems and software, and manufacturing engineering. Our teams deliver work across multiple industries including transportation, consumer and industrial products, and life sciences. We serve more than 4,500 clients, including many Fortune 500 brands. Learn more about how we can work together at actalentservices.com.
Contact Information
Recruiter: Michael Nanke
Phone: (248) 764-1617
Email: mnanke@actalentservices.com
Remote