Senior Automation Controls Engineer

Job Objective
TheRobotics Engineer is responsible for the programming, integration, commissioning, and optimization of robotic arc welding (MIG systems utilizingFANUC andNACHI platforms within the automotiveBodyshop. The primary goal is to ensure the structural and geometric integrity of body-in-white (BIW) sub-assemblies, minimizing spatter, thermal distortion, and cycle times while maintaining a highly repeatable, production-ready process,also responsible for following and establishing programming standards based on process requirements and application types, from commissioning through to start-up.
Core Responsibilities

• Path Generation & Optimization: Program and refine complex MIG welding trajectories on NACHI robots, ensuring optimal torch angles (work and travel angles) and proper electrode stick-out.
• Weld Process Optimization: Configure and fine-tune welding parameter schedules directly on the robots to eliminate common defects such as porosity, lack of fusion, undercut, or excessive burn-through.
• TCP Maintenance & Calibration: Implement automatic Tool Center Point (TCP) check routines to ensure the robot maintains precise weld placement after consumable changes (contact tips, nozzles, or goosenecks).
• Backup & Version Control: Maintain clean, documented version history and periodic image backups of all robot controllers under your scope.

• Education: Bachelor's degree in Robotics, Mechatronics, Automation, Welding, Electromechanical Engineering, or a related field.
• Experience: Minimum of5 years of hands-on experience programming and integrating FANUC and NACHI robots, with a heavy focus (at least 2 years) onMIG welding applications in an automotive BIW/Bodyshop
• Languages: Professional working proficiency in English to interface with global tooling suppliers and corporate engineering standards.

• FANUC Programming (ArcTool): Advanced mastery of theFANUC ArcTool software package, configuration of weld schedules, torch control, and tool coordinate system management (TCP/Weld Frame).
• NACHI Programming (MIG/Arc): Specialized configuration in NACHI controllers (FD/AX series) for arc applications, power source interfacing, and synchronization of travel speed with wire feed rate.
• MIG/MAG Welding Technology: Deep knowledge in adjusting and optimizing welding parameters (voltage, amperage, wire feed speed, gas flow) and transfer modes (short-circuit, globular, spray, pulsed arc).
• Welding Peripherals: Integration and maintenance of torch cleaning stations (reamers), wire cutters, neck aligners, and automated TCP calibration units.
• Power Source Integration: Communication setup and configuration of industrial interfaces (Digital/Analog, DeviceNet, EtherNet/IP) with leading power supplies such asFronius (TPS/i),Lincoln Electric, orMiller.
• Robot Safety Systems: Advanced implementation of safety software options, specificallyFanuc Dual Check Safety (DCS) andNachi RMU (Robot Monitoring Unit) for collaborative or restricted zone control.

• High-Pressure Troubleshooting: Rapid root-cause analysis of critical hardware/software faults during high-volume automotive production runs.
• Cross-Functional Collaboration: Strong teamwork skills to interface seamlessly with PLC programmers, mechanical designers, weld quality inspectors, and maintenance technicians.