Controls / Automation Engineer

Title: Automation / Controls Engineer

Position Summary

• Define, analyze, and validate deterministic solutions for large scale, fail-safe motion control systems

• Specify, design, and implement operator intensive, safety-critical control software using real-time operating systems

• Install, integrate, and test high capacity, man-rated control systems domestically and overseas

Position Responsibilities

• Define, analyze, and validate deterministic solutions for large scale, fail-safe motion control systems

• System Definition

• Distill early show concepts into realizable functionality then integrate into Ride Requirements

• Create and thoroughly analyze Track Layouts and Ride Systems which achieve challenging Capacity, Robustness, Operability, and Maintainability requirements

• Control System Architecture

• Ride Control Systems Functional Block Diagram

• Hardware/Software Tradeoffs

• Hardware/Software division of work

• I/O Lists

• Detailed Design Specifications

• Sub-System Decomposition

• Functional Requirements and how they will be achieved

• Interface Requirements

• Fault Handling

• Interface Control Documents

• Describes internal and external interfaces of the Ride Control System (sensors, motors, door security, station gates, etc.).

• Physical interface (data type, pin assignments, signal levels, protocols, etc.).

• Logical interface (definition of each state or message).

• Data rates (as applicable).

• Function.

• Timing considerations and restraints.

• Design and Develop Ride Control Systems Documents and Drawings

• Layout, Location and Interface Drawings

• Electrical Enclosures and OCC Locations

• Wiring Harness Routing/ Connector Locations

• Ride Control Equipment List

• Sizes

• Power Requirements

• Heat Loads (waste heat for AC)

• Equipment Layout/ Location (EER, Backstage, Show Space) Includes, equipment space requirements, access space requirements, mounting details for the following types of components:

• Control boxes

• Termination boxes

• Sensors

• Actuators

• Charging plates

• Motor control cabinets (RMCC)

• Ride Control Electrical Interconnect Drawings and Cable Schedule

• Drawings that show single line connections between all ride control assemblies and equipment.

• Point-to-point cable schedule

• Cable/Conduit Requirements and Locations/ Cable Tray Routing

• Separation requirements between AC power

• DC power

• Controls and emergency power

• I/O Cross Reference

• A list of input/output points and connections within the RCS/ride interface.

• Electrical Calculations

• Develop calculations based on electrical loading of the systems to assure sufficient power and signal qualities are available to the ride electrical and electronic systems.

• Single Line Schematics/ Wiring Diagrams

• Power system single line diagrams and schematics

• Ride Power System and Equipment Voltage Determination

• Power system single line diagrams and schematics

• Ride Power System Propulsion Method Determination. Document and describe how the propulsion system determination is made from the following options:

• Linear Induction Motors (LIM)

• Linear Synchronous Motors (LSM)

• Single Large Variable Frequency Drive

• Omni Mover

• Conventional Induction Motors (lifts, pacers, boosters)

• Energized Bus Bar

• Inductive Bus Bar

• Power Storage / Charging Stations

• Hybrid combination of methods.

• Ride Power System Details. Detailed list and description of the following items:

• Power load profile including impulses, peaks, and durations.

• Variable frequency drive type to be used for LIM or LSM systems (IGBT, 6 pulse, 12 pulse)

• Variable frequency drive characteristics including rating in kW, physical size, conduit and cable entries requirements.

• Input power disconnect location and rating.

• RCC cabinet quantities, sizes, conduit and cable entries.

• Braking resistors to be used with power regen back into facility system. Resistor cabinet size, weight, conduit and cable entry requirements.

• Shunt trip or under voltage trip on ride system incoming breaker or on upstream facility breaker.

• Harmonic filter design to meet IEEE 519. Identify filter design method (active or passive) & location. Must meet 5% THD of voltage and 5% TDD (total demand distortion) when the ratio of system short circuit to system load is less than 20.

• Power Storage / Charging System Details. Charging system details as follows:

• Charger size and rating

• Charging plate locations

• DC cable requirements

• Power cable requirements

• Fixed backstage charging station location

• Emergency Power. Identification of need for emergency or UPS power:

• Lifts

• Flume pumps

• Controls

• Launch systems

• Propulsion drive equipment

• Ride Power System Specialty Transformers. Identification and requirements of special transformers:

• Dedicated transformers isolated from facility power.

• Characteristics for LIM or LSM system transformers (30° phase shift, delta and wye secondary's, single transformer with two secondary windings or 2 separate transformers).

• Ride Control System Trackside Technology. Determination and requirements of trackside ride control technology method:

• Bus bar

• Leaky coax

• Wireless

• Hard wired sensors

• Wire guided

• RFID

• Ride Control System Misc. Provide details for the following miscellaneous items:

• Dispatch lantern locations and coordination with show

• Coordination of facility exit lighting "OFF" and cycle out duration / timing

• Ride Facility Intrusion System. Includes system requirements, equipment locations, wiring diagrams and details for the following:

• Mats

• Sensors

• IR Beams

• Laser Scans

• Main or Tower OCC displays / monitors

• Interface with facility or show systems

• Ride Controls Drawing Package. Project controls drawing package that includes drawing trees, assemblies, sub-assemblies and component level drawings including, but not limited to, electrical enclosures and locations, wire lists, schematics and wiring diagrams, controls hardware, breakout boxes and control boxes, control interfaces, and ride system interconnects. Some typical drawings are:

• Bus Bar Zones/ Block Zones Layout

• Indentured Drawing List/ Tree

• EER Layout

• Mounting Details and Interface Drawings

• Rack Configuration Documents

• Breakout Box/ Control Box Drawings

• Operator Console Layouts

• All Bills of Materials and component cut sheets

• Plan and Estimate hardware engineering jobs

• Budgets, Schedules, and Man Power Plans

• Task based estimates

• Software Development Plan

• Understand / Review Software Documentation (e.g. Software Development Plan, Software Design Documents, C+ and PLC programming Language); Mechanical, Pneumatic and Hydraulic schematics

• Hazard Analysis

• Failure Identification with associated Consequences and Mitigations

• Failure Mode Effects Analysis (FMEA)

• Test Strategies and Test Plans

• Acceptance Test Procedures (ATP) along with estimated durations for each test

• Specify, design, and implement operator intensive, safety-critical control software using real time operating systems

• Theory of Operation

• Multi-discipline operational and functional needs

• Use Cases

• Install, integrate, and test high capacity, man-rated control systems domestically and overseas

• I/O Checkout

• System Functions Testing

• Fault Testing

• Adjusting / Tuning

• Acceptance Testing using Earned Value tracking

Must Have Qualifications:

• Background in PLC programming / controls engineering

• Strong understanding and prior professional hands on experience with electrical engineering

• Strong understanding of power distribution

• Experience working with and managing vendors and/or original equipment manufacturers (OEMs)

• Strong understanding of field instrumentation

• Systems integration experience

• A minimum of a Bachelor's Degree

Additional Desired Qualifications

• Proficient with NEC 70 Code

• Proficient with UL508A Standard

• Strong Analytical Skills

• Physics - Motion Equations / Dynamics

• Persistent "What If" Thinker supported by physics, math, diagramming, ...

• Strong Technical Writing Ability

• Strong Team Skills - both able to lead and to follow

• More than 5 years additionally requires:

• Proven Leader

• Real-Time Control Experience (competent at ensuring deterministic system)

• Fail-Safe Control Experience (competent at creating safety timing analysis)

• Equipment Control Experience (motors, drives, sensors, effectors, servo, ...)

• Troubleshooting Skills Experience

• Proven ability to Multitask

• Ability to Innovate Demonstrated

• Able to Handle Demanding, Stressful Assignments

• Ride Control and/or Theme Park Experience

• Detailed Knowledge of similar Industry Standards

• Rapid Development and/or Agile Development Techniques

• Configuration Management / Version Control Tool Usage

• Proficiency at Unified Modeling Language (UML)

• Experience with System Modeling Language (SysML)

• Proficiency at Matlab

• Experience with Safety Programmable Logic Controllers (PLCs) and HMIs

• Allen Bradley ControlLogix or GuardLogix (RSLogix)

• Siemens SIMATIC Step 7 or Total Integrated Automation (TIA Portal)

• Control Theory

Education

• Bachelors Degree (B.S. or B.A.) from an accredited college or university

• Science (Physics, Computer Science, ...), Engineering, and/or Math

• Double Major or Major-Minor highly preferred

• Some Physics Coursework (Motion Equations / Dynamics) highly preferred

• Some Computer Science Coursework highly preferred

• Some Engineering Coursework highly preferred

• Control Systems Engineering and/or Control Theory a plus

• Hands On Project(s) a plus

About Actalent

Actalent is a global leader in engineering and sciences services and talent solutions. We help visionary companies advance their engineering and science initiatives through access to specialized experts who drive scale, innovation and speed to market. With a network of almost 30,000 consultants and more than 4,500 clients across the U.S., Canada, Asia and Europe, Actalent serves many of the Fortune 500.

Diversity, Equity & Inclusion

At Actalent, diversity and inclusion are a bridge towards the equity and success of our people. DE&I are 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

The company is an equal opportunity employer and will consider all applications without regard to race, sex, age, color, religion, national origin, veteran status, disability, sexual orientation, gender identity, genetic information or any characteristic protected by law.

If you would like to request a reasonable accommodation, such as the modification or adjustment of the job application process or interviewing process due to a disability, please email ~~~ (~~~) for other accommodation options.