Senior Developer Jobs in Tomah, WI (NOW HIRING)

POSITION TITLE: Senior Controls and Automation Engineer

DEPARTMENT: Engineering

REPORTS TO: Engineering Manager

LOCATION: Viola

JOB SUMMARY:

A Senior Controls & Automation Engineer to design, build, and support custom automated test equipment, manufacturing systems, and embedded control solutions for powertrain development and production support.This role bridges industrial automation, embedded hardware/firmware, and system integration, supporting everything from robotic test cells and PLC-controlled machinery to ECU-integrated embedded devices and Windows-based engineering tools.

The ideal candidate is a hands-on engineer comfortable working across electrical design, firmware, PLCs, robotics, HMIs, and on-site commissioning of one-off and low-volume systems

ESSENTIAL FUNCTIONS:

Industrial Automation & Controls

• Design, modify, and maintain automated test stands, endurance systems, and manufacturing equipment

• Program and troubleshoot PLCs and HMIs for presses, test fixtures, and special-purpose machinery

• Integrate industrial robots with presses and test systems, including interlocks and safety logic

• Retrofit and modernize legacy equipment where original electronics or controls are obsolete

• Support and repair custom, one-off automation equipment used in engineering and manufacturing

Embedded Hardware & Firmware

• Design custom embedded control hardware for test systems and product prototypes

• Develop firmware in C/C++ for microcontroller-based controllers

• Implement CAN bus communication with ECUs and vehicle subsystems

• Create embedded solutions for sensors, actuators, motor control, and data acquisition

• Support prototype development through testing, iteration, and limited production readiness

Test Systems & Instrumentation

• Develop automated engine and motorcycle test systems for endurance, EPA mileage accumulation, and performance testing

• Build systems for dyno automation, robotic control, and long-duration unattended operation

• Integrate sensors, cameras, and data acquisition hardware for mechanical and powertrain analysis

• Develop data visualization and processing tools for test and lab environments

Software & Interfaces

• Develop Windows-based engineering and test applications (Visual Studio / C#)

• Interface off-the-shelf HMIs and custom hardware for operator control and remote monitoring

• Support configuration and calibration tools for embedded and test systems

ECU & System Integration

• Integrate and interface with automotive ECUs, including CAN messaging and control features

• Support ECU feature development and experimentation for R&D projects

• Work closely with engineering and manufacturing teams to support powertrain development

• Reverse engineer CAN bus data in order to interface various ECUs with custom test equipment

QUALIFICATIONS:

• Bachelor’s degree in Electrical Engineering, Computer Engineering, Mechatronics, or equivalent experience

• 5+ years experience in industrial automation, controls engineering, or custom machinery

• Strong experience with:

  • PLC programming and industrial I/O

  • Embedded firmware development (C/C++)

  • Electrical schematics and hardware design, PCB layout.

  • Sensors, actuators, motors, VFDs, and safety circuits

• Hands-on experience commissioning and troubleshooting machines in real-world environments

• Comfortable working independently on one-off and prototype systems

• Ability to work independently in a small company with entrepreneurial energy and creative tendencies

• General interest in the motorcycle/motorsports industry a plus

WORKING CONDITIONS & PHYSICAL REQUIREMENTS:

• Work is performed in an office environment with occasional exposure to test cells and production environment

• While performing the duties of this job, the employee is regularly required to sit, stand, walk, use hands, reach with hands and arms, and may be required to balance, stoop, kneel or crawl.

• The employee may occasionally lift and/or move up to 20 pounds

• Must comply with safety equipment standards: safety glasses, hearing protection, and safety toe shoes when present on production floor

• Occasional overnight travel may be required

Applicants must be authorized to work in the United States without the need for current or future employer-sponsored work authorization