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Senior Controls Engineer 

EOE StatementWe are an equal employment opportunity employer. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, national origin, disability status, protected veteran status or any other characteristic protected by law.
Req Number ENG-18-00052  
Position Senior Controls Engineer  
Division Miller Electric Mfg. LLC, an ITW Company  
Location Appleton, WI  
Dept 124 

Assigned Shift First Shift 

Full-Time/Part-Time Full-Time  
Exempt/Non-Exempt Exempt  


ITW Welding continues to build its capabilities in embedded systems development as a core competency in digitally controlled welding equipment, processes, and systems. To support this effort, we are looking for a Senior Controls Engineer to play a key role in both R&D and New Product Development for welding and heating equipment. The Senior Controls Engineer will be a key contributor in the investigation, development, and implementation of digital control systems for new and innovative products with three key areas of focus; power conversion, wire feed delivery, and weld process control. This position requires a highly motivated individual with exceptional communication and interpersonal skills to work collaboratively across multi-discipline project teams consisting of electrical, software, mechanical and welding engineers.


  • Establish controls architectures for a variety of welding equipment platforms.
  • Model and derive transfer functions (Laplace and Z-domain) for power conversion control, wire feed motor control and various weld process controls
  • Design PID, LEAD/LAG and other forms of compensators to meet steady state and dynamic requirements
  • Work closely with power conversion and software engineers to validate control loop performance and stability. Develop simulation models correlating with measured results
Position Requirements


  • Bachelor’s Degree in Electrical Engineering (Master’s Degree with Controls emphasis preferred) with a minimum of 7 years of experience.
  • Experience designing control systems for power conversion equipment
  • Experience designing control systems for brushed and brushless DC motors
  • Experience with Z-transforms using backward, forward and trapezoidal approximation rules
  • Knowledgeable on analog signal conditioning and digital sampling requirements
  • Knowledgeable on digital signal processing and filter design (FIR, IIR, Kalman, etc.)
  • Knowledgeable on modern, classic and state variable feedback techniques
  • Knowledgeable on tools and techniques for control loop stability analysis (analog and digital)

Desired Qualifications:

  • Experience implementing digital control loops in embedded C/C++ on resource limited 16/32-bit DSP or microcontroller, and/or VHDL on FPGA or CPLD
  • Experience developing embedded firmware for power conversion and/or motor controls
  • Experience developing embedded firmware with critical deterministic timing requirements

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