Emulation & Virtual Commissioning Engineer - Atlanta, GA
The employer specialises in industrial automation and advanced manufacturing systems integration, with a strong focus on virtual commissioning and digital engineering to improve efficiency and reduce commissioning risk. They have an exciting opportunity for a Senior Controls Engineer - Emulation & Virtual Commissioning to join their team. This role suits a technically strong, detail-oriented engineer looking to lead simulation-driven development while still supporting hands-on controls delivery.
This position sits within the Controls Engineering and Digital Engineering department and reports to the Engineering Manager / Head of Controls Engineering. You will own the emulation platform, develop reusable simulation components, define PLC-emulation I/O standards, and drive virtual commissioning across FAT, QA, training, and validation. You will also collaborate with Mechanical and Electrical teams to reduce on-site commissioning effort and provide PLC/HMI support (Rockwell, Beckhoff, Ignition) when required.
Responsibilities:
This list of duties and responsibilities is not all inclusive and may be expanded to include other duties and responsibilities as management may deem necessary from time to time.
Emulation Platform Ownership
* Define and maintain the I/O contract between PLC libraries (UDTs/AOIs/DUTs) and emulation objects, including "virtual mode" hooks and diagnostic UDTs.
* Build and curate a reusable emulation component catalog (transport conveyor, merges, gapping, scanners, divert/confirm, recirculation roadmap to shoe/cross-belt sorter behaviours).
* Establish fidelity guidelines-model what impacts decisions (timing, throughput, divert accuracy), simplify the rest document assumptions and limits.
* Stand up an automated FAT harness (scripted test decks, pass/fail gates, reports) tied to DOO/FDS and project KPIs.
* Create layout assembly tools and workflows so engineers can rapidly reconfigure models from ECAD/CAD.
Controls Engineering Support (as bandwidth allows)
* Contribute targeted PLC/HMI work: encoder/position tracking, device AOIs, diagnostic structures, Ignition Perspective widgets, gateway scripts (retry/backoff/audit).
* Support bench testing, I/O checkout, and selected FAT/SAT activities ensure parity between emulation and live systems.
Standards, Architecture & Tooling
* Partner with controls leadership to evolve standard PLC/HMI libraries and ensure the emulation catalog stays in lock-step (versioning, migration notes).
* Contribute to Git/GitHub workflows (branching, PR templates, release notes) and CI checks (linting, schema validation).
* Define the CAD "markup" standard (mass, friction, materials, sensor faces, elevations) needed from Mechanical to improve model fidelity and reduce rework.
Cross-Functional & Customer Collaboration
* Coordinate technical integration across Mechanical, Electrical, and Software align emulation with ECAD deliverables and device selections.
* Assist Sales/PM in scoping pilots (deliverables, acceptance criteria, ROI targets) and present emulation results to internal and external stakeholders.
Team Enablement & Mentorship
* Deliver training, "golden example" projects, docs/playbooks coach Controls Engineers to build/extend models without creating a single-person bottleneck.
* Promote a simulation-first, standards-first culture focused on measurable outcomes (hours saved, defects prevented, accuracy vs. site).
Requirements:
* Bachelor's in Electrical/Controls/Mechatronics/CS or related field (Master's a plus).
* 7+ years in industrial controls or virtual commissioning, including hands-on PLC/HMI work and model-based testing.
* Demonstrated experience leading emulation/virtual commissioning efforts tied to real PLC code (not visualization only).
* Emulation: Strong with Emulate3D / Controls-grade digital twins custom catalogs and scripted test decks.
* PLC: Rockwell Studio 5000 (AOIs/UDTs/ST) required Beckhoff TwinCAT (ST/POUs/DUTs) a plus device-level diagnostics and safe states.
* HMI/SCADA: Ignition (Perspective/Vision), alarm classes, historian basics, role/IdP security.
* Interfaces/Networks: OPC UA, Ethernet/IP (preferred), Profinet scanners, drives/VFDs, motion/servos safety fundamentals.
* Tooling: Git/GitHub, semantic versioning, release notes ability to script/automate (C#/Python) for test harnesses and data prep.
* Data: Comfort with KPIs (rate, gap distribution, divert accuracy, jam MTBF) and basic SQL/time-series queries.
Reasons why you should apply:
- 401(k) retirement savings plan to support your long-term financial security
- Comprehensive health insurance coverage
- Dental insurance for complete oral healthcare support
- Vision insurance to ensure eye care and visual health needs are covered
- Paid time off to promote a healthy work-life balance and personal wellbeing
How to Apply:
For more information on the role, or an informal discussion regarding opportunities we have available, please contact Jaimie Brackett on [email protected]
Why work with Proactive?
Proactive Global is an industry leading, specialist engineering recruitment agency focused on the automation, manufacturing and advanced technology sectors. We offer specialist recruitment services to a niche customer base, vetting that our clients offer the best opportunities for your career. Proactive encourages and promotes equality and diversity within the workforce. We act with honesty, integrity and impartiality, ensuring your application is considered on its own merits and without bias.
When registering with Proactive you will have the opportunity to apply for some of the most interesting, specialist, opportunities in the marketplace, with the biggest companies in the sector. Follow us on Linkedin and Facebook for industry news and download our app for live notifications about newly listed vacancies. We look forward to helping you find your next role!
Proactive Global is committed to equality in the workplace and is an equal opportunity employer.
Proactive Global is acting as an Employment Business in relation to this vacancy.
Emulation & Virtual Commissioning Engineer - Atlanta, GA
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