Your Guide to a High-Tech, In-Demand Career
If you’re exploring engineering career paths, you might have encountered the term “controls engineer” and wondered what it means. Controls engineers play a vital role in many industries, ensuring automated systems operate safely, efficiently, and as intended. Are you curious about this field? Whether you’re considering a career in controls engineering or exploring opportunities to work with Pigler Automation, this guide will help you understand what a controls engineer does and whether it’s the right career for you.
What Does a Controls Engineer Do?
At its core, a controls engineer programs and configures industrial automation systems. Their responsibilities typically include:
Configuring Hardware:
Controls engineers collaborate with process engineers, who design how a plant or manufacturing setup should operate. Once the design is in place, the controls engineer configures hardware like sensors, valves, and controllers to ensure all components communicate seamlessly.
Programming Process Logic:
Using the plant’s specifications, controls engineers create process control logic—the “instructions” that guide the system’s response to conditions such as temperature, pressure, or flow rates.
Developing HMIs (Human-Machine Interfaces):
Operators on the plant floor rely on clear, intuitive interfaces to monitor and control systems. Controls engineers design HMIs to present critical data and allow operators to make adjustments effortlessly.
Commissioning at the Facility:
Once everything is configured, controls engineers test and validate the system at the plant or facility. They ensure it runs as designed before it goes live.
How is a Controls Engineer Different from a Process Engineer?
While a process engineer designs the blueprint for how a plant should function—defining steps, sequences, and processes—a controls engineer brings that blueprint to life. Instead of writing code from scratch, controls engineers often use visual programming tools in Distributed Control Systems (DCS) or Supervisory Control and Data Acquisition (SCADA) systems. This streamlines the implementation and minimizes the need for traditional programming.
Tools of the Trade
Controls engineers rely on advanced platforms, such as DCS and SCADA systems, to integrate hardware (sensors, controllers, actuators) with software interfaces. These tools help manage intricate industrial environments, from opening a valve at the correct pressure to orchestrating a chemical production line, creating a unified system that operators can monitor, control, and optimize. (Want to learn more about the technology Pigler Automation Controls engineers work with? Learn more here.)
Where Do Controls Engineers Work?
Controls engineers are indispensable in industries that depend on automated processes. At Pigler Automation, for example, we serve clients in:
- Oil & Gas
- Energy & Power Generation
- Biopharma
- Chemical Processing
- Food & Beverage Manufacturing
- General Manufacturing
Each industry requires precise, reliable control systems to meet production goals, maintain quality, and ensure safety.
Who Can Become a Controls Engineer?
One of the most exciting aspects of this field is its accessibility. While many controls engineers come from mechanical, chemical, electrical, or computer engineering backgrounds, the field is open to anyone with a relevant degree and a passion for learning. Key qualities include:
Analytical Thinking:
The ability to understand complex systems and convert them into logical instructions.
Attention to Detail:
Ensure that every hardware component is configured accurately and that each process logic path is tested thoroughly.
Continuous Learning:
As technologies and industry standards evolve, staying curious and adaptable is crucial.
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Controls engineering offers a rewarding career path filled with opportunities to innovate and make a tangible impact across industries. If you’re ready to explore your future as a controls engineer or need a controls engineer to work on a project, Pigler Automation is here to guide you every step of the way.
