Controls Design Engineer

Overall purpose of role: 

The Controls Design Engineer is responsible for the design and development of electrical, pneumatic and functional safety systems for powder handling and process equipment applications.

The role focuses on the creation of compliant, manufacturable and supportable controls solutions from concept through detailed design, ensuring all systems meet applicable machinery safety, ATEX, cybersecurity and international compliance requirements.

Working closely with Mechanical Engineering, Operations and the Controls Software team, the Controls Design Engineer will develop robust control system architectures, technical documentation and design standards that support both project delivery and product development activities.

Key Responsibilities:

Controls System Design

• Develop electrical and pneumatic control system concepts for new and existing equipment.
• Prepare detailed electrical schematics, panel layouts and manufacturing documentation.
• Design control panel architectures for UK, European and North American markets.
• Select appropriate electrical, pneumatic, instrumentation and safety components.
• Develop network architectures including Ethernet/IP, Profinet and other industrial communication systems.
• Ensure compliance with relevant electrical standards and company design practices.

  Functional Safety & Compliance

• Lead controls-related risk reduction activities throughout the product lifecycle.
• Conduct and support risk assessments in accordance with ISO 12100.
• Design and validate safety-related control systems in accordance with ISO 13849-1.
• Produce Performance Level calculations and safety validation documentation.
• Develop safety circuit architectures including PL d and PL e systems.
• Support CE & Machinery Regulation compliance, maintain technical files and design records.

  Hazardous Area & Compliance

• Design systems for ATEX and hazardous area applications.
• Develop and maintain ATEX documentation and supporting calculations.
• Maintain awareness of emerging legislation, standards and industry best practices and ensure all documentation complies with Quality Management System requirements.

  Documentation & Standards

• Produce Functional Design Specifications (FDS).
• Develop and maintain standard controls design templates and documentation.
• Produce documentation suitable for manufacturing, testing, validation and customer acceptance.
• Support the creation and maintenance of company design standards.

  Product Development & Technical Support

• Support new product development projects.
• Review customer URS documentation and develop compliant technical solutions.
• Participate in design reviews, product development, and standardisation initiatives.
• Provide technical guidance to Software Engineers, Technicians and other stakeholders.
• Provide technical support to internal stakeholders, suppliers and customers.
• Provide customer-facing technical support.

Skills & Abilities:

• Strong understanding of industrial control systems.
• Electrical and pneumatic system design experience.
• Knowledge of AutoCAD Electrical or equivalent design software.
• Ability to produce detailed engineering documentation.
• Strong problem-solving and analytical skills.
• Excellent written and verbal communication skills.
• Ability to work independently and collaboratively.
• Strong attention to detail and commitment to engineering quality.

  Technical Knowledge:

• Machinery Regulation (EU 2023/1230)
• EN ISO 12100 Risk Assessment & EN ISO 13849-1 Functional Safety
• Performance Level calculations and Safety circuit design
• ATEX and hazardous area system design
• Industrial cybersecurity principles (IEC 62443)
• Pneumatic design principles (ISO 4414)
• Ethernet/IP and Profinet industrial networks
• CE and UKCA compliance requirements
• UL508A / UL698A awareness

  Experience & Qualifications:

  Training:

• Functional training on areas such as ACAD and other software tools will be provided
• Training on internal systems and procedures specific for the role will be provided as required
• Compliance & CI training will be provided where required.
• Familiarisation with Matcon products, standards and procedures.
• Ongoing training will be agreed on as required

• HNC, HND, Degree or equivalent qualification in Electrical/Controls Engineering.
• Proven Engineering experience in controls design for industrial machinery or process systems.
• Experience of electrical and pneumatic control panel design.
• Experience producing technical documentation and engineering drawings.
• Experience with ATEX and hazardous area applications.

Location:  Matcon Head Office, Evesham, Worcestershire, UK. Some overseas travel may be required from time to time.