Overhead Crane Controls Engineer / Technician
Controls & Automation Consultants, Austin, TX, United States
Overhead Crane Controls Engineer / Technician
Position Overview
We are seeking a skilled Contract Controls Engineer / Technician to support the design, programming, commissioning, and troubleshooting of overhead crane systems in industrial environments. This role is hands‑on and field‑focused, working with PLCs, HMIs, drives, and safety systems to ensure reliable and safe crane operation.
The ideal candidate will have experience with Siemens SIMATIC S7 platforms, including failsafe (F) systems, and a strong understanding of motion control and industrial safety as it relates to crane operations.
Key Responsibilities
Perform PLC and HMI programming for overhead crane systems using Siemens S7 (TIA Portal / Step 7)
Develop and modify safety logic using S7 F-systems and Step 7 Safety Advanced
Configure and commission VFDs and motion control systems for hoist, trolley, and bridge travel
Execute loop checks, I/O verification, and point‑to‑point testing of field devices
Support commissioning activities including startup, functional testing, and system validation
Troubleshoot electrical, controls, and communication issues in real‑time during commissioning and operations
Implement and validate safety functions including E‑stops, limit switches, overload protection, and anti‑collision systems
Work with HMI/SCADA systems to develop operator interfaces, alarms, and diagnostics
Collaborate with mechanical, electrical, and operations teams to ensure system performance and reliability
Document system changes, test results, and commissioning activities
Key Systems & Equipment
Overhead bridge cranes, gantry cranes, and hoist systems
HMI systems (Siemens WinCC or equivalent)
Variable Frequency Drives (VFDs) and motor control systems
Industrial communication protocols (PROFINET, PROFIBUS, Ethernet/IP as applicable)
Safety devices including light curtains, safety relays, encoders, and limit switches
Important Aspects of the Role
Functional Safety
Strong understanding of safety‑rated systems (SIL / Performance Level concepts)
Experience implementing and validating failsafe logic in S7 F‑systems
Ability to design and troubleshoot safety circuits for crane operations
Understanding of coordinated motion between hoist, trolley, and bridge
Experience with acceleration/deceleration tuning to minimize load swing
Familiarity with positioning systems and encoder feedback
Experience with crane‑to‑crane anti‑collision systems
Implementation of travel limits, zoning, and restricted areas
Integration of sensors for position and proximity detection
Comfortable working in heavy industrial environments (manufacturing, steel, logistics, etc.)
Ability to support long shifts during commissioning and startup phases
Strong troubleshooting mindset under real‑time operational pressure
Qualifications
5+ years of experience in industrial controls or automation
Hands‑on experience with Siemens S7 PLC programming (TIA Portal / Step 7)
Experience with S7 F‑systems and Safety Advanced programming preferred
Background in crane systems, material handling, or heavy industrial equipment strongly preferred
Experience with HMI/SCADA development and integration
Strong understanding of electrical systems, instrumentation, and control panels
Ability to read and interpret electrical schematics and control drawings
Preferred Experience
Commissioning of overhead or gantry crane systems
Integration of crane systems into plant‑wide controls or MES systems
Experience with multi‑crane coordination and safety zoning
Familiarity with industry standards related to crane safety and operation
Field‑based role with onsite commissioning and support activities
Travel may be required depending on project location
Work performed in industrial settings with adherence to site safety protocols
Additional Notes
Candidates should be capable of working independently while collaborating with cross‑functional teams
Strong communication skills are essential for coordinating with clients and internal teams
Flexibility to support accelerated schedules during critical project phases
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Position Overview
We are seeking a skilled Contract Controls Engineer / Technician to support the design, programming, commissioning, and troubleshooting of overhead crane systems in industrial environments. This role is hands‑on and field‑focused, working with PLCs, HMIs, drives, and safety systems to ensure reliable and safe crane operation.
The ideal candidate will have experience with Siemens SIMATIC S7 platforms, including failsafe (F) systems, and a strong understanding of motion control and industrial safety as it relates to crane operations.
Key Responsibilities
Perform PLC and HMI programming for overhead crane systems using Siemens S7 (TIA Portal / Step 7)
Develop and modify safety logic using S7 F-systems and Step 7 Safety Advanced
Configure and commission VFDs and motion control systems for hoist, trolley, and bridge travel
Execute loop checks, I/O verification, and point‑to‑point testing of field devices
Support commissioning activities including startup, functional testing, and system validation
Troubleshoot electrical, controls, and communication issues in real‑time during commissioning and operations
Implement and validate safety functions including E‑stops, limit switches, overload protection, and anti‑collision systems
Work with HMI/SCADA systems to develop operator interfaces, alarms, and diagnostics
Collaborate with mechanical, electrical, and operations teams to ensure system performance and reliability
Document system changes, test results, and commissioning activities
Key Systems & Equipment
Overhead bridge cranes, gantry cranes, and hoist systems
HMI systems (Siemens WinCC or equivalent)
Variable Frequency Drives (VFDs) and motor control systems
Industrial communication protocols (PROFINET, PROFIBUS, Ethernet/IP as applicable)
Safety devices including light curtains, safety relays, encoders, and limit switches
Important Aspects of the Role
Functional Safety
Strong understanding of safety‑rated systems (SIL / Performance Level concepts)
Experience implementing and validating failsafe logic in S7 F‑systems
Ability to design and troubleshoot safety circuits for crane operations
Understanding of coordinated motion between hoist, trolley, and bridge
Experience with acceleration/deceleration tuning to minimize load swing
Familiarity with positioning systems and encoder feedback
Experience with crane‑to‑crane anti‑collision systems
Implementation of travel limits, zoning, and restricted areas
Integration of sensors for position and proximity detection
Comfortable working in heavy industrial environments (manufacturing, steel, logistics, etc.)
Ability to support long shifts during commissioning and startup phases
Strong troubleshooting mindset under real‑time operational pressure
Qualifications
5+ years of experience in industrial controls or automation
Hands‑on experience with Siemens S7 PLC programming (TIA Portal / Step 7)
Experience with S7 F‑systems and Safety Advanced programming preferred
Background in crane systems, material handling, or heavy industrial equipment strongly preferred
Experience with HMI/SCADA development and integration
Strong understanding of electrical systems, instrumentation, and control panels
Ability to read and interpret electrical schematics and control drawings
Preferred Experience
Commissioning of overhead or gantry crane systems
Integration of crane systems into plant‑wide controls or MES systems
Experience with multi‑crane coordination and safety zoning
Familiarity with industry standards related to crane safety and operation
Field‑based role with onsite commissioning and support activities
Travel may be required depending on project location
Work performed in industrial settings with adherence to site safety protocols
Additional Notes
Candidates should be capable of working independently while collaborating with cross‑functional teams
Strong communication skills are essential for coordinating with clients and internal teams
Flexibility to support accelerated schedules during critical project phases
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