Tesla · 1 month ago
Controls Engineer, Power Conversion System
Fremont, CA
Full-time
Onsite
Mid Level
$80K/yr - $168K/yr
3+ years expTesla is a leading electric vehicle and clean energy company, and they are seeking a Manufacturing Controls Engineer for their Power Conversion System line. The role focuses on sustaining and improving advanced automation systems critical to the assembly and validation of Tesla’s next-generation battery packs, requiring strong technical skills in PLC and controls fundamentals.
AutomotiveElectric VehicleEnergyManufacturingRenewable EnergyTransportation
Responsibilities
Lead controls engineering activities across PCS2 assembly and end-of-line validation stations — including fastener automation, HV connection, seal verification, and leak testing systems
Develop and sustain PLC and HMI programs (Siemens TIA Portal or Beckhoff TwinCAT) that ensure high equipment uptime, safety compliance, and operator efficiency
Collaborate with test and equipment engineering to integrate new test sequences, data interfaces, and product change requirements into existing automation
Drive process improvement using data-driven insights (OEE, downtime, MTBF) to optimize cycle time, quality, and safety
Troubleshoot PLCs, servo drives, robots, and field networks (EtherCAT, Profinet, or CANOpen) in real time to minimize production downtime
Design and approve electrical schematics, ensuring compliance with high-voltage and functional safety standards (SIL/PL)
Integrate and maintain third-party devices such as Atlas Copco DC Tools, CTS Leak Testers, Hipot Testers, and Weld Controllers for PCS-specific manufacturing operations
Conduct safety risk assessments and support pre-launch design reviews for new process cells
Partner with cross-functional teams (test, product, quality, and process) to implement controls solutions aligned with next-gen pack design and manufacturing strategies
Support 24/7 manufacturing operations and provide rapid responses to equipment faults or production-critical issues
Qualification
Required
Degree in Electrical, Controls, or Mechatronics Engineering, or equivalent experience
3+ years of hands-on experience in controls engineering for automated manufacturing or electro-mechanical assembly systems
Proficiency in IEC 61131-3 PLC programming languages, especially structured text and ladder logic
Experience with Siemens TIA Portal (S7 series PLCs) / Beckhoff TwinCAT, Safety PLCs (SIMATIC Safety or TwinSAFE), and HMI/SCADA (WinCC, TwinCAT HMI, or Ignition)
Strong knowledge of motion control, servo systems, Conveyors, VFDs and fieldbus communications (EtherCAT, Profinet, DeviceNet)
Familiarity with battery pack assembly processes, including high-voltage system safety, leak testing, and electrical validation
Experience integrating vision systems (iRVision, Cognex, Keyence) and industrial robots (Fanuc, KUKA SCARA)
Experience in programming Fanuc and KUKA robots for dispense and pick and place applications
Demonstrated ability to perform root cause analysis and implement permanent corrective actions under fast-paced, high-stakes conditions
Understanding of automation architecture, component selection (sensors, drives, relays, circuit protection), and design for maintainability
Benefits
Aetna PPO and HSA plans > 2 medical plan options with $0 payroll deduction
Family-building, fertility, adoption and surrogacy benefits
Dental (including orthodontic coverage) and vision plans, both have options with a $0 paycheck contribution
Company Paid (Health Savings Account) HSA Contribution when enrolled in the High Deductible Aetna medical plan with HSA
Healthcare and Dependent Care Flexible Spending Accounts (FSA)
401(k) with employer match, Employee Stock Purchase Plans, and other financial benefits
Company paid Basic Life, AD&D, short-term and long-term disability insurance
Employee Assistance Program
Sick and Vacation time (Flex time for salary positions), and Paid Holidays
Back-up childcare and parenting support resources
Voluntary benefits to include: critical illness, hospital indemnity, accident insurance, theft & legal services, and pet insurance
Weight Loss and Tobacco Cessation Programs
Tesla Babies program
Commuter benefits
Employee discounts and perks program
Company
Tesla
Tesla is an electric vehicle and clean energy company that provides electric cars, solar, and renewable energy solutions.
10001+ employees
H1B Sponsorship
Tesla has a track record of offering H1B sponsorships. Please note that this does not
guarantee sponsorship for this specific role. Below presents additional info for your
reference. (Data Powered by US Department of Labor)
Distribution of Different Job Fields Receiving Sponsorship
Represents job field similar to this job
Trends of Total Sponsorships
2025 (2796)
2024 (2113)
2023 (1304)
2022 (1227)
2021 (1102)
2020 (723)
Funding
Current Stage
Public CompanyTotal Funding
$20.12BKey Investors
Societe GeneraleEuropean UnionPennDOT
2024-10-05Post Ipo Debt· $783M
2023-09-13Grant· $159.6M
2023-08-15Grant· $0.23M
Leadership Team
Vaibhav Taneja
Chief Financial Officer
Tom Zhu
SVP of Automotive
Recent News
2026-01-11
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