Virtual Commissioning Engineer, Controls Engineering

Description:
The Virtual Commissioning Engineer develops and deploys high‑fidelity simulation and digital‑twin environments to validate automated equipment, PLC logic, motion control, and system behavior prior to commissioning.
You will integrate physics‑based models with real‑time control systems, execute model‑in‑loop and hardware‑in‑loop testing, build reusable component libraries, and contribute to predictive, model‑driven engineering workflows.
This role sits at the intersection of controls engineering, automation, and system modeling, requiring the ability to reason across both the virtual and physical domains. The ideal candidate is equally comfortable with PLC logic and with high‑fidelity simulation or digital‑twin development.

Responsibilities:
Develop 2D/3D and physics‑based simulation environments for automated machinery and industrial equipment
Build and validate MIL (model‑in‑loop), SIL (software‑in‑loop), and HIL (hardware‑in‑loop) test setups for PLC‑controlled systems
Create and maintain simulation/VC component libraries representing automation hardware and controllers
Implement automated test frameworks to validate logic behavior before deployment
Validate PLC, HMI, and supervisory system interactions within a virtual commissioning environment
Conduct virtual FATs and pre‑startup validation to reduce onsite commissioning time
Develop multi‑domain digital twins capturing mechanical, motion, web-handling (roll-to-roll), or other coupled physics
Build model identification and calibration pipelines, including parameter estimation, uncertainty analysis, and automated regression testing
Combine evidence from first‑principles models, reduced‑order models, empirical data, and experiment‑driven methods to achieve robust model fidelity
Integrate digital twins with real‑world telemetry, instrumentation, logging systems, and data pipelines to support prediction and what‑if analysis

Requirements:
Bachelor’s degree or equivalent experience in mechatronics, automation, controls engineering, or related field
Experience with digital twins, system modeling, or virtual commissioning
Hands‑on experience with PLC commissioning — Beckhoff TwinCAT, Siemens or other platforms beneficial
Experience working with industrial networks (e.g., EtherCAT, OPC UA, ADS, Ethernet/IP, PROFINET)
Strong programming ability in Python, C++, MATLAB, SIMULINK or similar
Strong analytical and problem‑solving skills, with the ability to work across both simulated and real systems
Experience with virtual commissioning tools such as iPhysics, Process Simulate, WinMOD, MapleSim, Emulate3D, EKS, or equivalent
Experience integrating simulation with supervisory systems (e.g., MES, SCADA, GRAFANA)
Experience with physics‑informed neural networks (PINNs) for modeling, system identification, or surrogate modeling is preferred
Familiarity with machine learning for parameter estimation or surrogate modeling
Experience in automation‑intensive industries (automotive, packaging, high‑volume manufacturing, robotics, etc.)

Compensation & Benefits:
Benefits

Along with competitive pay, as a full-time Tesla employee, you are eligible for the following benefits at day 1 of hire:
Medical plans > 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 Accounts) HSA Contribution when enrolled in the High-Deductible 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 (90 day waiting period)
Employee Assistance Program
Sick and Vacation time (Flex time for salary positions, Accrued hours for Hourly 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

Expected Compensation
$91,600 - $164,400/annual salary + cash and stock awards + benefitsPay offered may vary depending on multiple individualized factors, including market location, job-related knowledge, skills, and experience. The total compensation package for this position may also include other elements dependent on the position offered. Details of participation in these benefit plans will be provided if an employee receives an offer of employment.