Automation Software Engineer - PC & Industrial Controls Integration

Job Description

Pivotal Systems – Fremont CA

Automation Software Engineer – PC & Industrial Controls Integration

Position Summary

We are seeking an Automation Software Engineer specializing in the integration of PC-based software, industrial automation controllers, instrumentation, and digital/analog I/O systems. This position will design, develop, integrate, and support automation platforms used to control sophisticated industrial and process equipment.

The ideal candidate combines strong software development skills with practical knowledge of Beckhoff/TwinCAT control systems, industrial networking, PLC/IPC architectures, real-time control, instrumentation, and equipment communications.

The engineer will be responsible for developing the software and communications architecture connecting Windows or industrial PCs to automation controllers, sensors, actuators, instrumentation, safety systems, and process equipment.

Key Responsibilities

Automation & Controls Software Development

Design, develop, test, and maintain software for automated process and equipment control systems.

Develop control applications using Beckhoff TwinCAT, PLC programming environments, and PC-based automation platforms.

Develop PLC logic using IEC 61131-3 languages including Structured Text (ST), Function Block Diagram (FBD), and Ladder Logic.

Develop PC-side applications and utilities using languages such as C#, C++, Python, or equivalent.

Implement deterministic and real-time control functions where required.

Develop equipment state machines, sequences, recipes, interlocks, alarms, fault handling, and recovery logic.

Develop software interfaces between process equipment and higher-level supervisory or factory systems.

PC-to-Controller Integration

Integrate Windows-based PCs and industrial PCs with PLCs, motion controllers, remote I/O, instrumentation, and embedded control systems.

Configure and troubleshoot communication between PC applications and industrial controllers.

Develop interfaces for command/control, data acquisition, process monitoring, configuration, diagnostics, and equipment status.

Implement reliable communication architectures capable of operating continuously in an industrial environment.

Diagnose hardware/software interface problems using protocol analyzers, oscilloscopes, logic analyzers, network tools, and software debugging tools.

Beckhoff / EtherCAT Systems

Configure and program Beckhoff CX and C-series industrial PCs/controllers and associated I/O hardware.

Develop automation applications using TwinCAT 3.

Configure and troubleshoot EtherCAT networks, terminals, distributed I/O, drives, and third-party EtherCAT devices.

Perform EtherCAT device mapping and PDO configuration.

Diagnose network timing, communication, synchronization, and device-state issues.

Integrate Beckhoff analog, digital, temperature, pressure, motion, and specialty I/O modules.

Work with TwinCAT ADS and related interfaces for communication between PC software and the real-time control environment.

Analog & Digital I/O Integration

Integrate and troubleshoot industrial instrumentation and I/O including:

0–10 V analog signals

10 V analog signals

4–20 mA current loops

RTD and thermocouple inputs

Digital inputs and outputs

Relay and solid-state outputs

Pulse/frequency inputs

Encoder signals

PWM outputs

Pressure and vacuum sensors

Temperature sensors

Flow sensors and mass flow controllers

Solenoid and pneumatic valves

Pumps, motors, heaters, and other process devices

Develop appropriate scaling, calibration, filtering, linearization, range checking, alarm limits, and diagnostic functions for instrumentation.

Industrial Communications

Develop, configure, and troubleshoot industrial communication interfaces and protocols including:

EtherCAT

RS-232

RS-485, Modbus RTU

Modbus TCP, Ethernet/IP

TCP/IP and UDP

OPC UA

CAN / CANopen

Serial ASCII and proprietary equipment protocols

Experience integrating third-party instruments through published command sets and communication specifications is highly desirable.

Process Automation

Develop control strategies for process equipment involving:

Gas flow and pressure control

Vacuum systems

Temperature control

PID control loops

Mass flow controllers

Pressure controllers

Pumps and valves

Pneumatic systems

Heaters and thermal systems

Gas delivery systems

Data acquisition and process monitoring

Develop sequencing and interlock logic to ensure safe and repeatable equipment operation.

HMI & User Interface Development

Develop or integrate graphical user interfaces for equipment operation.

Create equipment status screens, process displays, alarm screens, maintenance interfaces, and engineering diagnostic tools.

Implement real-time process trending and data visualization.

Develop parameter configuration and recipe management interfaces.

Design software tools that allow engineering and service personnel to quickly diagnose equipment problems.

Data Acquisition & Logging

Implement high-reliability process data acquisition.

Develop data logging and historical trending systems.

Interface automation systems with SQL databases or other data storage platforms.

Develop traceability for alarms, operator actions, recipes, process parameters, and equipment events.

Support collection of engineering data for equipment characterization and process development.

System Architecture

Participate in defining complete equipment-control architectures including:

Industrial PC Automation Controller EtherCAT/Industrial Network Remote I/O Sensors/Actuators/Process Equipment

Responsibilities include selection and integration of:

Industrial PCs

Automation controllers

Remote I/O

Network interfaces

Serial communication hardware

Analog and digital I/O

Instrumentation

Motion-control hardware

Power supplies

Safety interfaces

Work closely with electrical engineers to define control panels, wiring, grounding, shielding, electrical interfaces, and I/O requirements.

Equipment Safety & Reliability

Develop equipment interlocks and fail-safe control logic.

Implement watchdogs, communication-loss detection, timeout handling, and fault recovery.

Define safe equipment states following power loss, controller failure, sensor failure, or communication failure.

Participate in equipment risk assessments and design reviews.

Support integration with emergency-off circuits, safety relays, safety PLCs, gas detection systems, and facility interlocks where applicable.

Troubleshooting & Commissioning

Perform hands-on equipment startup and commissioning.

Troubleshoot electrical, software, network, instrumentation, and control-system problems.

Verify I/O operation and perform system-level functional testing.

Develop commissioning procedures and automated diagnostic tests.

Support prototype equipment through transition into production.

Provide technical support to manufacturing, field service, applications, and process engineering teams.

Documentation

Develop and maintain:

Software design specifications

Control architecture diagrams

I/O maps

Communication protocol specifications

State diagrams and sequence-of-operation documents

Software revision documentation

Test and validation procedures

Equipment troubleshooting documentation

Interface Control Documents (ICDs)

Maintain software using appropriate version-control and change-management systems, such as Git.

Required Qualifications

Bachelor's degree in Electrical Engineering, Computer Engineering, Computer Science, Automation Engineering, Mechatronics, or a related technical discipline.

Approximately 3+ years of experience developing industrial automation, equipment-control, or process-control systems.

Strong understanding of PC-based industrial automation.

Experience integrating software with physical hardware.

Experience with PLC or industrial controller programming.

Working knowledge of industrial analog and digital I/O.

Experience with serial and Ethernet-based equipment communications.

Ability to interpret electrical schematics, wiring diagrams, I/O drawings, and equipment specifications.

Strong systematic troubleshooting and debugging skills.

Ability to work directly with prototype and production equipment in a laboratory or manufacturing environment.

Preferred Qualifications

Experience with several of the following is highly desirable:

Beckhoff automation hardware

TwinCAT 3

EtherCAT

TwinCAT ADS

IEC 61131-3 Structured Text

C# / .NET

C++

Python

Visual Studio

RS-232 / RS-485

Modbus RTU/TCP

OPC UA

CAN/CANopen

SQL mySQL or Mongo databases

Industrial Ethernet

Real-time control systems

PID control

Motion control

Servo and stepper systems

Industrial instrumentation

Automated test equipment

Data acquisition systems

Semiconductor / High-Tech Equipment Experience – Preferred

Experience developing automation systems for semiconductor manufacturing, semiconductor equipment, vacuum systems, gas delivery, analytical instrumentation, or other high-technology process equipment is strongly preferred.

Relevant experience may include integration of:

Mass flow controllers (MFCs)

Pressure transducers and pressure controllers

Vacuum gauges

Vacuum pumps

Pneumatic isolation and control valves

Gas cabinets and gas delivery systems

Temperature controllers

RF or plasma systems

Process chambers

Safety and facility interlocks

Familiarity with SEMI equipment standards and SECS/GEM communications is an additional advantage.

Desired Engineering Profile

The successful candidate should be comfortable working across the boundary between software, electronics, instrumentation, controls, and physical process equipment.

This is not strictly a PLC programming position. The engineer should be capable of understanding the entire control chain:

PC Software Industrial Controller Communication Network I/O Hardware Instrumentation Physical Process

The position is particularly suited to an engineer who enjoys hands-on development and can move effectively between software debugging, network troubleshooting, electrical I/O, instrumentation, and process-control problems.

Full-time