Automation Software Engineer – PC & Industrial Controls Integration

Pivotal Systems – Fremont CA

Automation Software Engineer – PC & Industrial Controls Integration

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.

• 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.

• 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.

• 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.

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.

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.

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…