Controls Engineer

Position Summary

Air Joule is seeking a Controls Engineer (Python Software Development & Automation) to design, develop, and maintain software used for automation, control system integration, and operational tooling. This role will heavily emphasize Python development to support machine automation, instrumentation integration, data acquisition, test automation, and system monitoring.

The ideal candidate is a strong Python developer who also understands controls fundamentals and industrial systems, and can build reliable software that supports commissioning, operation, and continuous improvement.

• Develop and maintain Python-based automation software supporting system operation, commissioning, and diagnostics.
• Build modular, maintainable Python code for:
• control sequencing / automation workflows
• system interlocks, per missives, and fault handling
• command and control interfaces for hardware subsystems
• Create reusable libraries for interacting with instrumentation and controls hardware.

• Integrate sensors, actuators, valves, motors, pumps, and power electronics into software workflows.
• Implement and maintain communication interfaces using Python, such as:
• Modbus TCP/RTU
• OPC UA
• Ether Net/IP (where applicable via gateways/APIs)
• Serial protocols (RS-232/RS-485)
• TCP/IP sockets and vendor APIs
• Develop software interfaces to PLCs, PCBA, industrial PCs, DAQs, and embedded controllers.

• Create Python test automation frameworks for validation of controls logic and hardware behavior.
• Develop automated tools for:
• I/O checkout
• regression testing of system sequences
• Support lab bring-up and commissioning with rapid debugging and iterative software improvement.

• Build Python pipelines for:
• real-time data acquisition from sensors and control systems
• structured logging and event/alarm recording
• performance monitoring and anomaly detection
• Implement clean data interfaces for engineering review and operational optimization.
• Support integration with databases, historians, or cloud systems (as needed).

• Improve automation reliability through:
• robust error handling and safe recovery routines
• watchdogs, heartbeat monitoring, and state validation
• improved diagnostic visibility (logs, traces, dashboards)
• Reduce downtime by improving fault detection and troubleshooting workflows.

• Write clear technical documentation for Python tools, APIs, and control workflows.
• Use best practices including:
• version control (Git)
• unit/integration testing
• packaging and dependency management
• CI practices where applicable

• Minimum Education: Bachelor’s degree in Engineering, Computer Science, or equivalent practical experience.
• Minimum Experience: 3+ years professional experience writing Python in production, automation, or controls environments.
• Strong understanding of software fundamentals:
• performance and reliability considerations
• Hands‑on experience integrating software with hardware systems.

• MQTT broker architecture and topic design
• AWS IoT or similar cloud telemetry platform experience
• Deployment experience in cellular bandwidth‑constrained, or air‑gapped environments
• Understanding of security fundamentals: certificate / key management, MQTT authentication, ACLs, and firewalls
• Familiarity with PLC programming (ladder logic and / or Structured Text)
• Familiarity with embedded systems and hardware‑software integration testing
• Experience with controls/automation systems (industrial, lab automation, robotics, or process systems).
• Familiarity with PLC systems and industrial automation (Rockwell / Siemens / Beckhoff / Codesys).
• Experience with:
• Python async systems, multiprocessing, threading
• GUI development for engineering/operator tools (PyQt, Dash, Streamlit)
• MQTT / REST APIs / gRPC
• Experience with Linux & Windows‑based systems and deployment on industrial PCs.
• Understanding of PID loops, state machine, and control theory fundamentals.