Automation Software Engineer – PC & Industrial Controls Integration

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

Employment type
Full-Time

Work arrangement
No