Digital Power Controls Engineer

Full-time

Description

About us:

LayerZero Power Systems Inc. is a leader in power management products for mission and process critical applications. Our customer base is comprised of companies in the computer service provider (on-line commerce streaming hosting etc.) semiconductor manufacturing and financial sectors. LayerZero provides innovative products to ensure user safety and ultimate reliability of computers servers communication gear and other critical equipment. LayerZero manufactures best-in-class products representing high-end solutions. LayerZero Power Systems is on a trajectory of sustained growth with a loyal base of existing Fortune 100 customers and an expanding portfolio of new customers.

We are seeking a skilled Digital Power Controls Engineer to develop embedded firmware for advanced power conversion systems and energy infrastructure products. This role will be responsible for designing implementing testing and optimizing real-time control algorithms for AC/DC power conversion systems while supporting system monitoring communications protection and safety functions.

The ideal candidate will have hands-on experience developing embedded firmware for power electronics applications such as converters inverters UPS systems battery energy storage systems (BESS) EV charging systems and other digitally controlled power conversion products.

Key Responsibilities

Embedded Firmware Development

• Develop embedded firmware for real-time control of AC/DC and DC/DC power conversion stages.
• Design implement and optimize control algorithms for power converters inverters rectifiers and related systems.
• Develop firmware using real-time embedded architectures and microcontroller/DSP platforms.
• Support firmware verification validation debugging and performance optimization activities.

Digital Power Control and Converter Implementation

• Develop implement and tune closed-loop digital control algorithms for switching power converters including current regulation DC-bus voltage regulation power control and transient response.
• Implement and validate real-time control functions using MCU/DSP peripherals including synchronized ADC sampling PWM generation interrupt-driven execution and deterministic control-loop timing.
• Analyze converter dynamics and control-loop stability including compensator design bandwidth phase margin and response to input and load disturbances.
• Support converter hardware bring-up and control validation using oscilloscopes voltage and current probes programmable power sources electronic loads and automated test systems as appropriate.
• Collaborate with the Power Electronics Design Lead to validate control performance against power-stage models simulation results and measured hardware behavior.

Monitoring Protection & Safety

• Develop converter state machines including startup precharge coordination enable/disable sequencing fault handling controlled shutdown and restart interlocks.
• Implement firmware-based fault detection and protection coordination including overcurrent overvoltage undervoltage overtemperature and other system-level safety and protection requirements.
• Implement fault monitoring.
• Develop safety permissives and protection coordination strategies in collaboration with the Power Electronics Design Lead.
• Support parallel operation of converter modules including module coordination current or power sharing DC-bus regulation and fault response as applicable to the product architecture.
• Implement droop regulation on both AC and DC.

Communications & System Integration

• Develop and maintain Modbus communication interfaces for telemetry configuration diagnostics alarms and event logging.
• Support integration of additional communication protocols such as CAN Ethernet TCP/IP RS-485 UART SPI and I²C.
• Partner with system controls and software engineers to ensure seamless product integration.
• Support HMI supervisory controller and cloud connectivity interfaces.

Product Development & Design Reviews

• Participate in system architecture discussions and firmware design reviews.
• Develop firmware requirements design documentation and test procedures.
• Support prototype bring-up hardware integration and product qualification activities.
• Contribute to root-cause analysis and corrective actions for field and manufacturing issues.

Requirements

Required Qualifications

• Bachelors degree in Electrical Engineering Computer Engineering Computer Science or related field.
• 10 years of embedded firmware development experience.
• Demonstrated hands-on experience implementing or tuning closed-loop digital control for a power converter inverter rectifier or comparable power-electronics system.
• Strong proficiency in C/C for embedded systems development.
• Experience with microcontrollers DSPs ARM-based processors or real-time embedded platforms.
• Practical understanding of PWM switching ADC sampling real-time control-loop timing and digital control implementation.
• Experience debugging embedded control systems integrated with physical hardware and validating performance through instrumented testing.
• Working knowledge of control-loop stability compensator design and converter transient response.
• Knowledge of:
• Digital control systems
• Power electronics fundamentals
• Real-time operating systems (RTOS)
• Embedded communications protocols
• Fault management and protection systems
• Control loop design and implementation

Preferred Qualifications

• Experience with three-phase active rectifiers high-voltage DC links or bidirectional AC/DC and DC/DC conversion.
• Experience with parallel converter operation current sharing and modular power-conversion architectures.
• Experience with hardware-in-the-loop (HIL) testing automated control validation and model-based development.
• Experience with DSP-based digital power controllers or MCU platforms equipped with high-resolution PWM and synchronized ADC peripherals.
• Experience with MATLAB/Simulink code generation tools and model-based design.
• Familiarity with UL IEC IEEE and functional safety standards.

Key Competencies

• Embedded Firmware Development
• Real-Time Control Systems
• AC/DC Power Conversion
• Digital Power Electronics Control
• Fault Detection & Protection
• Modbus Communications
• System Integration
• Firmware Verification & Validation
• Root Cause Analysis
• Cross-Functional Collaboration

What We Offer:

• Competitive pay with performance incentives
• 100% company-paid medical dental and vision
• 401(k) with company match
• 4 weeks PTO 10 paid holidays and 2 floating holidays

Why You Will Love Working with Us:

• Impact: Develop your skills and expertise in a rapidly growing industry with your work directly influencing the success of mission-critical projects.
• Innovation: Immerse yourself in an environment that celebrates forward-thinking and continuous improvement.
• Collaborative spirit: Work closely with engineers marketers and other professionals to bring ideas to life.
• Grow with us: We are committed to your personal and professional development offering endless opportunities to improve your skills and advance your career

At LayerZero we are proud to be an Equal Opportunity Employer. We welcome and celebrate diversity and we are committed to creating an inclusive environment for all employees.

Required Experience:

IC