Automation Software Engineer - PC & Industrial Controls Integration

Job Description

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.