Automation Software Engineer – PC & Industrial Controls Integration

Pivotal Systems; Fremont (CA); On-site; USD 120,000 - 180,000; Full time

Job summary

Pivotal Systems is seeking an Automation Software Engineer specializing in PC-based software and industrial controls integration. You will design and support automation platforms connecting Windows PCs to controllers, sensors, and I/O systems.

Responsibilities include developing control software with Beckhoff TwinCAT, PLC programming, and PC-side utilities in C#, C++, or Python, ensuring real-time operation and robust communications across equipment and process systems.

Qualifications

• Design, develop, integrate, and support automation software for industrial systems.
• Experience with Beckhoff TwinCAT and PLC environments, and PC-based automation platforms.
• Proficiency in IEC 61131-3 languages and real-time control concepts.

Responsibilities

• Design, develop, test, and maintain software for automated process and equipment control systems.
• Develop control applications using Beckhoff TwinCAT and PLC environments.
• Develop PC-side applications in C#, C++, Python, or equivalent.
• Ensure deterministic and real-time control where required.
• Diagnose hardware/software interface problems and troubleshoot communications.

Skills

Beckhoff TwinCAT

IEC 61131-3

Structured Text

C#

C++

Python

Tools

Beckhoff CX

EtherCAT

Job description

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.
• 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.
• 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:

• RTD and thermocouple inputs
• Digital inputs and outputs
• Relay and solid-state outputs
• Pulse/frequency inputs
• Encoder signals
• Pressure and vacuum sensors
• Temperature sensors
• Flow sensors and mass flow controllers