Control Engineer

GCS Recruitment; United States; On-site; USD 140,000 - 190,000; Full time

Job summary

Senior Software Engineer - Controls Engineer is sought for a hybrid role connected to GCS Recruitment client’s automation team. The job focuses on designing and deploying CODESYS-based control software for a standardized conveyance platform, with strong emphasis on EtherCAT integration and hardware-software co-design.

The candidate will work with a collaborative team, develop reusable components, and contribute to large-scale fulfillment automation projects across multiple hub locations in the

Qualifications

• 5+ years in machine control or industrial automation software.
• Hands-on Beckhoff TwinCAT ST programming experience.
• Expertise in IEC 61131-3 ST and Function Block development.
• Proficiency in OOP with CODESYS and CASE-based state machines.
• Experience integrating automation hardware on EtherCAT networks and Linux IPCs.

Responsibilities

• Design and develop CODESYS V3 control software for the conveyance platform.
• Create reusable Function Blocks and libraries using IEC 61131-3 ST.
• Implement CASE-based state machines with fault recovery and safety.
• Integrate hardware (motors, sensors, IO-Link, actuators) and validate EtherCAT networks.
• Collaborate via Git workflows, Asana, Slack; support testing and deployment.

Skills

Beckhoff TwinCAT ST

IEC 61131-3 ST

Function Block development

CODESYS OOP

CASE-based state machines

EtherCAT

Linux-based IPCs

Git and modern dev practices

Requirements gathering

Edge-case analysis

Tools

Git

Asana

Slack

Linux

Job description

Position Title

Senior Software Engineer - Controls Engineer

Location

Hybrid (Hub-Based)

Preferred Locations:

• Seattle/Bellevue, WA
• Boston, MA
• Atlanta, GA
• Arlington, VA

Candidates must be located near an approved hub location or willing to relocate. This is not a fully remote role.

About the Role

We are seeking experienced CODESYS Controls Developers to join client's Automation Integration Technologies (AIT) team within Outbound Material Handling Systems (OMHS). This role will focus on designing, developing, and deploying software for client's next-generation standardized conveyance control platform, supporting large-scale fulfillment center automation globally.

As part of a highly collaborative engineering team, you will develop reusable control software, integrate industrial hardware, and build scalable applications that power client's automated material handling systems. The platform leverages CODESYS V3 running on Linux-based Advantech IPCs, with EtherCAT as the primary fieldbus communication protocol.

This position requires strong expertise in industrial automation software development, state-machine architecture, object-oriented programming in CODESYS, and real-world hardware integration.

Key Responsibilities

Software Development

• Design and develop CODESYS V3 control software for client's standardized conveyance platform ("Sprocket").
• Create reusable, modular Function Blocks and software libraries using IEC 61131-3 Structured Text.
• Implement robust control logic using CASE-based state machine architecture.
• Apply object-oriented principles including methods, properties, interfaces, and encapsulation to develop scalable automation frameworks.
• Develop conveyor-level features, hardware abstractions, and control applications for large-scale deployment.

Requirements & System Design

• Gather and analyze requirements before implementation.
• Produce clear requirements documents outlining scope, assumptions, edge cases, recovery behaviors, and fault handling.
• Lead early design reviews and technical discussions with client engineering teams.
• Translate operational and hardware requirements into software solutions.

Hardware Integration & Validation

• Integrate and validate industrial hardware including:
  • Motors and motor drives
  • Sensors and photo-eyes
  • IO-Link devices
  • Actuators
  • MDR (Motor Driven Roller) systems
• Configure and troubleshoot EtherCAT-based device networks.
• Conduct hardware validation and testing in client's Bellevue automation lab.

Application Assembly & Deployment

• Interpret electrical schematics and control area drawings.
• Develop JSON-based application configurations following predefined schemas.
• Assemble control applications using reusable software components and hardware abstractions.
• Support testing, commissioning, and deployment activities.

Collaboration & Agile Execution

• Participate in code reviews with client Control Area Leads.
• Collaborate through Git-based development workflows.
• Manage deliverables using Asana.
• Participate in daily Slack standups and weekly engineering sync meetings.
• Deliver software iteratively and seek feedback throughout development.

Required Qualifications

Technical Skills

• 5+ years of experience developing machine control or industrial automation software.
• Strong hands-on experience with:
  • Beckhoff TwinCAT Structured Text programming
• Advanced expertise in:
  • IEC 61131-3 Structured Text
  • Function Block development
  • Object-Oriented Programming in CODESYS
• Proven experience designing software using:
  • CASE-based state-machine architectures
  • Fault recovery, safety, and operational state management
• Experience integrating industrial automation hardware on EtherCAT networks.
• Familiarity with Linux-based industrial PCs.
• Experience using Git and modern software development practices.

Behavioral & Engineering Competencies

• Strong requirements-gathering and technical analysis skills.
• Ability to identify edge cases and ask clarifying questions before implementation.
• Demonstrated ability to deliver incrementally and adapt to changing requirements.
• Strong communication and collaboration skills within cross-functional teams.

Preferred Qualifications

• Experience within:
  • Material Handling Systems (MHS)
  • Conveyance and Sortation Systems
  • Packaging Automation
  • High-Throughput Industrial Automation
• Deep understanding of:
  • EtherCAT network architecture
  • IO-Link device integration
• Ability to read and interpret:
  • Electrical schematics
  • Control system drawings
  • Wiring diagrams
• Experience with configuration-driven applications using JSON schemas.
• Exposure to C++ and/or Rust development.
• Previous client Robotics experience (subject to rehire eligibility verification).
• Experience supporting commissioning and field deployment activities.

Project Overview

The team is building a standardized software-defined conveyance control platform that will be deployed across client's global fulfillment network.

The architecture follows a modular "Lego-style" design where:

• Hardware devices are abstracted into reusable software components.
• Conveyor features are developed as reusable CODESYS Function Blocks.
• Applications are configured through JSON-based schemas rather than custom software development.
• Standardized control software can be deployed across thousands of equipment instances.