Senior Controls & Automation Engineer

Mainspringenergy; Edison (CA); On-site; USD 140,000 - 190,000; Full time

Job summary

Mainspring Energy in Menlo Park, CA seeks a Senior Automation & Controls Engineer to design and deliver industrial automation systems using Beckhoff Platform. This role spans electrical design to controls software deployment, with 20-25% on upgrading existing equipment and collaboration with manufacturing, electrical, mechanical, and software teams.

You should have 5–10 years of industrial automation experience, hands-on PLC work with Beckhoff TwinCAT and Allen-Bradley, and strong IEC 61131-3

Qualifications

• 5–10 years of experience in industrial automation or controls engineering.
• Hands-on experience with PLC platforms such as Beckhoff TwinCAT (TwinCAT 3), Allen-Bradley.
• Strong proficiency in IEC 61131-3 with emphasis on Structured Text.
• Experience with motion control, robotics, or high-performance automation systems.
• Familiarity with EtherCAT architecture and performance tuning.
• Experience with industrial networks (OT networks).
• Experience working alongside MES, SCADA, or higher-level software systems.
• Prior experience acting as a technical lead on projects.

Responsibilities

• System Design & Architecture: Lead the design of complex automation systems, including PLCs, HMIs, and robotics.
• Programming & Implementation: Program and debug control systems using Beckhoff, with Rockwell/Siemens/Schneider as options.
• Project Execution: Own engineering projects from conception to completion, ensuring timelines, budgets, and quality.
• Continuous Improvement: Analyze manufacturing processes to identify inefficiencies and bottlenecks.
• Safety & Compliance: Design and deploy safety interlock systems and ensure NFPA 79, SEMI, UL508A compliance.
• Collaboration & Mentorship: Work with mechanical, hardware, and software teams; may mentor junior staff.
• Maintenance & Upgrades: Dedicate 20–25% of time to maintenance, improvement, and upgrading existing equipment.

Skills

Beckhoff TwinCAT

Allen-Bradley

IEC 61131-3

Structured Text

Git version control

Motion control

Robotics

EtherCAT

Industrial networks

Technical leadership

Tools

CAD software

Job description

About Mainspring

Mainspring Energy manufactures and delivers fuel-flexible, low-emissions local power solutions that rapidly add new capacity and deliver reliable, affordable, and sustainable electric power. The company began commercial shipments of its Mainspring Linear Generators in 2020 and today has hundreds of megawatts in advanced development and field operations for leading Fortune 500 companies, data centers, and utilities. Mainspring also partners with global energy leaders including AEP, NextEra Energy Resources, Schneider Electric, and more.

The core values that ground our work, guide our decisions, and connect us together:

• Pragmatic Optimism
• Excellence without Ego
• Proactive Collaboration

Job Overview

We are seeking a Senior Automation & Controls Engineer who applies sound software engineering practices to design and deliver industrial automation systems using the Beckhoff Platform. This role focuses on building reliable, maintainable, and scalable control systems in a real-world manufacturing environment.

You will develop automation solutions that balance deterministic control requirements with modern engineering practices such as modular design, version control, code reviews, and disciplined change management. While the work is rooted in traditional industrial automation, there is an increasing emphasis on improving the development, testing, and deployment of control software.

In this role, you will work across the full lifecycle of automation systems—from electrical design and hardware selection to controls software development, deployment, commissioning, and long-term support. A significant portion of your time, approximately 20-25%, will also be dedicated to the maintenance, improvement, and upgrading of existing equipment. You will collaborate closely with manufacturing, electrical, mechanical, and software teams to ensure systems are safe, reliable, and adaptable to evolving production needs.

The role is based at Mainspring Headquarters in Menlo Park, California, and is primarily on-site with some travel within North America.

• System Design & Architecture: Lead the design of complex automation systems, including PLCs, HMIs, and robotics. Create and maintain electrical schematics, control enclosure layouts, and wiring diagrams using CAD software
• Programming & Implementation: Program and debug control systems using platforms mainly in Beckhoff products with some possible use of Rockwell , Siemens TIA Portal and Schneider Electric products. Develop and implement closed-loop control systems and novel data structures
• Project Execution: Own specific engineering projects from conception to completion, ensuring timelines, budgets, and quality standards are met. Contributing to the successful completion of projects in a timely fashion
• Continuous Improvement: Analyze existing manufacturing processes to identify inefficiencies and bottlenecks. Conduct root cause analyses and troubleshooting to support process improvements
• Safety & Compliance: Design and deploy personnel safety interlock systems and ensure compliance with industry standards such as NFPA 79, SEMI, and UL508A
• Collaboration & Mentorship: Collaborate with multidisciplinary teams (mechanical, hardware, software) to ensure proper integration of automated systems. You may supervise the activities of a few others or mentor junior staff and technicians
• 5–10 years of experience in industrial automation or controls engineering
• Hands-on experience with PLC platforms such as Beckhoff TwinCAT (TwinCAT 3), Allen-Bradley
• Strong proficiency in IEC 61131-3 with emphasis on Structured Text
• Proven experience delivering industrial automation projects in manufacturing or production environments
• Solid understanding of: Industrial sensors and actuators | Electrical control systems and panel design | Industrial networking and fieldbus protocol
• Experience using Git or similar version control systems in a professional environment
• Experience with motion control, robotics, or high-performance automation systems
• Familiarity with EtherCAT architecture and performance tuning
• Experience with industrial networks (OT networks)
• Experience working alongside MES, SCADA, or higher-level software systems
• Prior experience acting as a technical lead on projects

Does your experience not meet all of our posted requirements? Studies have shown that some people are less likely to apply to positions unless they meet every listed requirement. At Mainspring, we are committed to building a diverse, inclusive, flexible, and collaborative environment, so if you want to help us transition the world to clean and affordable electricity, and don’t meet all posted requirements for a particular role, we’d still love to hear from you. Mainspring can sometimes be flexible enough to shift responsibilities for the right person, or otherwise identify open or upcoming roles that may better fit your professional background.

In more traditional words, Mainspring Energy, Inc is an Equal Opportunity Employer. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, or protected veteran status and will not be discriminated against on the basis of disability.

This compensation and benefits information is based on Mainspring Energy's estimate as of the date of publication and may be modified in the future. We generally do not negotiate on salary once we have made an offer. The level of pay within the range will depend on a variety of job-related factors that may include location, relevant prior experience and/or education, or particular skills and expertise. New hires joining the company tend to be paid within the starting base pay range noted above, with opportunities to increase pay over time based on development of additional skills, competencies, and company-specific knowledge.