Technosoft Engineering · 1 day ago
Controls Engineer – Safety PLC
Lowell, MA
Contract
Onsite
Mid Level
3+ years expTechnosoft Engineering is seeking an experienced Autonomous Mobile Robots controls engineer with expertise in functional safety and SICK safety PLCs. The role involves designing, implementing, validating, and maintaining safety functions for autonomous mobile robots while coordinating with various teams to ensure compliance with safety standards.
Industrial EngineeringInformation TechnologyMechanical Engineering
Hiring Manager
Brian Onsite Technosoft Engineering
Responsibilities
Own the safety architecture for AMR platforms: hazard analysis, risk assessment, and safety concept definition
Design and program safety logic in SICK safety PLCs (e.g., Flexi Soft) including safe-state handling and diagnostics
Integrate SICK safety scanners (e.g., microScan3), safety encoders, safe I/O, and interlocks with drives/PLCs
Implement and validate safety functions: STO, SS1, SOS, SLS, SLP, SDI, SSM; map to PL/SIL targets
Develop safety I/O maps, safety task flows, and communication over PROFINET / EtherNet/IP / CIP Safety as applicable
Support perception & navigation teams (ROS/ROS2, SLAM, localization) to ensure safe speed/zone monitoring and field sets
Lead Safety Verification & Validation (SV&V): test plans, traceability, evidence, and safety case documentation
Perform PL/SIL calculations using SISTEMA (or equivalent) and document MTTFd, DCavg, PFHd per component/channel
Conduct change management, FMEA/FTA for safety-related changes; own release readiness and compliance gates
Interface with certification bodies and auditors; prepare documentation to comply with ISO 3691-4, IEC 61508, ISO 13849-1, IEC 62061
Troubleshoot field issues; root-cause analysis and corrective actions (hardware, firmware, configuration, timing)
Train operations and service teams on safe commissioning, maintenance, and periodic proof testing
Qualification
Required
Bachelor's degree in electrical, Electronics, Instrumentation, Mechatronics, or related field
3–5 years total experience in industrial automation/robotics; 2+ years specifically on AMR/AGV safety
Hands-on programming/configuration of SICK safety PLCs (Flexi Soft/Safety Designer) and SICK scanners/encoders
Demonstrated experience with CIP Safety over EtherNet/IP and/or PROFINET PROFIsafe for safe communications
Strong knowledge of ISO 3691-4 (industrial trucks—driverless), ISO 13849-1 (PL), IEC 62061 (SIL), and IEC 61508 fundamentals
Experience defining and validating safety functions for mobile robots (zones, field sets, protective stops, e-stop)
Competence in PL/SIL calculation tools (e.g., SISTEMA) and compiling a safety case with traceability
Familiarity with drives and safe motion integrations (Siemens, Beckhoff, Rockwell, Yaskawa, etc.)
Ability to read electrical schematics; select safety-rated components (relays, contactors, e-stops, light curtains)
Proficiency in creating test plans, requirement documents, and change control records
Excellent communication and cross-functional collaboration skills
Preferred
Exposure to ROS/ROS2 and integrating safety constraints with navigation stack and mission control
Experience with SICK microScan3 configuration (field sets), safe encoders HIPERFACE/SSI, and Flexi Soft gateways
Hands-on with Siemens TIA Portal, Beckhoff TwinCAT, or Rockwell Studio 5000 for standard control (non-safety) will be added advantage
Knowledge of functional safety lifecycle, safety requirements allocation, and verification plans
Experience with EMC, environmental, and compliance testing for mobile platforms
Company
Technosoft Engineering
Technosoft Engineering is a global technology service company offering mechanical engineering, electrical engineering and IT services.
501-1000 employees
H1B Sponsorship
Technosoft Engineering has a track record of offering H1B sponsorships. Please note that this does not
guarantee sponsorship for this specific role. Below presents additional info for your
reference. (Data Powered by US Department of Labor)
Distribution of Different Job Fields Receiving Sponsorship
Represents job field similar to this job
Trends of Total Sponsorships
2025 (44)
2024 (50)
2023 (62)
2022 (54)
2021 (38)
2020 (63)
Funding
Current Stage
Late StageLeadership Team
Sharun Kumar
Client Partner
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