Firmware Controls Engineer

About the role

This role focuses on designing, implementing, and maintaining software and firmware control algorithms for precision variable frequency drives (VFDs) within embedded systems. The Firmware Controls Engineer applies advanced control theory to electric motor drives and DC/DC converters, collaborates closely with hardware engineering teams, and ensures that embedded control solutions meet both technical specifications and customer requirements.

Responsibilities

• Design, implement, test, debug, and support operating system and application software for precision variable frequency drives that meet technical and customer requirements.
• Develop, implement, and refine control algorithms for electric motors and DC/DC converters using control theory and embedded systems techniques.
• Adhere to established coding standards, revision control practices, and software development processes to ensure high-quality, maintainable code.
• Solicit, analyze, and incorporate feedback from customers and end users to enhance product functionality, performance, and usability.
• Conduct and participate in code reviews and design reviews to improve software quality and ensure robust system architecture.
• Propose and champion new ideas, features, and enhancements, and present them constructively to stakeholders and team members.
• Document software and firmware designs thoroughly, including code comments, design reports, and technical descriptions for future reference and knowledge sharing.
• Track, prioritize, and resolve reported software and firmware bugs, performing thorough testing and verification to confirm the effectiveness and stability of fixes.
• Design and develop reusable software and system components, and integrate them into both existing and new product designs to improve efficiency and consistency.
• Collaborate closely with electrical hardware engineers in planning, design, and development to ensure software and hardware compatibility and optimal system performance.
• Serve as a technical lead on assigned projects, coordinating with cross-functional teams and customers to meet deliverables and resolve technical or product issues.
• Use tools such as Matlab, Simulink, and related modeling environments to design, simulate, and validate control algorithms prior to implementation.
• Apply knowledge of real-time operating systems and embedded C/C++ development to implement deterministic, reliable control firmware.
• Utilize version control tools such as GIT to manage source code, branching, merging, and release processes.
• Contribute to continuous improvement of development processes, tools, and methodologies within the firmware and controls engineering team.

Qualifications

• Master's degree in Electrical Engineering or Mechanical Engineering with an emphasis on control of electric motors and/or DC/DC converters.
• Strong experience in control theory and its application to engineering problems, particularly in electric motor drives and power electronics.
• Solid understanding of basic physics relevant to electromechanical systems and power conversion.
• Expert-level proficiency with Matlab and Simulink for modeling, simulation, and analysis of control systems.
• Experience with real-time operating systems for embedded applications.
• Experience with Verilog HDL code development for digital hardware or FPGA-based control implementations.
• Experience with C and C++ for embedded software development on microcontrollers or DSPs.
• Experience using GIT or similar version control systems for source code management.
• Minimum of 3 years of related experience in firmware, controls engineering, or embedded systems development.
• Ability to work closely with electrical hardware engineers to ensure hardware-software compatibility and system-level performance.
• Ability to design, implement, test, and debug embedded control software and firmware for precision variable frequency drives.
• Capability to conduct and participate in code and design reviews and to follow established coding and revision control standards.

Additional Skills & Qualifications

• Experience with Vivado and Vitis design suites for FPGA and embedded system development.
• Experience with Matlab/System Generator for FPGA-based control and signal processing design.
• Experience with Mathematica or similar tools for advanced mathematical modeling and analysis.
• Familiarity with power electronics, including variable frequency drives, DC/DC converters, and electric motor control systems.
• Experience working with PC boards and understanding of hardware interfaces relevant to embedded control systems.
• Experience with firmware development for embedded systems in power electronics applications.
• Strong analytical and problem-solving skills, with the ability to diagnose and resolve complex control and firmware issues.
• Effective communication skills for collaborating with cross-functional teams and engaging with customers and end users.
• Ability to document designs clearly and thoroughly, including reports, design descriptions, and code-level documentation.
• Interest in championing new ideas and features and contributing to continuous product improvement.

Work Environment

This is an onsite role in a hardware-focused engineering environment where firmware, controls, and power electronics development occur in close collaboration. The Firmware Controls Engineer works directly with electrical hardware engineers, power electronics equipment, and embedded development platforms to design and validate control solutions for variable frequency drives and related systems. The position involves hands-on work with embedded systems, test setups, and laboratory equipment, as well as frequent use of software tools such as Matlab, Simulink, Verilog development environments, Vivado, Vitis, and version control systems like GIT. Working hours follow a standard onsite engineering schedule, with in-person collaboration, design reviews, and lab testing forming a key part of the daily routine.

Job Type & Location

This is a Permanent position based out of Franksville, WI.

Pay and Benefits

The pay range for this position is $100,000.00 - $160,000.00/yr. Individual compensation offered for this position within this range will depend on many factors, including qualifications, skills, relevant experience, job knowledge, geographic location, internal equity, and other pertinent job-related factors.

Full Company Benefits - Health, Dental, Vision, 401K, Etc.