Interface Software Engineer

Main Purpose of the Job
This permanent, hands-on engineering role involves integrating Proximity Detection Systems (PDS) with trackless mobile machinery (TMM) using third-party vehicle interfaces, enabling non-intelligent machines to respond to collision-avoidance commands.

The role covers the full integration process, from vehicle assessments and CAN trace analysis to wiring harness design, connector identification, mounting solutions and, where required, hydraulic interventions.

Working mainly with surface yellow fleet equipment across various OEMs, the incumbent must develop, test and document customised integration solutions for each vehicle type before rollout.

The role also serves as Booyco’s in-house technical custodian of the interface software, responsible for understanding, maintaining and modifying code where required, while ensuring compliance with PDS and OEM interfacing requirements.

Education, experience and competencies

• BEng/BSc in Electrical, Electronic or Mechatronic Engineering, or equivalent.
• Valid driver's licence (Code B/EB minimum).
• Minimum 3 years' experience in vehicle electronics, embedded systems or machine control integration.
• Demonstrable experience working with CAN bus on vehicles or machines.
• Practical experience writing or maintaining code for embedded or control systems.
• Sound understanding of electronics fundamentals: voltage, current, resistance, signals, grounding, and 12 V / 24 V vehicle electrical systems.
• Ability to read and interpret electrical wiring diagrams, schematics and OEM service documentation.
• Working knowledge of CAN bus and SAE J1939 (PGNs, SPNs, source addresses, scaling and diagnostic messages) and use of CAN tools (e.g. PCAN, Kvaser, SavvyCAN, CANalyzer).
• Ability to decode unknown or proprietary CAN messages by correlating bus data with vehicle actions.
• Programming ability in C/C++ for embedded targets, plus a scripting language (e.g. Python) for data analysis and tooling; ability to read and maintain code written by others.
• Use of version control (e.g. Git) and a disciplined approach to software releases.
• Basic hydraulic knowledge: reading hydraulic schematics and understanding valves, pressures and braking circuits on mobile machines.
• Confident use of a multimeter and oscilloscope; able to identify sensor types (analog, PWM, frequency/pulse, switched) by measurement.
• Practical wiring skills: crimping, connector termination, soldering, harness building, protection and routing to vehicle standards.
• Mechanical aptitude for designing and fabricating brackets and mounting electronics on heavy equipment; basic CAD skills.
• Clear technical writing: produces diagrams, reports and test records that someone else can follow.

Responsibilities
Vehicle assessment and integration design

• Site vehicle assessment. Visit sites to inspect new vehicle types and establish how each one operates: drivetrain, throttle or accelerator control, service and park braking, retarders, speed sensing, available data buses, the electrical system and the hydraulic system. Use OEM documentation, wiring and hydraulic diagrams and hands-on measurement.
• Integration method selection. Decide how the interface should act on the vehicle, e.g. via the CAN bus (J1939 or proprietary messages), by switching outputs or relays, by using a pulse counter on a speed sensor, or via a hydraulic intervention. Justify the choice in terms of safety, reliability and impact on OEM systems.
• CAN trace capture and decoding. Capture CAN traffic, identify the messages and signals needed (e.g. vehicle speed, engine speed, throttle position, gear, park brake, brake pressure) and confirm scaling and behaviour. This includes decoding proprietary, undocumented OEM messages and maintaining signal definitions (e.g. DBC files).
• Hydraulic interface evaluation. From time to time, assess whether speed or stop control requires a hydraulic intervention (e.g. on service brake, park brake or propel circuits). Read hydraulic schematics, specify valves, pressure sensors or switches, and work with hydraulic specialists and the OEM so that any intervention fails safe and does not compromise the machine's braking or steering performance.

Hardware: connectors, harnesses and brackets

• Connectors and harnesses. Identify OEM connectors and integration points, specify mating connectors and design, modify and build vehicle-specific harnesses (including T-harnesses that avoid cutting OEM wiring). Maintain harness drawings and pin-outs so every installation can be reproduced.
• Brackets and mounting. Determine safe, serviceable mounting positions for the interface, sensors and harness routing. Design new brackets where required (sketches or CAD) and manage their fabrication, accounting for vibration, heat, water, dust and maintenance access.
• Bill of materials. Compile a bill of materials and installation kit list for each vehicle type to enable repeatable rollout.

Interface software

• Software maintenance. In-house owner of the interface software: hold and understand the source code, maintain version control, build and deploy firmware and configuration, and keep the software release history up to date.
• Coding when required. Make code changes where needed, such as adding new CAN message or signal mappings, adjusting control logic for a new vehicle type, and fixing defects. Follow an agreed review, test and release process for all changes to safety-related software.
• Profile configuration. Work out the correct profile values for each vehicle type (e.g. speed limits, sensor calibration such as pulses per distance, thresholds, ramp rates and timing values) and load them using the configuration tools.

PDS and OEM interfacing

• PDS integration. Understand how PDS solutions signal their outputs and states (warning, slow-down, stop, system fault), including differences between PDS suppliers and standard interfaces, and make sure the interface responds correctly, within the required response time, and moves to a safe state if communication or power is lost.
• OEM interfacing. Where an OEM offers a standard collision-avoidance interface (e.g. per ISO/TS 21815-2) or its own interface kit, evaluate it as an alternative to a third-party interface. Engage OEM representatives for documentation and approval and identify warranty or certification implications of any modification.
• Requirements and compliance. Work to the Mine Health and Safety Act and its regulations on trackless mobile machinery and collision management, the relevant ISO 21815 requirements, EMESRT guidance and each mine's own TMM/PDS standards. Contribute to risk assessments (e.g. FMEA or HAZOP) for each intervention method.

Testing, documentation and support

• Single-vehicle testing and commissioning. Plan and run controlled tests on one vehicle, including slow-down and stopping behaviour, response time and fail-safe behaviour. Record results and adjust the installation, software or profile until it performs as required, then sign off the vehicle type for rollout.
• Documentation. Produce a complete integration pack for each vehicle type: findings, CAN traces and signal maps, wiring and hydraulic diagrams, bracket drawings, bill of materials, profile values, software version, risk assessment, test plans and results.
• Rollout and field support. Train and support installation teams during rollout, investigate field faults and feed lessons learnt back into the integration pack and software.
• Development requirements. Identify where the interface cannot yet support a vehicle (e.g. a new sensor type, bus or control method) and raise a clear, evidence-based requirement.