Digital Transformation in Automation: Real-Time MATLAB–PLC Integration for Industry 4.0

In the era of Industry 4.0, real-time integration between simulation platforms and industrial hardware is vital for efficient design, testing, and operator training. This webinar presents a MATLAB-based solution that achieves low-latency communication between Simulink–Simscape models and Programmable Logic Controllers (PLCs) using the OPC UA protocol.

A custom MATLAB App Designer application forms the centrepiece of the system, combining interactive GUI control with modular model integration. To minimize latency, a C/C++ shared memory MEX function was implemented, enabling the exchange of only the latest simulation values while bypassing traditional logging mechanisms. Five methods support the framework: (1) command-based OPC UA communication, (2) modular Simscape model integration, (3) real-time GUI-based monitoring and control, (4) streamlined live data capture, and (5) closed-loop PLC training simulation.

This approach allows industries to perform safe, realistic operator training and validate control strategies without relying on physical assets. It further establishes a foundation for scaling into SCADA/IIoT integration, multi-zone plant simulations, and AI-driven control systems. Attendees will see how MATLAB and Simulink extend beyond prototyping into industrial-grade, real-time automation tools.