From Concept to Control: Beckhoff and MathWorks Bridge the Gap Between Simulation and Real-Time Automation
- Brandon Stiffler
- 5 days ago
- 2 min read
Uniting simulation and real-time control to drive the next generation of smart automation
In the latest edition of Beckhoff USA’s Webinar Wednesday, Software Product Manager Brandon Stiffler was joined by Mahaveer Satra, Senior Application Engineer at MathWorks, to explore how model-based design, simulation, and AI are shaping the future of industrial automation. This webinar highlights how the collaboration between Beckhoff and MathWorks helps engineers move seamlessly from concept to control using standard software tools.
Download the full webinar recording from the form below:
A Smarter, More Connected Automation Landscape
Automation systems today do far more than run machines; they are integral to data analytics, predictive maintenance, and sustainability initiatives. This shift has made software the heart of automation, bringing new opportunities to boost innovation and reduce engineering complexity. Beckhoff’s PC-based control platform and MathWorks’ MATLAB® and Simulink® environments combine to address that complexity head-on. Engineers can now develop, test, and deploy control logic in a unified workflow, dramatically reducing iteration time and risk in AI- and ML-enabled systems.
Model-Based Design and Simulation in Action
Model-based design (MBD) creates a “digital thread” throughout development. Instead of waiting for physical prototypes, engineers can simulate, validate, and optimize systems early, minimizing costly late-stage fixes. This approach accelerates design cycles, improves traceability, and fosters collaboration across teams.
Through model-in-the-loop (MiL), software-in-the-loop (SiL), and hardware-in-the-loop (HiL) testing, Beckhoff and MathWorks enable engineers to validate algorithms and controls before a single bolt is tightened. One striking example: an animatronic system for the entertainment industry modeled and tested in Simulink, then executed in real-time with Beckhoff TwinCAT®. The result, precise, lifelike motion in robotics achieved through virtual validation.
AI and Machine Learning on the Factory Floor
Beyond simulation, AI is rapidly becoming a differentiator in automation. MathWorks’ integrated tools help engineers train, test, and deploy AI models for predictive maintenance, quality inspection, and process optimization, without requiring extensive coding. Case studies from Hyundai Steel, DENSO, and Krones AG demonstrate how companies are already cutting waste, improving reliability, and accelerating product development through these combined workflows.
Closing the Loop
Together, Beckhoff and MathWorks enable a true digital lifecycle, from planning and design to production and continuous improvement. With seamless data flow, real-time simulation, and AI integration, the partnership empowers engineers to innovate faster and smarter.
Ready to discover how Beckhoff and MathWorks can help bring your next intelligent machine to life? Contact your local Beckhoff sales engineer today.
And check out our upcoming and on-demand webinars to stay current on the latest automation innovations from Beckhoff.
Brandon Stiffer is a Software Product Manager at Beckhoff Automation LLC
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