Oceaneering Uses Real‑Time PLC Data to Bring Digital Twin Training to Life
High-Fidelity Virtual Plant Enables Realistic Operator Training with PLC Integration
“By combining the modeling capabilities of MATLAB with PLC-based control systems, we create a unified environment for simulation, testing, and deployment, which bridges the gap between design and real-world execution.”
Key Outcomes
- Built a functional simulator integrated with PLC logic
- Used the same logic in interactions with the virtual plant as in the real system, reducing risks to hardware and improving safety
- Rapidly prototyped, validated, and deployed analytics and control logic without disrupting existing automation setups
Oceaneering delivers advanced automation systems by integrating robotics with simulation and data analytics. To support new engineers with onboarding, the company wanted an effective virtual-first approach that replicated real plant behavior without risking actual hardware and interfering with existing automation setups.
The virtual plant application that Oceaneering developed uses an object-oriented approach with Simulink®, so each plant subsystem is represented as an easily manageable object. High-fidelity Simscape™ models then replicate motor hydraulics, valves, and actuators. The high-fidelity digital twin built using Simulink and Simscape relays simulated inputs through standard industrial protocols to a real controller. The digital twin then receives simulated feedback, creating a closed-loop system. Finally, MATLAB® App Designer helped Oceaneering build a user interface for interactive operation.
The final packaged product was robust and scalable for real-time use, which was a key factor in accelerating Industry 4.0 adoption.
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