April 8, 2025

Implementing Industrial Automation with Gateworks SBCs, CODESYS SoftPLC and Ignition SCADA Integration

Industrial automation requires reliable, flexible and scalable solutions to manage industrial processes. Gateworks Industrial Single Board Computers (SBCs) combined with the CODESYS SoftPLC platform and Inductive Automation‘s Ignition SCADA integration software provide a powerful and adaptable solution for industrial automation. This article outlines how to configure a Gateworks SBC as an industry-grade SoftPLC using CODESYS and integrate it with Inductive Automation’s Ignition SCADA integration for real-time monitoring and control.

For a complete demonstration and getting started guide, refer to the following page on the Gateworks Support Wiki: SCADA/CODESYS SoftPLC Demo.

Why Gateworks SBCs for Industrial Automation?

Gateworks SBCs are rugged, industrial-grade embedded computers with features ideal for industrial automation applications:

  • Edge computing capabilities for efficient data processing
  • Linux-based flexibility: More adaptable than traditional PLC controllers
  • Reliable hardware, long lifecycle support and extended temperature range and made in the USA
  • Scalability: Expandable with Ethernet, GPIO and wireless connectivity options
  • Industrial networking support: MODBUS TCP, Profinet and VLAN isolation for security

System Overview

CODESYS provides a Linux-based SoftPLC runtime that turns Gateworks SBCs into powerful logic controllers, enabling industrial automation processes using ladder logic. Ignition SCADA integration software can configure tasks and conditionals and display comprehensive dashboards for configuring and monitoring systems remotely or on-site.

Gateworks SBCs serve as ideal platforms for edge computing, allowing real-time data processing and reducing network congestion. This capability is particularly useful in predictive maintenance applications, where AI-based analytics can detect potential failures before they occur.

Industrial Automation System Outline

Real-World Example: Modern Brewing Facility Demonstration

At embedded world Exhibition&Conference 2025, NXP Semiconductors showcased a modern brewing facility demonstration in their booth, powered by Gateworks SBCs running CODESYS SoftPLC and integrated with Ignition SCADA integration. This demonstration highlighted how Gateworks SBCs can be used in industrial automation applications and smart factories with real-time control and monitoring.

Key Features of the Brewing Automation Setup:

  • SCADA Integration Edge Device: The Gateworks GW7400 featuring the NXP i.MX 8M Plus acted as a central Supervisory Control and Data Acquisition (SCADA integration) edge device, orchestrating communication with five SoftPLC controllers throughout the brewing facility.
  • AI-Powered Predictive Maintenance: The built-in Neural Processing Unit (NPU) of the i.MX 8M Plus enabled AI and machine learning capabilities for predictive maintenance, anomaly detection, and real-time analytics at the edge computing level.
  • CODESYS SoftPLCS: Five Gateworks GW7100 SBCs, featuring the NXP i.MX 8M Mini SoC, functioned as SoftPLCS connected to the SCADA Integration Edge Device via MODBUS TCP over Ethernet for robust industrial data communication.
  • Wireless Connectivity: The NXP IW611 Wi-Fi 6 + BLE Silex Technology M.2 SDMAX Radio Module enabled reliable wireless integration with IoT sensors and PLCs, ensuring low-latency data transfer for industrial automation.
  • Real-Time Analytics & Automation: AI-driven predictive maintenance analytics identified potential failures such as clogged filters or pump malfunctions before they occurred.
  • Secure, Automated Data Logging: Ensured real-time compliance tracking, improving audit readiness while reducing manual data entry errors.

This real-world implementation demonstrated the practical benefits of using Gateworks SBCs for industrial automation, offering a scalable and efficient solution for industries beyond brewing, such as assembling and manufacturing factories.

Configuring a Gateworks SBC for SOFTPLC and SCADA Integration

The documentation linked above provides the steps to turn a Gateworks Industrial SBC into a SOFTPLC device running the CODESYS Runtime Environment and custom user-defined ladder logic, then connect it over MODBUS TCP to a SCADA integration controller.

  • Installation of CODESYS on both the development host and board
  • Basic ladder logic for interfacing and monitoring GPIOs (button to LED)
  • Connecting CODESYS to MODBUS TCP for remote access
  • Further information on using MODBUS TCP for SCADA Integration

Integrating with MODBUS TCP and Ignition SCADA Integration

Setting Up MODBUS TCP in CODESYS

  • Add an Ethernet Device to the SoftPLC
  • Configure a MODBUS TCP Server on the device
  • Assign holding registers to GPIO control bits
  • Deploy the MODBUS TCP setup and verify using the ‘mbpoll’ tool

Connecting to Ignition SCADA Integration

  • Configure Ignition SCADA Integration to read/write MODBUS TCP registers
  • Build a real-time dashboard for remote monitoring and control
  • Implement security best practices: Disable root SSH in production
  • Use VLAN isolation to restrict external access
  • Limit SoftPLC communication to MODBUS TCP only

Conclusion

By combining Gateworks SBCs, CODESYS SoftPLC, and Ignition SCADA integration, industrial automation solutions gain:

  • Edge computing capabilities for efficient data processing
  • Robust, scalable hardware for industrial environments
  • Secure and reliable SCADA Integration for real-time monitoring
  • AI-based predictive maintenance to optimize uptime and prevent failures

With this setup, manufacturers can implement efficient, secure, and high-performance industrial automation solutions using Gateworks SBCs. For more details, visit Gateworks’ Technical Documentation.

Read the complete getting started guide HERE.

Learn more about CODSYS HERE and Inductive Automation’s Ignition Software HERE.

View all Gateworks Single Board Computers for Industrial Automation HERE.