By Kenton Williston, Embedded Industry Writer 

Industrial automation continues its rapid evolution, with manufacturers well on the way to Industry 5.0. These shifts are driving fundamental changes in how control systems are implemented, with growing emphasis on software-defined functionality through technologies like virtual PLCs and IT/OT convergence on top of time-sensitive networking-based (TSN-based) solutions like Intel Time Coordinated Computing (Intel TCC). 

To understand what these trends entail for 2025, take note of TenAsys^®, a leader in real-time platforms, along with members of its ecosystem. Key take-aways from their participation at SPS 2024 in Nuremberg, Germany, include: 

• Software-based PLCs are replacing traditional hardware solutions, enabling faster deployment and deeper integration with enterprise systems. 

• Real-time and IT workloads are converging, driving a need for real-time operating systems (RTOS) like TenAsys^® INtime^®   that can run harmoniously on the same platform as Linux or Windows using hypervisors. 

• TSN is enabling new levels of integration between control and enterprise networks, with RTOSes like INtime^® providing the foundation for deterministic communication. 

• IT/OT integration is moving from concept to reality through new deployment models that maintain real-time performance while enabling enterprise connectivity. 

Here’s how these trends are reshaping industrial automation and what they mean for manufacturers. 

From Hardware to Virtual PLCs 

This shift from hardware to vPLCs represents one of the most visible changes in industrial automation. A traditional PLC might take weeks or months to gather, build, and program all the needed hardware. In contrast, “the integration of the PLC feature + communications protocols into a machine with INtime^® takes in general two days,” explains Pascal Girerd, International Sales Manager at STRATON AUTOMATION, a leading provider of IEC61131-3 automation platforms.  

The capabilities of platforms like INtime are also changing how control systems are debugged and maintained. “Our LogicLab solution offers real-time debug options that allow non-intrusive debugging without stopping the execution of the control application,” shares Michele Bertocci, CEO of AXEL, a specialist in IEC 61131-3 programming systems. “This is crucial in real-world automation applications its own controller based on INtime^® and Nodka’s PC, and Estun Automation develops its own robotic controller based on INtime and Nodka’s PC,” reports Tom Dong, Product Director at Nodka, a leading provider of industrial PCs and automation hardware. “Phoenix Contact software also provides a PLC solution based on INtime and Nodka’s PC.” 

Get more insights: Read the TenAsys Virtualized Control Systems white paper. 

Deterministic Workloads on PC-based Hardware 

One of the most significant trends in industrial automation is the convergence of real-time and non-real-time workloads on a single PC platform. This represents a major shift from traditional approaches where these functions were strictly separated. 

Recent hardware developments have accelerated this transition. In the past, machine builders would “struggle to identify PC platforms with low jitter and support for hard real-time use case,” explains Andreas Knape, TenAsys’ Vice President of Sales. Now, many platforms incorporate Intel TCC, which ensures deterministic performance not only locally but across the network. 

The result is a considerably reduced development cycle. “With our technology, seamless integrated CAN communication within INtime^®  is achieved,” says Hans Kuersten, Head of Product Marketing at esd electronics*, a leader in CAN and EtherCAT automation solutions. The solution is specifically “optimized for real-time environments, delivering seamless deployment and high efficiency compared to in-house development.” 

The practical implementation of this convergence is demonstrated by acontis technologies*, whose EtherCAT Master Stack is used by industry leaders like KUKA and Yaskawa. “Our solutions allow customers to easily combine existing non-real-time Windows applications with the real-time EtherCAT EC-Master to realize powerful but flexible controllers and HMIs,” describes Thomas Waggershauser, Head of Sales & Marketing at acontis. 

The Evolution of Industrial Networks 

This networking evolution is opening new possibilities across the industry. “Several customers around the globe use the EC-Master on TenAsys^® INtime^® for their applications,” notes acontis’s Waggershauser. “These customers profit from the fact that they can easily combine existing non-real-time Windows applications with the real-time EtherCAT EC-Master to realize powerful but flexible controllers and HMIs.” 

The transformation extends to protocol integration as well. “Thanks to our partnership with koenig, the PLC environment can be embedded easily to INtime^®, bringing at the same time the option for many communication protocols (Modbus, Profinet, EtherCAT*, OPC UA, MQTT) and motion control,” explains STRATON AUTOMATION’s Girerd. 

The ability to integrate real-time networking into consolidated, PC-based systems is driving significant innovation in industrial networking and TSN is emerging as a key enabler. At the University of Stuttgart, for example, the ISW automation research group has developed a TSN reference design demonstrating how INtime-based solutions can help manufacturers participate in TSN-based networks through a simplified API approach. 

The integration potential of these new networking standards is demonstrated in recently introduced Costantino CNC architecture from ISAC*, a pioneer in PLC and motion control solutions. This innovative system leverages both TSN and multicore processing capabilities while maintaining deterministic performance through INtime. This combination enables unprecedented levels of integration between control and higher-level systems. 

Enabling IT/OT Convergence 

The convergence of networking standards, software-based control systems, and unified hardware platforms is finally making true IT/OT integration practical. This integration is exemplified by new deployment options like the RTS embedded hypervisor with INtime^® Distributed RTOS, enabling novel combinations like a Linux-based PLC running alongside INtime motion applications. 

ISAC demonstrates this convergence in action, as their solutions are “based on INtime^® for Windows to run the hard real-time parts while allowing to host a rich HMI in Windows environments,” notes Andrea De Nardis, the company’s R&D Department Chief. This approach has proven particularly valuable for complex applications requiring both deterministic control and sophisticated user interfaces. 

The integration capabilities extend beyond HMI functionality. “Our shared memory system can also be used to connect to other applications or communication stacks,” adds STRATON AUTOMATION’s Girerd.  

Conclusion 

The path to 2025 is clear: integrated solutions that combine IT and OT capabilities will become the norm, not the exception. The convergence trends we’re seeing—from TSN and vPLCs to the merging of real-time and IT workloads—are fundamentally changing industrial automation. 

“Customers have increased need to enable IT/OT-level communications and due to INtime’s tight integration it is not difficult to derive data and exchange it between the two worlds by various means,” says Knape. “Evolving implementations like using the RTS embedded hypervisor with INtime^® Distributed RTOS enable new combinations, like Linux-based PLCs with motion control applications and a Windows or Linux user interface.” 

Manufacturers who embrace these changes while maintaining focus on practical implementation will be best positioned to succeed in this new industrial landscape. To achieve this success, they’ll need partners with proven experience in bridging traditional automation with modern IT systems. 

Want to know more about the future of automation? Download the new TenAsys e-book The Software-Defined Manufacturing Revolution.