Integrating deep learning, MATLAB, and advanced CAD for predictive root cause analysis in PLC systems: A multi-tool approach to enhancing industrial automation and reliability

The integration of Deep Learning (DL), MATLAB, and Advanced Computer- Aided Design (CAD) in the root cause analysis of prognostic errors in Programmable Logic Controller (PLC) systems represents a significant advancement in industrial automation and reliability. This research explores the synergistic application of these technologies to diagnose, predict, and mitigate failures in PLC systems, which are critical for controlling automated processes in various industries. By employing DL algorithms, the study enhances predictive maintenance capabilities, allowing for early detection of anomalies and reducing downtime. MATLAB is utilized as the central platform for data processing, algorithm development, and simulation, providing a versatile environment for integrating DL models with real-time data from PLCs. Advanced CAD tools are employed to model and visualize the physical systems controlled by the PLCs, offering a comprehensive view that bridges the gap between digital analysis and physical implementation. The research methodology includes data collection from PLC systems, DL model training and validation, MATLAB-based simulations, and CAD modelling. The findings demonstrate improved accuracy in identifying the root causes of PLC prognostic errors, leading to more efficient maintenance strategies and enhanced system reliability. This paper concludes that the integration of DL, MATLAB, and CAD provides a powerful approach for advancing predictive maintenance in industrial settings, ultimately contributing to greater operational efficiency and cost savings.