How electrical engineering is changing with Industry 4.0: a focus on control systems

Industrial automation, digitalization, and new paradigms shaping the future of electrical engineering

The evolution of industrial automation is rewriting the rules of electrical engineering. From smart sensors to advanced control systems, Industry 4.0 is driving a profound transformation of industrial processes. Today, designing and building electrical systems no longer means simply powering machines—it means integrating technologies that communicate, learn, and adapt.

What is Industry 4.0 and why it impacts electrical engineering

The term “Industry 4.0” refers to the fourth industrial revolution: a set of digital technologies that enable production plants to become smarter, more connected, and more autonomous. In this scenario, electrical engineering is evolving to meet new demands for:

• Real-time control
• Data management
• Predictive maintenance
• Energy efficiency

Electrical panels and control systems are at the heart of this revolution, transforming from simple energy containers into intelligent management hubs.

Control systems in industrial automation

In modern automation, control systems are designed to gather data from sensors and actuators, process information through algorithms, and dynamically control operations. Key components include:

• PLCs (Programmable Logic Controllers): the core logic of the plant
• SCADA systems: for remote supervision and control
• HMI interfaces: intuitive human-machine interaction
• Fieldbus networks: such as Modbus, Profinet, or EtherCAT

When properly integrated, these elements enable precise, flexible, and scalable control of production processes.

The central role of the electrical panel in automation

The industrial electrical panel is the junction point between power and control. In Industry 4.0, panels must:

• Support the integration of digital devices
• Manage complex communication across the network
• Enable remote connectivity and secure access
• Ensure operational continuity and preventive diagnostics

Designing such systems requires a multidisciplinary approach involving electronics, IT, and industrial engineering.

Tangible benefits for companies

Investing in advanced control systems and automation yields clear benefits:

• Reduced downtime through continuous monitoring
• Optimized energy consumption with smart logic
• Improved product quality via precise parameter control
• Increased safety for both operators and systems

According to a report by McKinsey & Company, companies that implement advanced automation systems can improve productivity by up to 30% within two years.

Challenges of the digital transition

Adopting industrial automation also involves key challenges:

• Training technical staff on new technologies
• Industrial cybersecurity to protect networks and sensitive data
• System interoperability between different vendors
• Upgrading existing infrastructure (revamping)

Choosing reliable partners capable of designing and building panels and control systems that meet international standards is essential.

2025 trends in industrial automation

Emerging technologies shaping electrical engineering include:

• Edge computing: processing data directly on-site without central servers
• AI-based predictive maintenance
• Digital twins: virtual simulations for process optimization
• Self-learning systems based on machine learning

These solutions require a new way of thinking about electrical design: more integrated, adaptable, and data-driven.

The role of technical standards

Technological evolution goes hand in hand with updated regulations. In Italy and across Europe, key references include:

• CEI EN 61439: for low-voltage switchgear and controlgear
• IEC 61131: PLC programming standards
• ISO 50001: energy management systems

Compliance ensures safety, legal conformity, and eligibility for digital and energy transition incentives.

Conclusion: electrical engineering enters the digital era

Industrial automation is no longer optional—it’s a necessity for staying competitive. Electrical panels and control systems are the technical backbone of this transformation. Investing in advanced design, connectivity, and intelligent control today means building more resilient, efficient, and future-ready plants.