What are the benefits of using PLC simulation software?

PLC simulation software is very useful to troubleshoot and debug the PLC code but you cannot check and verify all aspects of the logic and working of the machine. But there are lot of advantages to simulate before testing in the actual machine like verifying IO mapping , HMI simulation with connecting to virtual plc or if you use a digital twin you can verify how the code works with visual feedback also. But with just PLC simulator you can do limited tests only.

PLCs (and other compute resources for providing operational control) have come a long way since inception. The memory capacity nows allows for improved object-oriented programming techniques which enables the addition of capabilities, such as simulation, into the device and operational layers of the code. It is now possible, and recommended, to have embedded logic that can provide testing and validation prior to implementation, which translates to cost savings due to reduce downtime. This same logic gives field staff the ability to work on failed devices, readiness verification and troubleshoot without adversely affecting production.

My experience has been that in machine development there is a back and forth between the machanical systems and the controls which simulation cannot address. There are also timing issues, communication loading issues, etc. which are always the toughest to sort and simulation has never helped me find any of these issues. So my preference would be to not use simulation.

PLC simulation software is great for developing and testing PLC programs in a virtual environment, eliminating the need for physical hardware. It's cost-effective, reduces the risk of errors, and allows for flexible design changes. Ideal for hands-on training, the software accelerates development, supports realistic testing, and enables remote collaboration. Its documentation features aid in troubleshooting and auditing, making it an essential resource for those new to PLCs.

I've found PLC simulation software invaluable to cut down on commissioning times. Any oddities in the program/HMI is identified and solved before commissioning.

The simulators I have used are fine to show which outputs will be on given a combination of inputs, but of course these are not specific to a particular process or piece of equipment. They are good to a certain point. For complex programming projects, the only method I have used is to actually wire devices from the machinery being controlled to the PLC and testing it. I have used HMI simulators which are good since these actually connect to the PLC from my PC and I can debug my HMI screens while connected to the PLC.

When developing large systems PLC simulation software is invaluable. It allows us to produce detailed works tests before installing systems on site, in what are often short duration plant outages.

Using PLC simulation software is super helpful because it lets you test and fine-tune your control logic in a virtual environment before deploying it to real equipment. This actually saves time and money since there's no need to set up physical hardware just to experiment. It also helps catching bugs early and safely explore different scenarios. By simulating I/O devices and process behavior, teams can improve accuracy, safety, and even collaboration, making it an essential tool in modern industrial automation. It just makes the whole development process smoother and more reliable.

!NO HAY EXCUSAS! Debería ser obligatorio usar los software de simulación. Nunca debería realizarse una implementación de un código nuevo o una modificación directamente sobre el PLC en producción, sin haber pasado ese código por un entorno de simulación previamente. Implementar cualquier código (pequeño o grande) sobre una instalación "viva" es asumir el mismo riesgo que volcar un vaso de agua sobre la fuente de alimentación del sistema. Cualquier software de sistema de control moderno ya incorpora un entorno de simulación lo suficientemente robusto y fiable para hacer esas pruebas previas. Si se prueba el código antes de la puesta en marcha en un entorno simulado, porque no se va a hacer lo mismo con cualquier modificación en planta...