Top 10 Best PLC Simulation PC Software for 2025

In the rapidly evolving world of industrial automation, the ability to test, debug, and validate control logic without physical hardware is not just a convenience—it’s a necessity. This is where a powerful PLC simulation PC software becomes an indispensable tool for engineers, students, and hobbyists alike. A robust PLC simulation PC software platform allows for the creation of virtual environments where Programmable Logic Controller (PLC) code can be rigorously tested against simulated real-world processes, saving immense time, cost, and mitigating risk before deployment.

As we look towards 2025, the landscape of these simulation tools is being shaped by integration with the Industrial Internet of Things (IIoT), digital twin technology, and cloud computing. This article delves into the top 10 best PLC simulation PC software solutions that are leading the charge and will be essential in the year ahead.

1. Siemens PLCSIM Advanced & TIA Portal

Siemens stands as a titan in the automation industry, and its simulation offerings are second to none. While the basic PLCSIM is integrated into the TIA Portal (Totally Integrated Automation) for simple code testing, PLCSIM Advanced is the star for deep simulation.

• Key Features: It allows you to create virtual S7-1500 PLCs that have their own IP address on your network. This means you can connect other software (like HMIs, SCADA, or even other PLCs) to your virtual controller as if it were real hardware. Integrated seamlessly with the TIA Portal, it supports advanced communication protocols.

• Best For: Professionals and large enterprises deeply invested in the Siemens ecosystem who need to develop and test complex automation systems with high fidelity.

2. Rockwell Automation Emulate 3D & Studio 5000

Rockwell Automation’s solution takes simulation to a visual dimension. Studio 5000 Logix Emulator allows for logic emulation, but when combined with Emulate 3D, it creates a powerful digital twin environment.

• Key Features: Emulate 3D lets you model and simulate entire mechatronic systems, including conveyors, robots, and sliders. You can see your PLC code from Studio 5000 physically play out in a 3D animated environment, identifying collisions, bottlenecks, and design flaws early in the design phase.

• Best For: System integrators and OEMs designing complex material handling or packaging systems who require a holistic view of both control logic and mechanical operation.

3. Factory I/O by Real Games

Factory I/O is a revolutionary, real-time 3D simulation software that brings an unparalleled level of interactivity to industrial training. It is a standalone PLC simulation PC software that can connect to almost any PLC on the market via standard drivers (OPC UA, Modbus TCP, etc.) or its integrated soft-PLC.

• Key Features: It features a wide range of pre-built industrial application scenarios (sorting, painting, assembly) that users can modify or use as a starting point. Its intuitive drag-and-drop interface makes building a virtual plant quick and easy. The visual feedback is immediate and highly engaging.

• Best For: Educators, trainers, and students, as well as engineers looking for a visually intuitive way to test logic across different PLC platforms.

4. CODESYS Simulation

CODESYS is not just a programming environment; it’s a complete development ecosystem. Its integrated soft-PLC runtime and simulation functionality mean you can write, compile, debug, and test your entire application entirely on your PC without any hardware.

• Key Features: The simulation mode includes a virtual PLC that executes your code and allows you to create simulated I/O and visualizations. Since CODESYS is a vendor-independent IEC 61131-3 platform, skills learned here are highly transferable.

• Best For: Developers working with any of the hundreds of PLC brands that use the CODESYS runtime, and those who value an all-in-one, hardware-independent development workflow.

5. Automation Studio by Famic Technologies

Automation Studio is a comprehensive multi-disciplinary simulation platform that goes beyond just PLCs. It covers electrical, hydraulic, pneumatic, and control system design, allowing for integrated simulation.

• Key Features: You can design your control circuit in ladder logic or function block diagram and connect it to a simulated electro-pneumatic system. This allows for a true mechatronic approach to system design and troubleshooting.

• Best For: Engineers and designers in fields like heavy machinery, mobile equipment, or aerospace where fluid power and electrical controls are deeply intertwined.

6. MX OPC Server by Software Toolbox

Sometimes, simulation isn’t about the PLC itself, but about creating a virtual process for a real PLC to interact with. The MX OPC Server with its Simulation Toolkit is a powerhouse for this exact purpose.

• Key Features: It allows you to build high-performance, complex process simulations (like chemical reactions, tank levels, and batch processes) and connect them to a real PLC via OPC UA or DA. This is perfect for testing a physical PLC’s program under realistic and stressful conditions.

• Best For: Advanced users and system integrators who need to create high-fidelity process models for testing SCADA systems and physical PLC hardware.

7. Beckhoff TwinCAT 3

TwinCAT 3 from Beckhoff transforms a standard PC into a real-time PLC and motion controller. Its simulation capabilities are deeply embedded in the Microsoft Visual Studio environment.

• Key Features: TwinCAT 3 includes a powerful scope, PLC simulation mode, and the ability to create .NET simulations that interact with the PLC logic. It’s ideal for creating virtual commissioning environments for complex machines, especially those involving advanced motion control.

• Best For: Machine builders and control engineers focused on high-speed, precision automation who are comfortable in a .NET/Visual Studio environment.

8. Do-more Simulator by Automation Direct

Automation Direct is known for providing high-value automation products, and their Do-more Simulator is a perfect example. It is a free, fully-functional simulator for their Do-more PLC series.

• Key Features: It fully emulates the Do-more PLC CPU, allowing users to write, debug, and test programs without any hardware. It’s an excellent, cost-effective tool for learning ladder logic and the capabilities of the Do-more platform.

• Best For: Hobbyists, students, and small businesses getting started with PLCs or those specifically using Automation Direct’s product line.

9. LogixPro 500 PLC Simulator

While somewhat dated, LogixPro 500 remains a highly popular and effective learning tool. It emulates the Allen-Bradley RSLogix 500 interface and provides several simulation labs (like a silo process and a door simulator).

• Key Features: Its simplicity and focused exercises make it one of the best tools for beginners to grasp fundamental PLC concepts like ladder logic programming, I/O scanning, and timer/counter instructions.

• Best For: Absolute beginners in PLC programming who want a low-cost, no-fuss environment to learn the ropes of Allen-Bradley-style ladder logic.

10. Mosaic Simulator (for Schneider Electric EcoStruxure)

For those in the Schneider Electric/Modicon ecosystem, the simulation functionality within EcoStruxure Machine Expert (formerly SoMachine) and EcoStruxure Control Expert (formerly Unity Pro) provides a solid, integrated solution.

• Key Features: It allows for full simulation of the control application, including the ability to force and modify variables, and test program logic. It integrates directly with the programming software for a seamless workflow.

• Best For: Engineers and technicians programming and maintaining Schneider Electric PLCs, such as the Modicon M series.

FAQ (Frequently Asked Questions)

Q1: Can I use PLC simulation software without a physical PLC?
A: Absolutely. The primary purpose of a PLC simulation PC software is to function as a virtual PLC, executing your control logic on your computer. You do not need physical hardware for the core simulation and testing process.

Q2: Are there any free PLC simulators available?
A: Yes, several options are free or have free versions. CODESYS, the Do-more Simulator, and Factory I/O (with a limited-time trial) are excellent examples. LogixPro is also very affordable and acts as a low-cost training tool.

Q3: What is the difference between an “emulator” and a “simulator”?
A: The terms are often used interchangeably, but technically, an emulator (like Rockwell’s Logix Emulate) tries to replicate the exact internal behavior and cycle of a specific PLC model. A simulator (like Factory I/O) often focuses on replicating the external process or environment that the PLC controls. The best PLC simulation PC software suites often combine both capabilities.

Q4: How important is simulation for creating a “Digital Twin”?
A: It is fundamental. A digital twin is a virtual representation of a physical asset or system. The simulation software provides the dynamic, behavioral model of the system (the “brain” and “body”), while the PLC code acts as the control logic. Together, they form a complete digital twin for virtual commissioning and continuous optimization.

Q5: Which software is best for a beginner?
A: For a complete beginner, Factory I/O combined with its integrated soft-PLC or LogixPro 500 are highly recommended due to their visual nature and immediate feedback, which makes learning engaging and intuitive.

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Comparison Table at a Glance (2025)

Conclusion

Choosing the right PLC simulation software in 2025 will depend heavily on your specific PLC platform, budget, and project requirements. Whether you are a student just starting out with the free CODESYS platform, a trainer using the immersive Factory I/O, or a professional engineer commissioning a full digital twin with Siemens or Rockwell tools, the power of virtual testing is undeniable. By investing in the right simulation tool, you empower yourself to build better, more reliable, and more efficient automated systems for the future.