6ES7392-1AM00-PB02 SIEMENS Simulation output module

A Siemens Simulation Module is a dedicated tool—either hardware or software—designed to replace or mimic the function of real field devices (actuators) and sensors (inputs) during the development and testing phases of a PLC program.

• Hardware Simulation Modules (Physical SIM): These are compact, physical modules that fit directly onto the PLC (e.g., S7-1200 CPU). They typically feature toggle switches to simulate digital inputs and potentiometers to simulate analog input values. Critically, for output simulation, they are used to visualize the output status. They do not drive a load but provide LEDs to show the program’s intended state of the digital and analog outputs.
• Software Simulation Modules (e.g., S7-PLCSIM Advanced): This is a powerful software tool that creates a “Virtual PLC” on a PC, running the exact same PLC program as the real controller. It includes virtual representations of I/O modules, allowing the user to force digital and analog output values to test the control logic without any physical hardware. It is the core of the digital twin concept for automation.

Product Parameters

Product Advantages

• Risk-Free Testing: Allows extensive testing of the PLC control logic, including fault scenarios and complex sequences, without the risk of damaging expensive physical hardware or disrupting a live process.
• Cost and Time Savings: Eliminates the need for physical hardware during the initial programming and testing phases, significantly reducing commissioning time and allowing parallel development between software and mechanical teams.
• Virtual Commissioning (Software): The advanced software variant supports the Digital Twin concept, enabling the connection of the virtual PLC to a mechanical simulation model (e.g., 3D kinematics), leading to highly efficient and validated startup procedures.
• Training and Education: Provides a safe and reproducible environment for operator training, troubleshooting practice, and engineer development without requiring access to a live, running plant.
• Test Automation (Software): The API and networking features allow for the creation of automated test scripts to run predefined test cases, ensuring high software quality and consistency across multiple projects.

Important Notes

• I/O Coverage: Physical simulation modules are typically designed for basic functional tests and may not cover all input/output channels or special functions (like high-speed counting) of the controller.
• Software Licensing (Software SIM): Advanced simulation tools require dedicated software licenses (separate from the PLC programming software) to unlock the full virtual networking and API functionality.
• Real-World Fidelity: While powerful, no simulation can perfectly replicate all nuances of the physical world, such as signal noise, electrical interference, or complex mechanical behavior. Final commissioning on the actual hardware is still mandatory.
• Data Refresh Rate: In software simulation, the synchronization between the virtual PLC and any external simulation models (e.g., robotics) must be properly configured to ensure accurate, real-time-like behavior.

 Product Applications

• Machine Building (OEMs): Testing and pre-commissioning the entire machine control software before the machine is fully built or shipped to the customer site.
• Process and Factory Acceptance Tests (FAT/SAT): Conducting virtual FATs with the customer, allowing them to test and approve the control system functionality remotely and early in the project.
• Software Regression Testing: Re-validating previously tested PLC code after modifications or updates to ensure no existing functionality has been inadvertently broken.
• System Integration: Testing the entire automation network, including PLC-to-HMI communication and PLC-to-Robot/Drive communication, all within a safe virtual environment.