PLC Programming Software and Tools

Programmable Logic Controllers (PLCs) are the backbone of modern industrial automation. To configure, program, test, and maintain these systems, engineers rely on specialized PLC programming software and tools. These platforms not only allow you to write logic but also enable simulation, monitoring, diagnostics, and integration with systems like SCADA, MES, and ERP. Selecting the right PLC programming software is a key step toward smooth commissioning, high availability, and long-term maintainability.

Comparison of Siemens TIA Portal, Allen-Bradley Studio 5000, and Schneider EcoStruxure Machine Expert PLC programming environments — PLC Programming Software Platforms – Siemens, Allen-Bradley, Schneider Electric

1. Core Functions of PLC Programming Software

Most PLC IDEs cover these functions end-to-end:

Logic Development: IEC 61131-3 languages such as Ladder Diagram (LD), Structured Text (ST), Function Block Diagram (FBD), Sequential Function Chart (SFC), and Instruction List (IL, legacy).
Simulation & Testing: Offline simulators validate logic before deployment, reducing commissioning time and risk.
Real-Time Monitoring: Live I/O, watch tables, scan-time profiling, diagnostics, and trend tracing.
Hardware Configuration: CPU type, I/O modules, fieldbus networks, and safety parameters.

Modern platforms also include integrated HMI design, motion control setup, IIoT connectivity, versioning, and cybersecurity controls.

2. Leading PLC Programming Software Platforms

A. Siemens TIA Portal (Totally Integrated Automation)

Manufacturer: Siemens
Best For: Large-scale automation, process industries, and integrated PLC–HMI–Drive control

Single workspace for PLC, HMI, drives, and networks.
Advanced trace, diagnostics, and safety programming.
Native Profinet/Profibus and OPC UA interoperability.

Example: Automotive assembly with robotics, conveyors, and inline vision inspection in a unified project.

B. Allen-Bradley Studio 5000 (formerly RSLogix 5000)

Manufacturer: Rockwell Automation
Best For: High-speed packaging, motion control, connected enterprise

IEC 61131-3 (LD, ST, FBD) plus robust motion profiles.
EtherNet/IP diagnostics and online edits across the plant.
FactoryTalk integration for SCADA/MES connectivity.

Example: F&B packaging lines with recipe management, OEE dashboards, and safety control.

C. Mitsubishi GX Works3

Manufacturer: Mitsubishi Electric
Best For: SMB cells, energy-efficient automation

Supports iQ-R, iQ-F, FX, and L series PLCs.
Drag-and-drop configuration; predictive maintenance and energy monitoring.
Multi-language programming and motion functions.

Example: Pharma batching, filling, and packaging under strict quality compliance.

D. Schneider EcoStruxure Machine Expert (SoMachine)

Manufacturer: Schneider Electric
Best For: Hybrid control, energy management, smart buildings

Full IEC 61131-3 compliance and reusable function blocks.
Secure remote diagnostics and cloud connectivity.
Integration with energy analytics and monitoring platforms.

Example: Building automation (HVAC, lighting, access) with energy optimization.

E. Omron Sysmac Studio

Manufacturer: Omron
Best For: Machine vision, AI-powered automation, smart sensors

Built-in AI tools for predictive maintenance and anomaly detection.
Tight vision system integration for quality inspection.
Multi-axis motion and high-speed logic execution.

Example: Electronics lines detecting PCB defects and rejecting faulty units automatically.

3. Free and Open-Source PLC Programming Software

A. OpenPLC

Best For: Learning PLC programming, hobby projects, research
Supports IEC 61131-3 languages
Runs on Arduino, Raspberry Pi, and industrial hardware

B. CODESYS

Best For: Multi-vendor PLC apps and cost-effective industrial solutions
Cross-platform development (Windows, Linux, Raspberry Pi)
Built-in simulation and debugging

Example: Universities and training centers run OpenPLC/CODESYS in PLC labs for hands-on learning.

4. How to Choose the Right PLC Programming Software

Industry & Application: Manufacturing, energy, pharma, F&B, or smart buildings?
PLC Compatibility: Verify brand, model, and firmware support.
Language Support: Ensure the IEC 61131-3 languages you need (LD, ST, FBD, SFC).
Simulation & Debugging: Offline simulation, trace, watch tables, diagnostics.
Integration: SCADA/MES, OPC UA/MQTT, historians, and data lakes.
Cost & Licensing: Community vs. professional licenses, support SLAs.

5. Comparison Table – PLC Programming Software

Software	Languages	Simulator	Online Edit	Integration	OS	License
Siemens TIA Portal	LD, FBD, SCL/ST	Yes	Yes	OPC UA, Profinet, HMI/Drives	Windows	Paid
Rockwell Studio 5000	LD, FBD, ST	Yes	Yes	EtherNet/IP, FactoryTalk	Windows	Paid
Mitsubishi GX Works3	LD, ST	Yes	Yes	iQ Platform, CC-Link	Windows	Paid
Schneider EcoStruxure Machine Expert	LD, FBD, ST	Yes	Yes	Modbus/TCP, OPC UA	Windows	Paid
Omron Sysmac Studio	LD, ST, FBD	Yes	Yes	EtherCAT, Vision, Robotics	Windows	Paid
CODESYS	All IEC 61131-3	Yes	Yes	OPC UA, MQTT (plugins)	Windows, Linux	Free + Paid
OpenPLC	LD, ST, FBD	Yes	No	Arduino, RPi, Modbus	Windows, macOS, Linux	Free (Open Source)

6. The Future of PLC Programming Tools

Cloud Engineering: Remote development, deployment, and monitoring.
AI Diagnostics: Predictive maintenance and anomaly detection.
No-Code/Low-Code: Drag-and-drop logic for rapid prototyping.
Security by Design: Signed firmware, RBAC, network segmentation.

Conclusion

PLC programming software is a complete engineering platform across the control lifecycle. Whether you build large-scale control with Siemens TIA Portal, commission high-speed packaging with Allen-Bradley Studio 5000, optimize energy-smart cells with Mitsubishi GX Works3, integrate hybrid systems with Schneider EcoStruxure Machine Expert, or prototype with CODESYS/OpenPLC, the right choice improves uptime, scalability, and total cost of ownership.