PLC training Rigs, Systems & Equipment

In this section you will learn more about PLC training rigs and different instructional tools, and how they are used to teach learners about industrial automation.

 

What is a PLC?

A PLC is a Programmable Logic Controller, a rugged computer designed with inputs and outputs (I/O) in a durable casing housing the processor.

PLCs are modular devises which can be combined and networked into hundreds or thousands of inputs and outputs while controlled by other PLCs or SCADA systems.

They are designed to be used in industrial settings such as manufacturing, power generation & distribution, building automation, defense industry and much more.

 

Why teach PLC programming?

With the megatrend of increased automation of industry, the need for qualified PLC technicians is quickly growing. Many companies are looking to increase efficiency and competitiveness through faster, more flexible, and smarter operations through industrial automation.

The average salary for a PLC programmer in the USA is about $79,494 annually with good benefit packages. These jobs are sought after but still the demand from employers is higher than the supply or the trained workforce.

Therefore, we should teach PLC programming because the career prospects are good and the jobs available offer a good pay and benefit packages.

 

How to learn PLC programming

There are several pathways to becoming a PLC technician or programmer, each offering different levels of depth and industry recognition.

College and university programmes. The most common route is a two-year associate degree or diploma in industrial automation, mechatronics, or electrical technology at a community college, TVET college, or polytechnic. These programmes combine PLC programming with complementary skills — electrical circuits, motor controls, instrumentation, and industrial networking. Some universities offer PLC programming within four-year engineering technology degrees.

Manufacturer certification programmes. The major PLC manufacturers run their own training and certification schemes. Siemens offers the SCE (Siemens Certification of Education) programme with multiple certification levels. Rockwell Automation provides training through its LearnSpark and Toolbox platforms. Schneider Electric, ABB, and Omron offer similar programmes. These certifications are directly recognised by employers using that manufacturer's equipment — a Siemens Certified Programmer credential carries weight at any facility running S7 PLCs.

Professional association certifications. The Electronics Technicians Association (ETA), the Association for Advancing Automation (A3), and the Manufacturing Skills Standards Council (MSSC) all offer credentials relevant to PLC technicians. These tend to be broader than manufacturer-specific certifications and demonstrate general automation competency.

Online simulation platforms. Tools like Factory I/O, PLCLogix, and Codesys provide virtual environments for practising PLC programming without physical hardware. These are valuable for remote learning and self-study, but do not replace hands-on experience with real I/O, wiring, and troubleshooting — which is what PLC training rigs provide.

For most students, the optimal path combines a college programme (for foundational knowledge and hands-on lab time) with one or two manufacturer-specific certifications (for employability). The PLC brand taught in your lab often determines which manufacturer certification your students pursue — another reason the PLC brand decision matters when specifying training equipment.

 

Best practice teaching PLC

As with any type of vocational skills its very important to learn them in a hands-on manner, since that triggers engagement, increases content retainment, favors critical thinking, and increases future workplace safety.

PLC is best taught when integrated with study areas of mechanics, electronics and process controls, and should also cover concepts such as hydraulics, pneumatics, robotics, scada, electrical circuits, electrical machinery, and human-machine interfaces.

It is also important for a future PLC technician to understand the importance of jurisdictional or site-specific codes and regulations so if this can be somehow integrated with the coursework that is preferrable.

Any program for PLC technicians or programmers should aim to foster critical thinking, manual dexterity, mechanical aptitude, attention to detail, strong problem-solving skills, communications, and mathematical and scientific aptitude.

 

What is a PLC training rig?

A PLC training rig is a technical training system, or a piece of equipment used for teaching students about programmable logic controllers.

The aim of a PLC training rig is to help the trainers and educators to introduce learners to PLCs and industrial automation in a hands-on manner, so that the student can learn while doing.

Most PLC training rigs can be equipped with PLCs from different types of manufacturers, such as Rockwell, ABB, Siemens, Schneider Electric, Honeywell, Panasonic, Eaton, Bosch Rexroth etc.

Mostly PLC training rigs are used in technical schools, community colleges, TVET colleges, polytechnics, universities or vocational training centers.

 

PLC Simulators

PLC simulators are software-based tools designed to teach the same programming concepts as physical PLC training rigs, but in a digital environment. While they lack the hands-on wiring and I/O troubleshooting experience of real equipment, they offer significant advantages: students can practise anywhere, anytime, and the cost per seat is a fraction of a physical workstation. Most training institutions use PLC simulators as a complement to their physical training centre, not a replacement.

Factory I/O. Built by Portuguese company Realgames, Factory I/O provides a 3D automation sandbox where users build and simulate industrial systems — sorting lines, pick-and-place stations, warehouse operations — and control them through real or virtual PLC connections. It supports Siemens, Allen-Bradley, and other major PLC platforms via OPC-UA or Modbus, making it one of the most versatile simulation tools available.

PLCLogix. Developed by LogixPro, this simulator emulates an Allen-Bradley SLC 500 / MicroLogix environment with pre-built virtual processes (traffic lights, batch mixing, bottling line, etc.). Students write ladder logic programmes and immediately see the results on animated process simulations. It is widely used in community colleges across North America as an introductory PLC programming tool.

Codesys. An IEC 61131-3 compliant development environment that supports all five PLC programming languages (Ladder Diagram, Function Block Diagram, Structured Text, Instruction List, Sequential Function Chart). Codesys is used by hundreds of hardware manufacturers and is free to download for simulation purposes, making it accessible for self-directed learners. It is particularly relevant for programmes teaching vendor-neutral PLC programming standards.

The best learning approach uses simulators for initial programming practice and conceptual understanding, then transitions to physical PLC training rigs for wiring, I/O configuration, sensor integration, and fault diagnosis — the hands-on skills that employers specifically hire for.

 

How to Specify PLC Training Equipment

PLC training rigs range from basic I/O demonstration boards ($2,000–$5,000) to fully integrated automation workstations with process simulation, HMI, and industrial networking ($15,000–$40,000+). The specification depends on your programme level and target industry.

Key decisions:

PLC brand. This is the single most consequential decision. Siemens (S7-1200/1500, TIA Portal) dominates in Europe and much of Asia. Rockwell/Allen-Bradley (CompactLogix/ControlLogix, Studio 5000) dominates in North America. Schneider Electric (Modicon, EcoStruxure) has a strong presence in process industries. Choose based on your local industry — graduates fluent in the locally dominant PLC platform are immediately employable.

Some training systems are designed to accept multiple PLC brands on the same rig (modular mounting, standard I/O connections). This is useful for multi-brand programmes but adds cost.

I/O complexity. Basic trainers include discrete inputs (switches, sensors) and discrete outputs (relays, indicators). More advanced systems add analogue I/O (temperature, pressure, flow sensors; variable speed drive control), which is essential for process control and industrial instrumentation topics.

Process simulation. The best PLC training rigs include physical process simulations — conveyor belts, sorting stations, filling stations, lift/elevator models, traffic light simulators — that give students real objects to control. Programming a PLC to flash an LED is qualitatively different from programming it to sort objects on a moving conveyor using sensor feedback.

HMI integration. Human-Machine Interface screens are standard in industrial automation. Training rigs that include an HMI panel teach students to design operator screens, configure alarms, and create data logging — skills that are part of most PLC technician job descriptions.

Industrial networking. Modern PLC systems communicate over industrial Ethernet protocols (Profinet, EtherNet/IP, Modbus TCP). Training rigs that include networking capability prepare students for the connected automation environments they will encounter in industry.

Expandability. A PLC training lab often starts with basic discrete I/O trainers and grows over time to include process control, robotics, and networking stations. Choose a platform that allows modular expansion without replacing the core equipment.