Hardware-in-the-Loop Simulation

Hardware-in-the-Loop (HIL) simulation is a technique where you connect a digital twin to your PLC to test the control software before it is applied to the real plant. Controllab offers digital twins for HIL simulation. These are real-time simulation models that very accurately mimic a real plant, allowing you to test all of your PLC software in advance.


We provide HIL simulators for modern PLCs with a fast Ethernet connection:

  • Siemens
  • Beckhoff
  • Allen-Bradley
  • Bachmann
HIL simulator of a steel crane.


Our HIL simulators are based on physics and accurate 3D CAD. With them you can

  • Gain Insight: Learn what your software will do to a plant or a machine.
  • Automate: Batch test new software against pre-defined test scenarios
  • Test Everything: Test operations that are too dangerous or too costly if the software fails.



Using a HIL simulator to test your PLC code will:

  • Improve quality: Optimize safety, test hazardous operations and emergencies.
  • Increase efficiency: Test every software change against pre-defined scenarios.
  • Save costs: Reduce commissioning delays.



Please reach out to Frank Groen, who oversees the integration of our HIL (Hardware-in-the-Loop) simulators with PLCs. He can provide valuable insights on how our HIL simulators have significantly contributed to:

  • detect faults in the software
  • test complex automation tasks
  • test a new generation UHPLC pumps