A Virtual PLC is a software-based version of a traditional PLC. Instead of residing on a dedicated piece of hardware, it operates in a virtualized environment—typically running on industrial PCs, edge devices, or cloud platforms. The software replicates the functions of a physical PLC, such as real-time control, input/output (I/O) handling, and communication with field devices.

How Do Virtual PLCs Work?

Virtualization of the controller gives us the possibility of decoupling of hardware and software. The software runs on computers in the factory with industrial edge computing while the hardware remains directly in the shop floor. The control logic is still created in the same programming languages, but the execution takes place in a software-defined environment, which allows for greater flexibility, scaling, and integration with other IT systems.

Here's a first look into the benefits of virtual PLCs, why they’re gaining momentum, and what's to come:

**Stay tuned for more exciting related content to be posted soon! 

Prepared for the Unknown

Many factory operators oversize their PLC software to prepare for unknown future needs—like buying an SUV when a compact car would do. Virtual PLCs eliminate that guesswork by running on existing hardware and adapting in real time to current requirements. This flexible model helps reduce operational costs while ensuring your system stays right-sized for your actual needs.

Centrally Managed Software Updates

Traditionally, updating PLC software requires manual, on-site changes for each individual controller. With virtual PLCs, updates and new features can be managed centrally across an entire system. Even better, changes can be tested in a virtual environment before deployment, streamlining administration and significantly reducing maintenance efforts.

Administration, like applying software updates to PLCs, is often done manually, on-site and individually for each controller. Adding new functionalities is much easier with the virtual PLC, since you can administer automation software for an entire cluster. This is really exciting, because all software updates can be managed centrally. In addition, different scenarios and configurations can be tested virtually first before deploying changes. This eases administration measures and decreases maintenance efforts. 

Easier Integration with IT/OT Systems

The best decisions come from clear, reliable information—not assumptions. That’s why breaking down the traditional barriers between operations technology (OT) and information technology (IT) is critical.

Virtual PLCs help drive IT/OT convergence, delivering better data flow between the factory floor and enterprise systems allowing you to make better decisions on performance, productivity, flexibility, sustainability, and more. Specifically:

• Manufacturing engineers can access and analyze real-time data quickly, enabling smarter process adjustments.
• IT specialists can deploy apps that use factory data to optimize automation—for example, identifying and rejecting low-quality materials in real time.

Because virtual PLCs run on the same platforms as your IT infrastructure, these integrations are smoother, faster, and more cost-effective.

Siemens SIMATIC S7-1500V - familiar functionalities, completely virtual

SIMATIC S7-1500V is an entirely virtual PLC. It is based on the functions and operation of the SIMATIC S7-1500 PLC and independent of its hardware. The virtual PLC can be downloaded as an Edge app and integrated directly into the IT environment. This way, untapped potential offered by digitalization can now be used.

This virtual controller represents a major step forward in digital transformation—unlocking new levels of modularity, flexibility, and efficiency for modern production environments.

What's Next

Virtual PLCs are one piece of a larger shift we’re seeing in smart manufacturing—from IT/OT convergence to edge computing and beyond. This evolving conversation will be critical to understanding how modern industrial systems are transforming and how your operation can stay ahead. So, stay tuned as we continue to expand on on this and other related topics! 

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