CODESYS Simulation for Engineer Training Modules

We have already completed the Factory I/O simulation part of our thesis project titled “Development of Training Modules for Fresh Engineers Using Industrial Simulation.”
The Factory I/O part covers the 3D visual process simulation, and now we need to develop the CODESYS simulation part that demonstrates PLC programming logic for the same training modules.

Objective

To create a fully functional CODESYS simulation (no real hardware) that replicates common beginner automation mistakes and their correct solutions.
The simulation will help demonstrate how trainees can identify, troubleshoot, and fix PLC-related issues using virtual controllers.

Develop simulation projects in CODESYS V3.x (preferably v3.5 or higher).

Use CODESYS Control Win (SoftPLC) for offline simulation (no hardware).

Create ladder logic or FBD programs for each of the following scenarios:

S1: Wrong wiring or signal mismatch (NPN/PNP input issue).

S2: Safety relay bypass / E-Stop not working.

S3: Poor documentation / unclear tag naming.

S4: Overcomplicated logic causing faulty sequence.

S5: Signal compatibility issue (analog/digital mix-up).

S6: No simulation or offline testing leading to unintended motion.

S7: Communication configuration error (e.g., wrong Modbus address).

S8: No fault detection logic (missing alarms).

S9: Real-time delay causing missed sensor signal.

S10: Lack of inter-disciplinary collaboration (uncoordinated modules).

Each scenario should include both:

A faulty version (showing the beginner mistake).

A corrected version (showing the proper logic and wiring).

dDevelop simulation projects in CODESYS V3.x (preferably v3.5 or higher).

Use CODESYS Control Win (SoftPLC) for offline simulation (no hardware).

Create ladder logic or FBD programs for each of the following scenarios:

S1: Wrong wiring or signal mismatch (NPN/PNP input issue).

S2: Safety relay bypass / E-Stop not working.

S3: Poor documentation / unclear tag naming.

S4: Overcomplicated logic causing faulty sequence.

S5: Signal compatibility issue (analog/digital mix-up).

S6: No simulation or offline testing leading to unintended motion.

S7: Communication configuration error (e.g., wrong Modbus address).

S8: No fault detection logic (missing alarms).

S9: Real-time delay causing missed sensor signal.

S10: Lack of inter-disciplinary collaboration (uncoordinated modules).

Each scenario should include both:

A faulty version (showing the beginner mistake).

A corrected version (showing the proper logic and wiring).