I’ve never heard of an issue like this happening due to the size of the project; it will naturally get bigger as you add programs, mappView pages, etc. Sometimes there are issues with the project build if the project path is too long, but since it sounds like the project is building okay that doesn’t seem likely either.
There is a Community post from a while back that has some troubleshooting steps for ARSim. You may find these useful. Here are some things I would look at if I was in your situation:
- Does this happen with any project, or just one project in particular? If you create a blank project right now, can you build it and successfully run ARSim?
- You mentioned that your project is working successfully on real hardware. Do you have multiple Configurations in your project for simulation vs. real hardware? If so, can you try running the “hardware” Configuration in simulation to verify this isn’t an issue localized to a particular Configuration?
- What is the output of the Console window (second tab in your screenshot)?
- If ARSim ever successfully started, it should have created log files that can be opened with the Logger. These files will be at [PROJECT_PATH]\Temp\Simulation[CONFIG_NAME]\[CPU_NAME]\RPSHD\SYSROM. In particular, the “arlogsys.br” file will contain system log entries. Can you try opening this file using the Automation Studio Logger (if it exists) and check if there are any critical errors before the shutdown?