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Automated Test Suites for Controllers - By Forcing I/O

06/08/2010 2:25 PM

I am looking to set up a testing system to automatically test a PLC. I don't want to use PLC simulation, I want to have the PLC operating in it's real-world environment, i.e. the test system is forcing IO as if the real world environment was changing. After I make significant changes to the PLC program, I want to set the tester to run overnight and run every test again to prove to the customer that nothing has inadvertently been broken. In the morning I expect to see a whole lot of green lights down the screen.

I'm basically thinking of an I/O rack that is controlled by PC, each output on the tester is connected to an input on the EUT (Equipment Under Test), each input on the tester connected to an output on the EUT. I only need clean-contact relays (drive and sense) and 4-20mA loops (drive and sense). 3 Phase 5A motor current simulators would be handy but I think that will make it significantly harder to achieve.

A Modbus Master incorporated would be great, so I can read a ton of internal registers from the EUT to correctly observe it's status.

I'm thinking of a higher level language interpreter to describe the test cases, e.g.:

Definitions (constant for entire program in EUT):
Force DIN 1 = Close Dout 1
SEQUENCE_ERROR = Modbus Input 58

Test Suite 1:
Force DIN 1 TRUE
Force DIN 2 TRUE
Force DIN 4 TRUE
Expect Fault SEQUENCE ERROR.

Does anyone know of good programs or systems for achieving such a test suite? Obviously price is important, but I am interested in all options.

Thanks for your help.
Regards,
Scott Critchley

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#1

Re: Automated Test Suites for Controllers - By Forcing I/O

06/08/2010 8:00 PM

Try National Instruments.

(Usual disclaimers. Many other companies supply similar gear, it's just the first one I thought of. You can get stuff which will do the same job much cheaper elsewhere, but you may have to do more of the work yourself).

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#2

Re: Automated Test Suites for Controllers - By Forcing I/O

06/09/2010 2:56 PM

Thats why redundant PLC and DCS systems are required in critical applications, its almost impossible to simulate computer errors as well as Human interface errors. There are systems out there that can run simulations, as in aircraft simulators, but it is not going to be cheap. The variables required for this is almost infinite on a large scale process control system. Your plc can most certainly be checked out on individual I/O points, encoders as well as motor simulators, valve simulator, and upsets in a systems process. But you can never prove that a part of the system will not be inadvertlently broken. repeatability only last so long , before a failure will upset the system. Proper PM and a constant histogram can help to insure a confident process to see problems that occur in an ongoing system, to prevent or replace componets on a regular schedule. Good Idea, just not cheap. Sell your customer this idea, with a good system with a back-up and an honest handshake.

Regards

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