Closed-Loop I/O Point Testing for Faster Factory Acceptance Tests
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Solution Overview
Problem
Current Factory Acceptance Test (FAT) processes for industrial automation systems are inefficient due to manual and time-consuming I/O testing procedures, requiring skilled personnel and extensive documentation, which delays project completion and increases costs.
Innovation Solution
An automated testing system comprising a testing server, user computing device, and Bluetooth-enabled meter that generates and measures test signals, providing a web user interface for operators to conduct and document I/O point testing, allowing for remote and rapid validation of I/O points with minimal manual intervention and comprehensive signal testing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual I/O testing procedures are used, then testing can be performed with basic equipment, but testing time is excessive and requires highly skilled personnel
Solution Approach 1:
The patent replaces manual mechanical testing procedures with an automated testing system that uses software agents, web interfaces, and automated meters to perform I/O testing. This substitution eliminates the need for manual operation while significantly increasing testing speed and reducing the skill level required for operators.
Solution Approach 2:
The testing system performs self-testing through automated software agents that can independently execute test cases, collect results, and generate documentation without requiring continuous human intervention. The system serves itself by automatically managing the testing workflow from setup to completion.
2Reliability
If comprehensive documentation is maintained during manual testing, then testing completeness is ensured, but time consumption increases significantly
Solution Approach 1:
The automated testing system implements continuous feedback loops where test results are automatically captured, validated, and documented in real-time. The system provides feedback on test status, pass/fail conditions, and documentation completeness, eliminating the need for manual documentation while ensuring comprehensive recording of all test outcomes.
Solution Approach 2:
The system creates digital copies of test results and documentation automatically through software agents that record all testing data. Instead of manual writing, the system generates electronic documentation copies that are stored and managed automatically, ensuring completeness without time consumption.
3Ease of operation
If remote testing is enabled, then accessibility is improved, but system complexity and cybersecurity requirements increase
Solution Approach 1:
The patent introduces a web-based user interface as an intermediary layer between remote operators and the control system. This web interface acts as a mediator that enables remote access without requiring direct connections to the control system, thereby simplifying the architecture while improving accessibility and maintaining security boundaries.
4Productivity
If automated testing is implemented, then testing speed increases, but initial setup cost and complexity increase
Solution Approach 1:
The automated testing system is designed with universal software agents and a standardized web interface that can test multiple types of I/O points (analog inputs, analog outputs, digital inputs, digital outputs) through a single platform. This multi-functionality reduces the need for separate specialized equipment for each test type, thereby reducing overall system complexity while maintaining high productivity.
Data Source
AI summary
System and methods for testing input/output (I/O) points in an automation system. A control system software agent in the automation system is configured to send and receive test setpoints for the automation system. A testing server specifies the test setpoints to the automation system for a plurality of I/O points to be tested and generates a web user interface presenting instructions for conducting testing of the I/O points using the specified test setpoints. A user computing device associated with the I/O points to be tested receives the web user interface and displays the instructions, communicates the instructions to a smart meter for applying input signals to the I/O points to be tested and/or measuring output signals from the I/O points to be tested in accordance with the instructions, and communicates results of the testing to the testing server for generating documentation.